Magnaflux A-2000 Series Operation Manual
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Magnaflux A-2000 Series Operation Manual

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A/AD/ADH-2000 SERIES
A/AD/ADH-2000 Series
Revised April 2020
www.magnaflux.com
Page | 1-0

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Summary of Contents for Magnaflux A-2000 Series

  • Page 1 A/AD/ADH-2000 SERIES A/AD/ADH-2000 Series Revised April 2020 www.magnaflux.com Page | 1-0...

  • Page 2: Table Of Contents

    Troubleshooting Guide ......................5-1 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 A/AD/ADH-2000 Series Revised April 2020 www.magnaflux.com 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 procedures as well as Lock Out/Tag Out requirements before working with this machine.

  • Page 4: Section 1: Equipment Specifications

    SCOPE OF THIS MANUAL This manual provides essential information required for installation, operation, and maintenance of standard Magnaflux A/AD/ADH-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 ampere (for Black Light) COMPRESSED AIR ( ”...
  • Page 6 *Some coils may be capable of handling more current but these levels are based on the duty cycle of the unit. Table 1-3. A/AD/ADH-2000 Series Duty Cycle Output Selection Seconds “On” Seconds “Off” At Maximum Output At 1000 A. Output A/AD/ADH-2000 Series Revised April 2020 www.magnaflux.com Page | 1-5...
  • Page 7 146" (370 cm) A-2***XL Table 1-7. A/AD/ADH-2000 Series Machine Weight Approximate Weight (Dry) Approximate Weight (Crated) Model No. Pounds Kilograms Pounds Kilograms A-2*** 1600 1875 A-2***L 1825 2100 A-2***XL 1925 2200 A/AD/ADH-2000 Series Revised April 2020 www.magnaflux.com Page | 1-6...

  • Page 8: Equipment Warranty

    Depth (Hood Closed) 120(305cm) 120(305cm) 120(305cm) Height (Hood Opened) 89½(227cm) 89½(227cm) 89½(227cm) Height (Hood Closed) 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: A/AD/ADH-2000 Series Revised April 2020 www.magnaflux.com Page | 1-7...
  • Page 9 PAGE LEFT BLANK INTENTIONALLY A/AD/ADH-2000 Series Revised April 2020 www.magnaflux.com 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 Connect a 60-100 psig compressed air supply to the Air Filter. Adjust the pressure regulating knob until the air pressure gauge indicates 40 psi. Figure 2-4 and 2-5 below show this regulator on the headstock end of the machine. A/AD/ADH-2000 Series Revised April 2020 www.magnaflux.com Page | 2-2...
  • Page 12 Figures 2-6 below shows the pump as it is shipped and normal operation. Figure 2-7 shows the front cover removed, however, you have to remove the entire cover to do any maintenance. Figure 2-7 Figure 2-6 A/AD/ADH-2000 Series Revised April 2020 www.magnaflux.com Page | 2-3...
  • Page 13 2. Unlock and position tailstock where the digital test meter kit shunt can be supported by the tailstock and head stock shelves. Lock tailstock. 3. Position the digital test meter kit shunt (Magnaflux Accessory Part #622350) as shown in Figures 2-9 and 2-10 on the following page, and specified in Table 4-5, between the headstock and tailstock.
  • Page 14 1. This unit is designed with one meter. The signal to the meter comes from the same source as the contacts. If the meter is accurate in the CONTACT mode, the meter is considered calibrated for the all modes. A/AD/ADH-2000 Series Revised April 2020 www.magnaflux.com Page | 2-5...
  • Page 15 2. Agitation system is checked for leaks prior to shipment with light oil. If using water bath, carefully clean the entire system with liquid detergent solution and re-circulate, followed by a thorough water rinse. If using oil bath, flush system with light oil (Specification MIL-L-15016) such as Magnaflux Carrier II.

