Operating Manual
Universal SW
YOUR MACHINE
Machine type Universal SW crack detection system
Manufacturer
MAGNAFLUX GmbH, Bahnhofstr 94-98, 73457 Essingen, Deutschland
Telephone: +49 (0) 7365 81-0 Fax: +49 (0) 7365 81-449
Email: sales.de@magnaflux.com Web: eu.magnaflux.com/de
Serial number
Year of manufacture
Model Universal 120 SW (clamping length: 1200 mm)
Universal 170 SW (clamping length: 1700 mm)
Universal 210 SW (clamping length: 2100 mm)
Universal 260 SW (clamping length: 2600 mm)
Universal 320 SW (clamping length: 3200 mm)
Magnetisation Axial current flux Coil magnetising
Field flux with threader bar Yoke magnetising
Induction flux
Magnetising coil Inner diameter (mm)
Manual movement Motor-driven movement
Spraying Hand hose Large surface shower
Hand shower with push button Nozzles in magnetising coil
UV lighting ST700 EV6000
Darkroom Darkroom With fan
With daylight lighting
Clamping units Left sleeve with pneumatic Left sleeve with pneumatic
Workpiece rotation
device
Left sleeve Right sleeve
Manual drive Motor-driven
Electrics Operating voltage (V) Frequency (Hz)
Power consumption (kVA) Line fuse, on-site (A)
Magnetising
currents
Axial current flux Coil magnetising
Flied flux with threader bar Yoke magnetising
Special designs T-Code (option)
QAP (option)
a
Section Page
- Using this manual 1
1 Description of the machine 1
1.1 Intended use 1
1.2 Technical data 2
1.3 Overview of main components 3
1.4 Safety devices 3
1.5 Working position 3
1.6 Signs on the machine 3
2 Functions and procedures 4
2.1 Overview of test procedures 4
2.2 Inserting and clamping workpieces 4
2.3 Magnetising the workpiece 4
2.4 Constant current control 6
2.5 Current flow control 6
2.6 Types of magnetisation in accordance
with DIN EN ISO 9934-1
6
2.7 Demagnetising the workpiece 6
2.8 Spraying the workpiece 7
2.9 Test liquid system 8
2.10 Pneumatic maintenance unit 9
2.11 Lighting your Universal SW 9
2.12 Visual inspection 9
3 Overview of controls 10
3.1 Main switch 10
3.2 Emergency stop button 10
3.3 Main operating console 10
3.4 Left operating panel 11
3.5 Right operating panel 12
4 General safety information 12
4.1 Hazards when using the machine 12
4.2 Magnetic fields in the workplace 13
4.3 In case of emergency 13
4.4 Responsibilities of the owner 13
4.5 Responsibilities of other personnel 13
4.6 Training 14
4.7 Personal protective clothing 14
4.8 Faulty protective and safety devices 14
4.9 Modifications to the machine 14
4.10 Spare parts and consumables 14
5 Transport 14
5.1 Equipment for transport 14
5.2 Preparing for transport 14
5.3 Transport in original packaging 15
5.4 Unpacking the machine 15
5.5 Transporting an unpacked machine 15
6 Installation 16
6.1 Set up the machine 16
6.2 Connect the power supply 16
6.3 Connect the test liquid pump 17
7 Commissioning 17
7.1 Safety information 17
7.2 Preparation 17
7.3 Switch on the machine 17
7.4 Test the machine functions 17
8 Preparing for operation 18
8.1 Fill with test liquid 18
8.2 Make adjustments 18
8.3 Adjust sleeve distance 18
8.4 Adjust workpiece support (standard) 18
8.5 Adjust workpiece support on the sleeve
or roller block (option)
19
8.6 Refit the threading conductor 19
8.7 Change the magnetising coil 20
8.8 Set magnetising parameters 21
9 Operation 21
9.1 Safety information 21
9.2 Turning the machine on and o 21
9.3 Initial position of the machine 22
9.4 Manual mode 22
9.5 Automatic mode 22
9.6 Cleaning the machine 28
9.7 Dealing with faults 29
10 Maintenance 29
10.1 Safety information 29
10.2 Inspection and maintenance schedule 29
10.3 Inspection procedures 30
10.4 Procedures for routine maintenance 32
10.5 Procedures for repair 35
11 Decommissioning and disposal 37
11.1 Safety information 37
11.2 Temporary shutdown of the machine 37
11.3 Final shutdown of the machine 37
11.4 Dispose of the machine 37
CONTENTS
b
USING THIS MANUAL
This operating manual describes the function,
installation, operation, maintenance and disposal
of your Universal SW machine, and gives important
information for its safe and ecient use. The manual
must be freely accessible at the machine for all
operating and maintenance personnel, and it must
be accompany the machine whenever you change its
location or ownership.
