Magnaflux CD-2000 Series User manual

CD-2000 Series Revised January 2020
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CD-2000 SERIES

CD-2000 Series Revised January 2020
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TABLE OF CONTENTS
GENERAL SAFETY INSTRUCTIONS
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 Check List.............................................................................3-1
Piece Part Set-up................................................................................................................3-2
Magnetizing Procedures .....................................................................................................3-3
Demagnetization.................................................................................................................3-3
Shutdown............................................................................................................................3-4
Emergency Shutdown.........................................................................................................3-4
SECTION 4 - MAINTENANCE .......................................................................................................4-1
General...............................................................................................................................4-1
Daily Operator Maintenance................................................................................................4-1
Weekly Operator Maintenance............................................................................................4-1
Monthly Operator Maintenance...........................................................................................4-2
Periodic Internal Maintenance.............................................................................................4-2
Operational Checkout Procedures......................................................................................4-3
Initial Set-up........................................................................................................................4-3
Magnetization Current Check..............................................................................................4-4
SECTION 5 –TROUBLESHOOTING.............................................................................................5-1
Demagnetization Adjustment ..............................................................................................5-1
Troubleshooting Guide........................................................................................................5-3
SECTION 6 –DRAWINGS & SPARE PARTS LIST.......................................................................6-1
SECTION 7 –HOOD INSTALLATION...........................................................................................7-1

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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 CD-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 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 current control potentiometers. Selection of Contacts or Coil
operation is provided by push buttons on the Operator Control Panel. A push button on the Operator Control
Panel 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. An ultraviolet black light causes the coated particles to glow, revealing flaws in the part being
tested.
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 end of the unit.
EQUIPMENT SPECIFICATIONS
CONVENIENCE OUTLETS 2 each 115 volts AC, 5 amperes (for Black Light)

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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)
CD-2060
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
CD-2100
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
CD-2100HV
460
3
400
300
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.
Table 1-2. Magnetization and Demagnetization Output
Model
Series
Mode
Maximum Current (Amperes)*
Current
Control
Demag
Average (DC)
Peak
CD-2060
Contacts
6000
6000
Continuously
Variable
In all cases
Reversing
Decaying DC
CD-2100
Contacts
10000
10000
Continuously
Variable
In all cases
Reversing
Decaying DC
CD-2100HV
Contacts
10000
10000
Continuously
Variable
In all cases
N/A

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Table 1-3. Duty Cycle
Model Series
Seconds “On”
Seconds “Off”
CD-2060 SERIES
At Maximum Output
At 1000 A. Output
0.5
0.5
10
5
CD-2100 SERIES
At Maximum Output
At 1000 A. Output
0.5
0.5
20
5
Dimensions and Capacities
Table 1-4. Machine Weight
Model No.
Approximate Weight (Dry)
Approximate Weight (Crated)
Pounds
Kilograms
Pounds
Kilograms
CD-2060
1000
454
1275
580
CD-2100
1250
570
1525
690
CD-2100HV
1535
698
1810
823
Table 1-5. Overall Dimensions
Description
CD-2***
Basic Unit (No Hood)
Length
Depth
Height
70 in. (178 cm)
34.5 in.(88 cm)
59 in.(150 cm)
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 the end of the 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 canopy (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 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.

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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 the end of the 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 side of the operator interface, 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 2-2 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.
Figure 2-1 Figure 2-2
In Figure 2-1 above, the rear panel on the operator interface side 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.

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Figure 2-3
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.
Table 2-2. Recommended Fuse Size
CD-2060
Voltage
Fuse
Line
Wire
Ground
wire
208
230
380
415
460
575
125
125
80
70
60
60
4
4
6
6
6
6
Same
as Line
CD-2100
Voltage
Fuse
Line
Wire
Ground
Wire
208
230
380
415
460
575
300
300
200
175
150
125
0
0
2
2
4
4
Same
as Line

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Black Light Installation
(Optional Accessory)
1. Plug black light cord into the BLACK LIGHT outlet on either end of the inspection unit. Test ground fault
interrupt for proper operation.
2. If using the optional 600086 BLACK LIGHT with the integral mag shot button, plug the mag shot cable into
the REMOTE MAG socket conveniently located on either end next to the BLACK LIGHT outlets.
Adjustment of Magnetizing Shot Duration
The duration of the magnetizing shot is set at 0.5 seconds from the factory.
1. Figure 2-7 shows the PLC, while Figure 2-8 shows the port cover open on the PLC. Adjust the top small
potentiometer behind the communication port cover on the PLC. The range is from 0.5 to 5 seconds. Use
caution not to exceed the duty cycle of the unit when adjusting the timer. With the screw turned all the way
counter clockwise, that equals 0.5 seconds. If the screw is turned all the way clockwise, that equals 5
seconds. A shot timer (Magnaflux Accessory Part #622901) should be used to provide the actual shot time
that has been set.
Figure 2-7 Figure 2-8