  • Page 16: 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 #1837A), and allow the suspension to settle for thirty minutes (water bath) or sixty minutes (oil bath) in a vibration-free location.
  • Page 17 Freight 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. A/AD/ADH-2000 Series Revised April 2020 www.magnaflux.com Page | 2-8...
  • Page 18 PAGE LEFT BLANK INTENTIONALLY A/AD/ADH-2000 Series Revised April 2020 www.magnaflux.com Page | 2-9...

  • Page 19: 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. A/AD/ADH-2000 Series Revised April 2020 www.magnaflux.com Page | 3-1...
  • Page 20 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 21 Figure 3-4 Figure 3-5 A/AD/ADH-2000 Series Revised April 2020 www.magnaflux.com Page | 3-3...
  • Page 22 Foot Switch (With Auto-Mag): Activates headstock clamping and mag shot. • Press once and release; part is clamped. The part is “magnetized,” then unclamped. • 2. Power Indicator: Light to indicate power to machine. A/AD/ADH-2000 Series Revised April 2020 www.magnaflux.com Page | 3-4...
  • Page 23 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. A/AD/ADH-2000 Series Revised April 2020 www.magnaflux.com Page | 3-5...
  • Page 24 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. Contact Current Control: Control amount of current for the Contact circuit.

  • Page 25: Daily Start Up And Operation Checklist

    All controls and indicators are illustrated in Figures 3-2, 3-3, 3-4, and 3-5. 1. Turn on external disconnect switch. Digital Ammeter and power indicator will light. 2. Check for proper volume of bath; see Table 1-6 in Section 1. A/AD/ADH-2000 Series Revised April 2020 www.magnaflux.com Page | 3-7...
  • Page 26 5. Allow black light to warm up for approximately 5 minutes. 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.

  • Page 27: Piece Part Setup

    1. If equipped with Auto-bath, adjust bath applicator ball valve for the desired bath flow. 2. If equipped with Auto-bath, adjust bath extend limit switch for the length of part being inspected. A/AD/ADH-2000 Series Revised April 2020 www.magnaflux.com Page | 3-9...
  • Page 28 Use Optional clamps, prods or cable wraps to magnetize parts for inspection. Figure 3-8 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 29: Magnetizing Procedures

    2. Press and release Auto-Mag button so light is bright. 3. Manually bathe the part, press and release the foot switch. 4. When foot switch is pressed, the part will be “magnetized” and released. A/AD/ADH-2000 Series Revised April 2020 www.magnaflux.com Page | 3-11...

  • Page 30: Demagnetization

    2. Open valve at bottom of the air filter bowl to blow out any contaminants or accumulated moisture. Close valve and then shut off air supply to machine. 3. If Optional hood is installed, close curtains. 4. Disconnect power from unit by turning external disconnect switch to OFF A/AD/ADH-2000 Series Revised April 2020 www.magnaflux.com Page | 3-12...

  • Page 31: Emergency Shutdown

    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. A/AD/ADH-2000 Series Revised April 2020 www.magnaflux.com Page | 3-13...
  • Page 32 PAGE LEFT BLANK INTENTIONALLY A/AD/ADH-2000 Series Revised April 2020 www.magnaflux.com Page | 3-14...

  • Page 33: Section 4: Maintenance

    Report problems to the designated authority. Do not remove any cover panels. Inspection 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 34: Weekly Operator Maintenance

    Blow accumulated dirt from rectifier heat sinks and fan blades. Do not use cleaning solvents. Do not blow firing board. Control panel wiring Check wiring for discoloration or burnt insulation, and that connectors are secure. A/AD/ADH-2000 Series Revised April 2020 www.magnaflux.com Page | 4-2...
  • Page 35 In Figure 4-1 below, this shows the entire assembly assembled. Figure 4-2 shows the brass fitting removed. Figure 4-1 Figure 4-2 The spring is shown below in Figure 4-3, and the bib flow on spray nozzle is shown in Figure 4-4. A/AD/ADH-2000 Series Revised April 2020 www.magnaflux.com Page | 4-3...