Before installing, operating, or maintaining the machine,
read the corresponding instructions. This way, you will
always have good understanding of the machine so
you can avoid dangerous situations and perform the
necessary measures and steps.
ALWAYS READ THE SAFETY INSTRUCTIONS. This is
a precondition for the safe operation of the machine.
Warnings and special safety instructions can be found
directly above the relevant instructions for us.
The instructions do not contain any assembly or
functional descriptions but will show you step-by-
step how to achieve your goal. Be sure to observe
the information on optimum conditions and any
additional tools required, as well as all warnings and
safety instructions. Follow the sequence of steps as
described.
1. DESCRIPTION OF THE MACHINE
1.1 INTENDED USE
The operational safety of the Universal SW machine is
dependent on it being used as intended. The machine
is exclusively intended for materials testing:
• of specified workpieces (see below)
• by magnetic particle inspection according to EN ISO
9934-1
• while stationary (fixed in place)
• within the specified limits
Incorrect use of the machine may lead to damage or
injury. The Universal SW must not be used:
• in potentially explosive atmospheres
• for mechanical or thermal treatment of workpieces
• in residential or small commercial premises
These uses constitute an abuse of the machine.
The operator assumes sole responsibility for any and
all results from unintended use, and from operations
which are not described in this manual. Such uses
invalidate any warranty claim against Magnaflux
GmbH (the manufacturer), who assumes no liability for
damages resulting from these uses.
WORKPIECE SPECIFICATIONS
Only workpieces that conform to the following specifi-
cations can be inspected using the Universal SW:
• Ferromagnetic materials with a magnetic conductivity
μ> 100
• Raw or sand-blasted surfaces that are free from
cinders, rust, oil and grease.
• Maximum diameter: 300 mm (depending on the
built-in magnetising coil)
• Maximum weight: 300 kg (option: 1000 kg)
• Maximum clamping length - see below.
Universal 120 SW 1200 mm
Universal 170 SW 1700 mm
Universal 210 SW 2100 mm
Universal 260 SW 2600 mm
Universal 320 SW 3200 mm
LIMITS OF THE MACHINE
Magnetising
current
Standard Option
Axial current
flux
infinitely adjustable
up to 3000 A
up to 4000 A
Coil
magnetisation
infinitely adjustable
up to 4,5 kAT
7,0 kAW)
1
Duty ratio (standard)
relative: 30% ED
absolute: coil in-motion time, max. 30 s
Crack detection is severely compromised or impossi-
ble under the following conditions:
• if the workpiece diers significantly from the spec-
ification,
• on the workpiece in the area of the support and
contact surfaces,
• if an unsuitable test liquid is used.