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Figure 2-9
CONTROL PANEL KEY
Item 1: Digital Ammeter
Item 9: Not Applicable
Item 2: Current Assurance Indicator
Item 10: Demag Select Button
Item 3: Contacts Current Adjust
Item 11: Not Applicable
Item 4: Coil Current Adjust
Item 12: Not Applicable
Item 5: Not Applicable
Item 13: Contacts Select Button
Item 6: Not Applicable
Item 14: Not Applicable
Item 7: Coil Selection Button
Item 15: Not Applicable
Item 8: Not Applicable
Item 16: Mag Button
MAGNETIZING AMPERES X 1000
PUMP FAN
PUSHBAR LIGHT
CONTACTS
COIL
CONTACTS
CURRENT CONTROL
1
010
9
45
2
3
6
8
7
AUTOBATH
AUTO MAG MAG
DEMAG
COIL
CURRENT CONTROL
1
0
9
10
5
4
2
3
6
7
8
1
34
56 7 9 10
1615
13
1211
2
8
14

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NOTE:The following procedure should be performed by a qualified maintenance technician.
Ammeter Accuracy Verification
1. Position the digital test meter kit shunt specified in Table 4-5 between the cables and selected
output.
2. Connect the shunt cable leads to the shunt terminals and the test meter shunt input as directed in
the test kit instructions.
3. Turn on disconnect switch; power indicator will light.
4. Turn the current control dial to 1/3 full scale and lock the dial.
5. Press the MAG button on the operator interface, and after the timed magnetizing “shot,” both the
unit’s and digital test kit’s ammeter should display within +/- 5% or 50 amps. If not, refer to Section
5 for Troubleshooting.
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. Place the CURRENT CONTROLS to the 0 positions. Disconnect power from the inspection unit by
placing the external disconnect switch in the off position.
2. Disconnect the black light (Optional). Pack and store in a plastic bag or carton on the grilles.
3. Cover the unit with paper, cardboard or plastic to prevent the accumulation of dust, dirt or other
contaminants.
Long Term Storage and/or Shipment
1. Place the CURRENT CONTROLS to the 0 positions. Disconnect power from the inspection unit by
placing the external disconnect switch in the off position.
2. Disconnect the black light (Optional). Pack and store in a plastic bag or carton.
3. Cover the unit with paper, cardboard or plastic to prevent the accumulation of dust, dirt or other
contaminants.
4. Remove the mounting screws and shims securing the unit to the floor.
5. 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 insure safe transportation to the point of
delivery. Estimated shipping dimensions and weight are listed in Tables 1-4 and 1-5. 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
All controls and indicators are illustrated in Figure 2-9.
WARNING: Do not operate this machine until you are familiar with all the electrical and mechanical
controls. Check controls for proper functioning before operating machine.
Digital Ammeter (1): Displays the amount of current passed through the circuit.
· A reading of 3.25 equals 3250 amperes.
· A reading of 0.95 equals 950 amperes.
Green Current Assurance Light (2): Indicates current is flowing through circuit.
Current Controls (3 & 4): Control amount of current for each circuit.
· Set to desired level and lock to prevent accidental change in setting.
NOTE: The following push-buttons are dimly lit when off and bright when on.
Coil (7): Selects coil output.
Demag (10): Selects a demag cycle. Button is bright when “Demagnetizing,” and returns to dim when
demagnetizing cycle is complete.
Contacts (13): Selects contacts circuit.
Magnetize (16): Initiates a magnetizing current “shot” each time switch is depressed. Locked out during
demagnetizing.
DAILY START UP AND OPERATION CHECKLIST
All controls and indicators are illustrated in Figures 2-9.
1. Turn on external disconnect switch. Digital Ammeter and power indicator will light.
2. Allow black light to warn up for approximately 5 minutes.
3. Check UV output of lamp using Magnaflux black light meter. Measure intensity at 15” from the lens,
Clean lens or replace bulb if reading is less than 1000 microwatts/cm^2.
WARNING: Lens on the black light may be extremely hot. Let the unit cool before cleaning or replacing
bulb.
4. Push the contacts button to activate this output.

