Magnaflux D-2000 Series Operation Manual
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Magnaflux D-2000 Series Operation Manual

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D-2000 SERIES
D-2000 Series
Revised March 2020
Page | 1-0

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Summary of Contents for Magnaflux D-2000 Series

  • Page 1 D-2000 SERIES D-2000 Series Revised March 2020 Page | 1-0...

  • Page 2: Table Of Contents

    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 D-2000 Series Revised March 2020 Page | 1-1...

  • Page 3: General Safety Instructions

    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 •...

  • Page 4: 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.

  • Page 5: Equipment Specifications

    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 ( ”...
  • Page 6 6000 In all cases Table 1-3. Duty Cycle Model Series Seconds “On” Seconds “Off” D-2060 SERIES At Maximum Output At 1000 A. Output D-2100 SERIES At Maximum Output At 1000 A. Output D-2000 Series Revised March 2020 Page | 1-5...
  • Page 7 278” (706 cm) Table 1-7. Machine Weight Approximate Weight (Dry) Approximate Weight (Crated) Model No. Pounds Kilograms Pounds Kilograms D-2*** 1600 1875 D-2***L 1825 2100 D-2***XL 1925 2200 D-2100XL4 6600 3000 D-2100XL5 7500 3400 D-2000 Series Revised March 2020 Page | 1-6...

  • Page 8: Equipment Warranty

    73(185cm) 73(185cm) Height (Hood Opened) 120(305cm) 120(305cm) 120(305cm) Height (Hood Closed) 89½(227cm) 89½(227cm) 89½(227cm) EQUIPMENT WARRANTY https://www.magnaflux.com/Files/Corporate/Equipment-Warranty-Statement.pdf The Equipment Warranty Statement can be found on our Web site at the following link: D-2000 Series Revised March 2020 Page | 1-7...
  • Page 9 PAGE LEFT BLANK INTENTIONALLY D-2000 Series Revised March 2020 Page | 1-8...

  • Page 10: Section 2: Installation And Storage

    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.
  • Page 11 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: 1.
  • Page 12 Multiplication Factors for Resistance Welders (NPFA National Electric Code 2011). 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. D-2000 Series Revised March 2020 Page | 2-3...
  • Page 13 After the tank is filled with oil or water bath, and the proper amount of magnetic particles, plug the pump in to the outlet located on the operator’s end of machine. Figures 2-7 below shows the pump as it is shipped and D-2000 Series Revised March 2020...
  • Page 14 (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 the unit. Refer to Figure 2-9 to locate both receptacles. Dual Palm Receptacle Foot Switch Receptacle Figure 2-9 D-2000 Series Revised March 2020 Page | 2-5...
  • Page 15 2. Unlock and position tailstock where the digital test meter kit shunt can be supported by the tailstock and headstock shelves. Lock tailstock. 3. Position the digital test meter kit shunt (Magnaflux Accessory Part Number 622350) as shown in Figures 2-10 and 2-11, and specified in Table 4-5, between the headstock and tailstock.
  • Page 16 If using oil bath, flush system with light oil (Specification MIL-L-15016) such as Magnaflux Carrier II. (NOTE: All units are tested with the oil bath during the certification process by Magnaflux. Look for the tag on the pump housing prior to adding the bath to the system.) 3.

  • Page 17: Preparation For Storage Or Shipment

    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 Number 1837A) and allow the suspension to settle for thirty minutes (water bath) or sixty minutes (oil bath) in a vibration-free location.
  • Page 18 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. D-2000 Series Revised March 2020 Page | 2-9...
  • Page 19 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. D-2000 Series Revised March 2020 Page | 2-10...
  • Page 20 PAGE LEFT BLANK INTENTIONALLY D-2000 Series Revised March 2020 Page | 2-11...

  • Page 21: Section 3: Operating Instructions

    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. D-2000 Series Revised March 2020 Page | 3-1...
  • Page 22 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.
  • Page 23 Figure 3-4 Figure 3-5 D-2000 Series Revised March 2020 Page | 3-3...
  • Page 24 Press once and release; part is clamped. The part is “magnetized,” then unclamped. • 2. Power Indicator: Light to indicate power to machine. 3. Headstock Pressure Regulator/Gauge: Controls amount of clamping force. D-2000 Series Revised March 2020 Page | 3-4...
  • Page 25 8. Digital Ammeter: Displays the amount of current passed through the circuit. 9. Green Current Assurance Light: Indicates current is flowing through circuit. 10. Pushbar ON/OFF Button: Enables pushbar(s) to initiate a mag shot. D-2000 Series Revised March 2020 Page | 3-5...
  • Page 26 14. Hood Fan Button (Optional): Toggles the fan in the hood ON/OFF. 15. Screen Brightness: Toggles the brightness of the screen (0-100%). 16. User Login: only for Magnaflux Authorized Service Center use. 17. Contacts Current Control: Control amount of current for circuit.