INSTALLATION SITE
The Universal SW fulfills the requirements of the stan-
dards applicable to electromagnetic compatibility:
• EN 61000-6-4: Electromagnetic compatibility (EMC)
- Emission standard for industrial environments•
• EN 61000-6-2: Electromagnetic compatibility (EMC)
- Immunity for industrial environments
1.2 TECHNICAL DATA
Dimensions (in mm) and weights
SW Model Length Width Height Weight
Magnetising station
120 SW 3000 1300 2000 900 kg
170 SW 3200 1400 2000 1100 kg
210 SW 3900 1300 2000 1200 kg
260 SW 4400 1300 2000 1300 kg
320 SW 5000 1300 2000 1400 kg
Dark room
120 SW 3400 2500 2400 200 kg
170 SW 3900 2500 2400 240 kg
210 SW 4300 2500 2400 280 kg
260 SW 4800 2500 2400 320 kg
320 SW 5400 2500 2400 360 kg
Control cabinet: approx. 220 kg
Test liquid tank: approx. 30 kg
Option: workpiece rotary device: approx. 200 kg
Electrics
The electric figures vary depending on the model - see
page 1 of this manual for your machine’s data.
Pneumatics
Air pressure 6 bar
Air quality dry, clean air
Pneumatic
connection
Hose coupling 7.2 mm diameter
Oil tank capacity 250 ml
Oil specification Hydraulic oil according to DIN
51524 part 2, viscosity 32 mm²/s
at 40°C (HLP 32)
Recommended
oils
Festo special oil OFSW-32,
ARAL Vitam GF 32, ESSO Nuto
32, MOBIL DTE 24, BP Energol
HLP–HM 32
Test liquid system
Tank capacity 40 litres
Operating voltage of pump AC 3x400 V / 50 Hz / PE
Power supply to pump:
• Receptacle at the base frame
• Connecting cable at the pump: length 1.5 m
• CEE connector, 16 A, 5-pins
Ambient conditions
Air temperature during operation 5 to 45 ° C
Air temperature in storage 5 to 55 ° C
Air humidity (during operation and storage):
max. 90% relative humidity, non-condensing
Emissions
EMC: in accordance with EMC directive and the valid
EMC standards for use in the industrial sector.
Noise:
• Emissions at the workplace in normal mode: 70 dB (A)
• Measured to DIN EN ISO 3744 Class 2
• Information in accordance with DIN 45 649 Part 1
Space requirements for installation
Width: min. 2600 mm
Length (min.):
120 SW 3500 mm
170 SW 4000 mm
210 SW 4400 mm
260 SW 4900 mm
320 SW 5500 mm
Power supply connection
Cable entry point at the bottom of the control cabinet.
2
1.3 OVERVIEW OF MAIN COMPONENTS
1. Main operating console (control cabinet)
2. Workpiece rotary device (optional, manual or
motorised)
3. Left sleeve with pneumatic clamping device
4. Magnetising coil
5. UV light
6. Blackout booth (option)
7. Right sleeve (option: with pneumatic clamping
device
8. Manual workpiece rotary device (motorised optional)
9. Test agent tank
10. Compressed air maintenance unit with pneumatic
connection
11. Transformer cabinet
1.4 SAFETY DEVICES
WARNING
Only operate the system if all
protective and safety devices are
complete and working. Check safe-
ty and protective devices regularly.
The Universal SW is equipped with the following
safety devices:
1. Main switch
2. Emergency stop button (option)
3. Two-hand control (option)
1.5 WORKING POSITION
The Universal SW must be operated by one person.
The main working position for normal operation is in
the front of the machine, within the blackout booth.
1.6 SIGNS ON THE MACHINE
The nameplate is mounted on the right front side of the
control cabinet near the main switch. It displays import-
ant information about the machine, its power supply
and the manufacturer.
Indicates conformity with EU direc-
tives which apply to the product and
which require the CE mark.
Hazard from electrical voltage. Work
on the electrical installation must
be only be performed by a qualified
electrician.
Hazard from magnetic fields. Observe
the safety distances.
Hazard from UV radiation. Protect
eyes and skin.
People with pacemakers or other
body implant devices must keep
away from this machine.
3
2. FUNCTIONS AND PROCEDURES
2.1 OVERVIEW OF TEST PROCEDURES
Dierent inspection processes are possible depend-
ing on the specification of your machine - see page 1
of this manual.