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5. Turn the current dial to 2.
6. Check for magnetizing current.
7. Make sure there is no connection between the cables of the contacts output.
8. Depress the MAG push-button while observing digital ammeter. The current assurance light should not
light. If there is any indication of current on the ammeter, or the current assurance light lights, an
electrical short exists. For correction action, refer to Section 5 for Troubleshooting.
9. Connect a suitable cable (load) between the output terminals of the activated output.
10. Depress the MAG push-button while observing the digital ammeter. The magnetizing current flowing
through the load should appear on the digital ammeter. The green current assurance light on the
ammeter should light indicating current flow.
NOTE: To ensure reliable processing of parts, all above conditions must be met. For corrective action, refer
to Section 5 Troubleshooting.
PIECE PART SET UP
WARNING: Heavy materials may cause severe damage or injury if dropped; always make sure part is
stabilized before processing for inspection.
Normal Piece Set Up
All controls and indicators are illustrated in Figures 2-9.
1. Contact: Align cables and part so that current will flow parallel to direction of expected flow. This places
magnetic field at right angles to flaw and provides best indications. Apply fluid or powder (continuous
method). Press MAG button. Apply fluid or powder (residual method).
2. Coil or Cable Wrap: Align part and cables so that field is perpendicular to direction of expected flaw.
Apply fluid or powder (continuous method). Press MAG button. Apply fluid or powder (residual
method).
Remote Operation Set-up
For remote operation, connect remote cables. Use optional clamps, prods, or cable wraps to magnetize parts
for inspection.
Central Conductor Set-up
If parts are hollow, tubular, ring-like, or have holes, it is generally better to magnetize them using a central
conductor rather than passing current directly through them. This method also reveals defects on the inside
diameter of the part. Circular Magnetization is accomplished by passing current through the central conductor.

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MAGNETIZING PROCEDURES
All controls and indicators are illustrated in Figures 2-9.
1. Clamp the part as described in PIECE PART SET UP.
WARNING: Set current at the appropriate level for the part cross section to avoid overheating.
2. Set the desired current for part being inspected on the appropriate CURRENT CONTROL. Tighten
lock(s).
3. Apply fluid or powder to the part.
4. As soon as the part (or part section) is thoroughly covered with fluid (powder), immediately apply
magnetizing current by depressing and releasing the MAG push-button or remote mag button.
5. The current assurance will light and remain lit for duration of magnetizing “shot.”
6. The digital ammeter will display and retain applied current.
NOTE: This technique is called the “wet continuous method.” For long parts, it may be necessary to
inspect in sections, each with a separate bath application and current “shot.” The “wet
residual method,” which applies bath after the current shot, is recommended only for parts with
high magnetic retentivity.
7. Examine part for indications.
DEMAGNETIZATION
All controls and indicators are illustrated in Figures 2-9.
Demagnetization is generally performed after inspection. A safety feature prevents accidental energizing of
the magnetizing circuit during the demagnetization cycle.
1. Connect cables and place part in same manner as described in PIECE PART SET UP.
2. Set the CURRENT CONTROL to the same or a value slightly higher than the setting used to magnetize
the part. Tighten lock.
3. Press and release DEMAG push-button to start demagnetization cycle. DEMAG light will remain lit
during complete cycle.
4. After demagnetization of part is complete, DEMAG light will go out.

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SHUTDOWN
All controls and indicators are illustrated in Figure 2-9.
1. If a hood assembly is installed, close curtains.
2. Disconnect power from unit by turning external disconnect switch to OFF.
EMERGENCY SHUTDOWN
To shut off the machine in an emergency, disconnect the power by turning OFF the external disconnect switch.
Lock Out unit as required.

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SECTION 4: MAINTENANCE
GENERAL
The following tables contain periodic visual and operational inspections designed to prevent or discover
malfunctions and defective parts. Many of these checks are based on ASTM E-1444. Do not operate the
inspection unit if it is found to be in need of repair or unsafe. Report problems to the designated authority. Do
not remove any cover panels. Inspections or maintenance requiring removal of cover panels are to be
performed by a qualified technician. A list of Authorized Magnaflux Service Centers is located at
www.magnaflux.com
DAILY OPERATOR MAINTENANCE
Table 4-1. Daily Operator Checks
Item
Action
Cable and bus bar
connections
Check bus bar and cable connections. Tighten as necessary.
Check wires and cables for worn or frayed insulation.
Power indicator
Check that indicator lights when power is supplied to inspection unit.
Push-buttons
Check push-buttons for proper operation. Push-buttons are dimly lit
when off and turn brighter when on.
Digital ammeter and pilot
light
Check ammeter readout and pilot light operations.
Automatic current control
Check for smooth and proper operation.
Black light assembly
Check for missing or broken filter or lamp. Check for damaged cord.
Curtains for Inspection
Area
Repair small cuts and tears with black plastic electrical tape.
WEEKLY OPERATOR MAINTENANCE
Table 4-2. Weekly Operator Checks
Item
Action
Ground Fault Interrupt
Check for proper operation of Black Light.