Magnaflux CSV Series User manual

Revised January 2020
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CSV SERIES

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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……………………………………………………………………………..... 1-6
SECTION 2 - INSTALLATION and STORAGE..............................................................................2-1
General...............................................................................................................................2-1
Installation...........................................................................................................................2-1
Preparation for Storage or Shipment.................................................................................2-19
SECTION 3 - OPERATING INSTRUCTIONS.................................................................................3-1
Operating Controls and Indicators.......................................................................................3-1
Daily Start Up and Operation Check List.............................................................................3-2
Normal Set-up...................................................................................................................3-25
Magnetizing Procedures ...................................................................................................3-25
Shutdown..........................................................................................................................3-26
Emergency Shutdown.......................................................................................................3-26
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
SECTION 5 –TROUBLESHOOTING.............................................................................................5-1
Troubleshooting Guide........................................................................................................5-2
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 CSV Series Stationary Power Pack 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 power pack magnetic particle inspection units consist of a power pack that provides low-voltage,
high-amperage 3-phase full wave direct current for magnetization, and reversing 3-phase full wave direct
current for demagnetization on output 1. Demagnetization on outputs 2 and 3 is an Optional Feature.
The output current levels are governed by 3 separate current controls. Selection of outputs 1, 2, and 3 is done
through a color touch screen operator interface. A push button next to the operator interface 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.
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 front side of the unit.

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EQUIPMENT SPECIFICATIONS
CONVENIENCE OUTLETS 2 each 115 volts AC, 5 ampere (for Black Light)
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 (Amp-
eres)
CSV-10
380
415
460
575
3
3
3
3
245
220
200
160
200
175
150
125
Model
Series
Input
Volts AC
Phase
Load
(Amperes)
Recommended
Line Fuse (Amp-
eres)
CSV-15
380
415
460
575
3
3
3
3
360
340
300
240
300
260
230
190
Model
Series
Input
Volts AC
Phase
Load
(Amperes)
Recommended
Line Fuse (Amp-
eres)
CSV-20
380
415
460
575
3
3
3
3
500
450
400
325
400
350
300
250

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Output Specifications
*All contacts current ratings are based on the maximum current through a 2000 amp/100 mv shunt.
NOTE: Testing is done using 30’ of 1000 MCM for CSV-10, 30’ of 1000MCM in parallel with double 30’ 4/0 for
CSV-15 and double 30’ 1000 MCM for the CSV-20.
Table 1-2. Magnetization and Demagnetization Output
Model
Series
Maximum
Current
(Amperes)
Current
Control
Demag
CSV-10
10,000
Continuously
Variable
In all cases
Reversing
Decaying DC
on Output 1
CSV-15
15,000
Continuously
Variable
In all cases
Reversing
Decaying DC
on Output 1
CSV-20
20,000
Continuously
Variable
In all cases
Reversing
Decaying DC
on Output 1
Seconds “On”
Seconds “Off”
CSV Series
At Maximum Output
0.5
20
Capacities
Table 1-7. Machine Weight
Model No.
Approximate Weight (Dry)
Approximate Weight (Crated)
Pounds
Kilograms
Pounds
Kilograms
CSV-10
3500
1588
4200
1906
CSV-15
4900
2223
5500
2495
CSV-20
5500
2495
7000
3176

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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 the front side of the inspection unit) capable of providing current per the nameplate.
2. A minimum of four feet is required at both ends and the rear of the inspection unit to ensure adequate
space for servicing and ventilation.
3. A firm, reasonably level floor capable of supporting the inspection unit and the materials awaiting
inspection.
4. Adequate space to accommodate 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 inspection unit to ensure it being 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

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The inspection unit as supplied is internally wired for operation from a power source as designated on the
Magnaflux Data Plate (located on the front of the inspection 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 right side panel where the white disconnect switch is located, as shown in Figure 2-1 below, or
Optional disconnect, to gain access to input power terminal block. A punch out is required through the
roof of the unit to feed the customer’s power line. The punch out would be located on the back right
corner of the unit.
WARNING: Turn off and lock-out the external disconnect switch (not normally supplied)
before opening the right side panel. Failure to disconnect incoming power could result in
severe electrical shock or death.
Figure 2-1
2. Connect external power source to the terminal block on the rear right side of the inspection unit, or the
top connectors in the Optional disconnect.
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.
Black Light Installation
(Optional Accessory)