Variant 1
• includes manual spraying
• no magnetising coil
Variant 2
• includes manual movable magnet-
ising coil
• includes manual spraying or ring
shower (option)
Variant 3
• includes motor-driven magnetising
coil
• includes manual spraying or ring
shower (option)
2.2 INSERTING AND CLAMPING WORKPIECES
Workpieces are inserted into the workpiece supports
by the operator or a suitable device, and removed
again after inspection.
Workpiece supports
Suitable supports for diverse workpieces are available.
In addition to fixed workpiece supports, the following
options are also possible:
• Roller block with manual drive
• Fixed supports with additional workpiece turning
devices.
Contact the sales department at MAGNAFLUX GmbH
for more information.
Workpiece clamping units
Depending on the type of workpiece and feed, the
workpiece may be clamped dierently.
• clamping on the left sleeve only
• clamping devices on the left and right sleeves
1. Clamping unit (pneumatic or electric)
2. Left sleeve
3. Workpiece
4. Right sleeve, mounted on carriage
5. Clamping unit (pneumatic or electric)
6. Sleeve carriage
Right sleeve without clamping unit
In the standard version, the right sleeve is permanently
mounted on a manually movable carriage, allowing the
distance between sleeves to be adjusted to the work-
piece length.
Optionally, a clamping unit can also be installed on the
right sleeve. As with the standard version, the distance
between the sleeves is adjusted by moving the carriage.
2.3 MAGNETISING THE WORKPIECE
NOTE: Where the magnetic powder method is used,
only those parts of the workpiece that have been treat-
ed with testing agent can be examined. It is not possi-
ble to detect cracks at contact points and surfaces.
Requirements for magnetisation
• Workpiece in magnetising position.
• Control on.
• The magnetisation circuit is powered.
• The magnetising intensity (magnetising current) is set
to a value of minimum 10% of the maximum value.
Magnetisation in automatic operating mode
As soon as the workpiece arrives in the magnetisation
station, it is clamped between the two sleeves. The
sleeves contact the workpiece and close the circuit for
the axial current flow.
If a magnetising coil is installed, this is moved around
the workpiece by hand or motor during magnetisation.
The magnetisation process comprises two phases:
• Spraying of test liquid and magnetisation (spraying
time)
• Magnetisation after spraying
Magnetisation is complete when the after-spray mag-
netisation time has lapsed. Magnetic particles will have
collected in any cracks, making them clearly visible.
Demagnetisation in automatic mode
After magnetisation, the magnetising current is reduced
to zero along an e-function, thereby demagnetising
the workpiece.
4
Circular magnetisation with current flux
When using circular magnetisation with axial current
flux, the magnetising current flows through the work-
piece [3]. Magnetisation intensity is dependent on the
current flux through the workpiece.
Current flux creates a magnetic circular field within
the workpiece [2]; this circular field allows detection of
longitudinal cracking in the workpiece.
The magnetising current can be continually adjusted
and is displayed on a gauge on the control cabinet as
RMS value.
1. Contact attachment on the left sleeve
2. Circular magnetic field arising from the current flux
3. Workpiece with current flux
4. Contact attachment on the right sleeve
5. Transformer
Circular magnetisation with current-carrying conductor
NOTE: For this type of magnetisation, you need an
additional magnetising mandrel. Please contact the
sales department of Magnaflux GmbH.
In circular magnetisation with a current-carrying
conductor, the magnetising current flows through a
conductor, e.g. a magnetising mandrel [2]. The current
flow of the conductor generates a circular magnetic
field [2] within the conductor. If the conductor is intro-
duced into a circular or tubular workpiece, the circular
field [3] is transferred to the workpiece [4].
Intensity of magnetisation depends upon the current
flux through the conductor. The circular field enables
the detection of longitudinal cracks in the workpiece.
The magnetising current is displayed on a gauge on
the control cabinet as eective value.