  • Page 27: Daily Start Up And Operation Checklist

    3. Press PUMP push-button to turn on and allow bath to circulate for a minimum of 15 minutes. 4. Check for proper magnetic particle concentration in bath; see Table 2-5 in Section 2. 5. Allow black light to warn up for approximately 5 minutes. D-2000 Series Revised March 2020 Page | 3-7...
  • Page 28 6. Check UV output of lamp using Magnaflux black light meter. Measure intensity 15" from the lens; clean lens or replace bulb if reading is less than 1000µW/cm². WARNING: Lens on the black light may be extremely hot. Let the unit cool before cleaning or replacing bulb.

  • Page 29: Piece Part Setup

    8. Position the part, press and release foot switch or Optional Dual Palm to clamp part in place. On units equipped with Auto-bath, the automatic cycle will begin if Auto-bath button is on. D-2000 Series Revised March 2020 Page | 3-9...

  • Page 30: Magnetizing Procedures

    Use Optional clamps, prods or cable wraps to magnetize parts for inspection. Figure 3-7 Central Conductor using a wet horizontal Magnaflux machine 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.

  • Page 31: Demagnetization

    2. Clamp test part between headstock and tailstock in same manner as described in Piece Part Set-up. 3. Set the CURRENT CONTROL to the same or a value slightly higher than setting used to magnetize the part using AMPERAGE SETPOINT on the HMI. D-2000 Series Revised March 2020 Page | 3-11...

  • Page 32: Shutdown

    4. 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. D-2000 Series Revised March 2020 Page | 3-12...
  • Page 33 PAGE LEFT BLANK INTENTIONALLY D-2000 Series Revised March 2020 Page | 3-13...

  • Page 34: Section 4: Maintenance

    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.

  • Page 35: Weekly Operator Maintenance

    Blow accumulated dirt from rectifier heat sinks and fan blades. Do not use cleaning solvents. Use dry air on PCB. Control panel wiring Check wiring for discoloration or burnt insulation, and that connectors are D-2000 Series Revised March 2020 Page | 4-2...
  • Page 36 NOTE: Due to the nature of the material used in Magnetic Particle Inspection, periodic maintenance is required on the pump seal. Replacement is recommended every 3 months, based on using Magnaflux materials for an 8 hour day, 5 days a week work schedule. It is recommended to maintain a back-up pump that can be switched out when the seal needs to be changed in order to decrease the amount of downtime on the machine.

  • Page 37: Operational Checkout Procedures

    Table 4-5. Test Equipment Recommended Test Equipment Tektronix TDS 2012B Two Channel Digital Storage Oscilloscope, 100 MHz, 1 GS/s Magnaflux 622350 Digital Test Meter Kit with Matching Shunt Steel Test Bar (1" diameter, 12"-18" long, 4140 H.T.) INITIAL SET-UP WARNING: Turn off and lock-out the external disconnect switch before opening the rear panel. Failure to disconnect incoming power could result in severe electrical shock or death.

  • Page 38: Circular (Contact) And Longitudinal (Coil) Magnetization Check

    “shot,” and the current should be indicated on both the Digital Ammeter and the digital test meter. Each ammeter reading should correspond within ±10% or 50 amps of the machine rating. {MOD AC (Optional) repeat for AC}. D-2000 Series Revised March 2020 Page | 4-5...
  • Page 39 (contact) and longitudinal (coil) demagnetization check performing only those steps not previously accomplished. If no further testing is to be done, disconnect the digital test meter and return it to its carrying case D-2000 Series Revised March 2020 Page | 4-6...
  • Page 40 PAGE LEFT BLANK INTENTIONALLY D-2000 Series Revised March 2020 Page | 4-7...

  • Page 41: Section 5: Troubleshooting

    3. Check that red “INHIBIT” LED is glowing. Push MAG button, red LED should go out for duration of mag shot. 4. If the issue is neither of the above, Contact a Magnaflux Authorized Service Center. D-2000 Series Revised March 2020...