  • Page 36: Operational Checkout Procedures

    If any discrepancies are noted, refer to the troubleshooting section, and correct all discrepancies before placing the machine into service. Table 4-5. Recommended Test Equipment Magnaflux 622350 Digital Test Meter Kit with Matching Shunt INITIAL SETUP WARNING: Turn off and lock-out the external disconnect switch before opening the rear panel.

  • Page 37: Circular (Contact) And Longitudinal (Coil) Magnetization Check

    Repeat for AC mode. 10. Press the foot switch or Optional Dual Palm to unclamp and remove the shunt. Re-clamp with a non- conductive test bar (2x4 piece of wood). A/AD/ADH-2000 Series Revised April 2020 www.magnaflux.com Page | 4-5...
  • Page 38 (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. A/AD/ADH-2000 Series Revised April 2020 www.magnaflux.com Page | 4-6...
  • Page 39 PAGE LEFT BLANK INTENTIONALLY A/AD/ADH-2000 Series Revised April 2020 www.magnaflux.com Page | 4-7...

  • Page 40: Section 5: Troubleshooting

    1. Turn off disconnect, wait until unit cools. Contacts, Coil. 2. No power at Contact or Coil 2. Check for Green LED on Firing Board. Firing Board Replace Fuse 1FU if blown. A/AD/ADH-2000 Series Revised April 2020 www.magnaflux.com Page | 5-1...
  • Page 41 2. Set Demag Current higher 2. Set Demag current approximately 5-10% higher than Mag current. Demag does not work. 1. Observe PLC 1. Contact Magnaflux or an Authorized Service Center. MAG, DEMAG, 1. Lamp burned out. 1. Replace lamp(s). CONTACT or COIL 2.
  • Page 42 1. Cycle power to the unit to reset fault and for red fault light on the PLC. enable communication to the PLC. If Fault light does not clear, contact Magnaflux. 2. Fuse 8FU blown 2. Replace Fuse 8FU. 3. No 24VDC Power Supply, 3.
  • Page 43 PAGE LEFT BLANK INTENTIONALLY A/AD/ADH-2000 Series Revised April 2020 www.magnaflux.com Page | 5-4...

  • Page 44: Section 6 - Drawings & Spare Parts List

    The first number identifies the corresponding drawing. 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 45 Fan only for Rectifier Stack 521374 Firing board only for Rectifier Stack 521095 SCR only for Rectifier Stack 624717 Momentary Assembly Pushbuttons 624928 Harness for 624717 629270 DVM Board for True Amps A/AD/ADH-2000 Series Revised April 2020 www.magnaflux.com Page | 6-2...
  • Page 46 PAGE LEFT BLANK INTENTIONALLY A/AD/ADH-2000 Series Revised April 2020 www.magnaflux.com Page | 6-3...

  • Page 47: 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 48 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 A/AD/ADH-2000 Series Revised April 2020 www.magnaflux.com Page 7-2...
  • Page 49 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 A/AD/ADH-2000 Series Revised April 2020 www.magnaflux.com Page 7-3...
  • Page 50 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 A/AD/ADH-2000 Series Revised April 2020 www.magnaflux.com Page 7-4...
  • Page 51 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. A/AD/ADH-2000 Series Revised April 2020 www.magnaflux.com Page 7-5...
  • Page 52 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. A/AD/ADH-2000 Series Revised April 2020 www.magnaflux.com Page 7-6...
  • Page 53 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 54: 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. A/AD/ADH-2000 Series Revised April 2020 www.magnaflux.com Page 7-8...
  • Page 55 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. A/AD/ADH-2000 Series Revised April 2020 www.magnaflux.com Page 7-9...
  • Page 56 155 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 A/AD/ADH-2000 Series Revised April 2020 www.magnaflux.com Page 7-10...

This manual is also suitable for:

Ad-2000 seriesAdh-2000 seriesA-2030Adh-2045Ad-2045

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