1. Contact attachment with magnetising mandrel
2. Circular magnetic field in the conductor
3. Circular magnetic field in the workpiece
4. Workpiece with circular magnetic field
5. Contact attachment.
6. Transformer
Longitudinal magnetisation with coil
When using longitudinal magnetisation with a coil, the
magnetising current flows through a coil [2], creating
circular magnetic fields around the individual conduc-
tors. These fields combine to a common longitudinal
field inside the coil [1]. The longitudinal field is trans-
ferred to the workpiece inside the coil.
The magnetic field flows through the workpiece [3] in
a longitudinal direction. The longitudinal field enables
the detection of transverse cracks in the workpiece.
The magnetising coil can be mounted so that it can be
moved along the entire length of the workpiece during
the magnetisation process. This allows for magnetisa-
tion of very long workpieces.
The magnetising current is displayed on gauge on the
control cabinet in kAW, as the product of the current
and the number of turns of the coil.
1. Longitudinal magnetic field in the coil and workpiece
2. Magnetisation coil
3. Workpiece
4. High current transformer
5
2.4 CURRENT CONSTANT CONTROL
During current flow, the strength of the magnetising
current is dependent on the electrical resistance of the
workpiece. The current strength defines the magnetic
field strength in the workpiece.
The constant current control regulates the voltage of
the magnetising circuits, depending on the current
flow at the time. The actual current value is maintained
during the entire magnetisation process in accordance
with the pre-selected set value.
2.5 CURRENT FLOW CONTROL
During magnetisation, the actual current value of the
magnetising current is constantly measured and com-
pared to the set value selected. If there is no current
flow, or too low a current, a current flow malfunction is
signaled.
The current flow control works in manual and automatic
operating modes but not in the intensity range of 0-10%
(the fault light will illuminate).
When experiencing a current flow malfunction, the
magnetisation cycle is repeated up to 3 times. If the
set value is not reached after the third attempt, a
malfunction is signaled and the machine is stopped.
2.6 TYPES OF MAGNETISING IN ACCORDANCE
WITH DIN EN ISO 99341
The types of magnetisation available for use depends
on the individual configuration of your machine
and its installed accessories. For more information,
please contact MAGNAFLUX GmbH.
DIN EN ISO 9934-1 (formerly DIN 54130) deals with
magnetic particle inspection in general, including all
types of magnetisation processes suitable for magne-
tising a workpiece. The most common magnetisation
methods are briefly described below
Axial current flux
• Magnetisation by current flux.
• Self-flux - the workpiece has direct contact and acts
like an electrical conductor.
• Generates a circular magnetic field around the
workpiece.
• Enables detection of longitudinal cracks.
Induction flux
• Magnetisation by current flux.
• Annular or tubular workpiece as secondary winding
(1 winding in short circuit) of a transformer.
• Generates a circular magnetic field around a work-
piece cross-section.
• Enables detection of longitudinal cracks
Yoke magnetising (stationary system)
• Magnetisation by magnetic field (field flux).
• Workpiece is placed within the magnetic field
between two electromagnetic yokes.
• Enables detection of transverse cracks.
Field flux with current-carrying conductor bar
• Magnetisation with current-carrying conductor
(auxiliary flux).
• Magnetising mandrel inside of tubular or circular
workpieces.
• Generates a circular magnetic field around the
conductor and the workpiece.
• Enables detection of longitudinal cracks.
Field flux with magnetising coil
• Magnetisation by magnetic field (field flux).
• Generates circular magnetic fields around the
conductor which combine to form a common
longitudinal field within the coil.
• Detection of longitudinal cracking.
2.7 DEMAGNETISING THE WORKPIECE
After testing for surface cracks with magnetic particle
inspection methods, residual magnetism remains in
the workpiece. Eliminating this residual magnetism
avoids negative eects during further processing or
when using the workpiece.
Decreasing the magnetic field intensity in the work-
piece can be achieved by using one of two methods:
• internal - magnetisation current is regulated against
zero along an exponential function to base e.