  • Page 42: Troubleshooting Guide

    Section above. mag shot. Continuous mag shot 1. Shorted SCR. 1. Call Authorized Service Center. on coil and/or contact. Main fuse to unit 1. Shorted SCR 1. Call Authorized Service Center. blown. D-2000 Series Revised March 2020 Page | 5-2...
  • Page 43 Maximum current 1. Defective SCR firing board. 1. Replace Firing Board. output at all settings. 2. Shorted SCR. 2. Contact Authorized Magnaflux Service Center Demag does not 1. Attempt using Extended 1. Use Extended Demag cycle on HMI. completely demag Demag on HMI.
  • Page 44 1. Adjustment of current control (Bias and Span Replaced POTs) is done on the firing board. Bias is set at 100A and Span is set at Max output (refer to Section 1 for AC output values). D-2000 Series Revised March 2020 Page | 5-4...
  • Page 45 PAGE LEFT BLANK INTENTIONALLY D-2000 Series Revised March 2020 Page | 5-5...

  • Page 46: Section 6 - Drawings & Spare Parts List

    PART NUMBER COLUMN On the first sheet of each drawing is a bill of material located in the lower right corner. Magnaflux part numbers are used to identify all parts except common commercial hardware. Commercial hardware is identified with a full identification in the DESCRIPTION column.
  • Page 47 622996 Firing board only for Rectifier Stack 521095 SCR only for Rectifier Stack 624717 Momentary Assembly Pushbuttons 624928 Harness for 624717 114184 Braided Lead Contact Pad 629270 DVM Board for True Amps D-2000 Series Revised March 2020 Page | 6-2...
  • Page 48 PAGE LEFT BLANK INTENTIONALLY D-2000 Series Revised March 2020 Page | 6-3...

  • Page 49: Section 7: Hood & Black Light Installation

    Figure 7-2 Figure 7-3 5. Place the Magnaflux machine on a solid surface and secure it based on Section 1 of this manual. Figure 7-3 above shows the unit. 6. Once it is secure, remove the accessory boxes containing the foot switch, and set aside in a safe place.
  • Page 50 13. With a person on either side of the hood, carefully lift it on to the unit and insert the frame into the mounting holes as shown in Figure 7-7 and Figure 7-8 below. Figure 7-8 Figure 7-7 Revised March 2020 www.magnaflux.com Page 7-2...
  • Page 51 18. Place the shoulder bolt through the hole in the stationary part of the frame. 19. With one washer on the inside and outside, tighten the nut to secure the frames together as shown in Figures 7-9 through 7-12 below. Figure 7-10 Figure 7-9 Figure 7-11 Figure 7-12 Revised March 2020 www.magnaflux.com Page 7-3...
  • Page 52 21. Locate the four (4) mounting bolts on the stationary frame as shown in Figures 7-15 through 7-18 below. NOTE: Two (2) are under the curtain. 22. Remove nuts and set aside. Figure 7-15 Figure 7-16 Revised March 2020 www.magnaflux.com Page 7-4...
  • Page 53 26. Standard mounting has the vent to the tailstock side of the unit as shown in Figures 7-20 and 7-21. 27. Removing and reorienting the vent direction is possible by removing the mounting hardware and rotating the vent. NOTE: Verify white light levels inside booth before changing the orientation. Revised March 2020 www.magnaflux.com Page 7-5...
  • Page 54 30. If power is available on the unit, the white light and fan operation can be tested by selecting these buttons on the main control panel, as shown in Figure 7-23 below. Figure 7-23 31. Now the left and right side curtains can be carefully unfolded as shown in Figure 7-24 below. Revised March 2020 www.magnaflux.com Page 7-6...
  • Page 55 33. Locate the front curtain and hang it from the front track with hooks as shown in Figure 7-26 below. Once the front curtain is installed, pull down the curtain with “Magnaflux” on it to block white light from entering the inspection booth.

  • Page 56: Black Light Installation

    This is shown in Figure 7-31 below. Figure 7-30 3. Plug the transformer cord into the outlet on the side of the unit as shown in Figure 7-31 below. Revised March 2020 www.magnaflux.com Page 7-8...
  • Page 57 Figure 7-31 Figure 7-32 4. Mount the EV6000 or EV6500 black light onto the peg provided, as shown in Figure 7-32. This completes the installation of the hood assembly. Revised March 2020 www.magnaflux.com Page 7-9...
  • Page 58 155 Harlem Avenue, Glenview, Illinois 60025 USA Telephone: 1-847-657-5300 Fax: 1-847-657-5388 Web: www.magnaflux.com E-mail: support@magnaflux.com Revised March 2020 www.magnaflux.com Page 7-10...

This manual is also suitable for:

D-2060D-2100D-2100xl4D-2100xl5D-2060lD-2060xl ... Show all

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