Demagnetisation is performed immediately after
magnetisation in the crack detection machine.
• external - demagnetisation is achieved by using an
external coil. The workpiece is continuously moved
out of the magnetic field.
Electronic demagnetising
Where the magnetisation was performed using
alternating current (AC), the workpieces must also
be demagnetised using AC. For that purpose, the
magnetising current is reduced along an e-function
until it reaches zero.
For demagnetising:
• a field with alternating polarity must be achieved
and
• the field intensity must be continuously reduced
until it is zero.
6
Electronic demagnetising works according to the
following principle:
• The workpiece is magnetised with the set magnet-
ising current during the magnetising cycle.
• After rinsing and demagnetisation, the magnetising
current is gradually reduced along an e-function
until it is zero.
Development of the magnetising current during the
demagnetising process
2.8 SPRAYING THE WORKPIECE
Test liquid
NOTE: The correct concentration of test liquid makes
a decisive contribution to the reliable detection of
cracks and flaws. Please note the manufacturer’s
instructions for the mixing ratio.
The test liquid is a suspension of magnetic powder
and a carrier medium, such as water or oil. The mag-
netic powder often has fluorescent dye added to it,
which makes the accumulation of test liquid in cracks
more clearly visible under UV lighting.
The test liquid must be applied evenly to the work-
piece in sucient quantity. For this reason, you must:
• ensure the correct mixing ratio of magnetic powder
and carrier medium
• mix the suspension thoroughly,
• replace the suspension when it gets contaminated.
Spraying with a hand-held hose
You can spray the workpiece [3] with test liquid using
a hand-held hose [1]. Use the stop-cock [2] to adjust
the flow of test liquid and to turn o the supply of test
liquid to the hose.
You can also use the hand-held hose to conveniently
clean the machine. Thoroughly spray out the working
area inside the test equipment drip tray before chang-
ing any test equipment.
OPTION: The hand-held shower spray system has an
integrated push-button to activate the magnetising
current and the test liquid spraying at the same time.
1. push-button to activate magnetisation
2. hand spray system
Spraying with ring shower
During coil magnetisation, the ring shower [1] [2] rinses
the workpiece [4] with test liquid. The ring shower is
mounted at the magnetising coil [3]. Two stop-cocks
{5} & [6] are mounted at the back of the ring shower;
use these to adjust and turn o the flow of test liquid.
1. Upper half of the ring shower
2. Lower half of the ring shower
3. Magnetising coil
4. Workpiece
5. Stop-cock for the upper half of the ring shower
6. Stop-cock for the lower half of the ring shower
7
Spraying with large surface shower
As an option, a large surface shower can be installed
It will enable you to spray the workpiece [2] com-
fortably and evenly with test liquid. A stop-cock is
installed in each shower head [1]. so you can adjust
each flow individually.
1. Large surface shower
2. Workpiece
3. Universal SW
Test liquid circulation
1. Test liquid tank
2. Pump
3. Stop-cock, mounted on the test liquid tank
4. Solenoid valve
5. Tap at workstation (optional)
6. Spray heads or hand-held hose
7. Test liquid collector tray
8. Runo (return to test liquid tank via dirt filter)
WARNING: if the system is switched
on but not used for more than one
hour, it is necessary to keep the
pump running in circulation mode*
to enable cooling of the test liquid.
Otherwise, the quality of the test liquid may be com-
promised, and oil-based test liquids may even ignite
at higher temperatures
*
e.g. via the opened valve for the test liquid hose to
enable a closed circuit through the test liquid collect-
ing tray)
WARNING - FIRE HAZARD - Oil-based
test liquids are highly flammable. Use
only flame-retardant test liquids with a
flash point > 100 °C.
When using oil-based test liquids, have a fire exting-
uisher at hand and ensure you comply with the
instructions provided by the test liquid manufacturer.
NOTE: the ability to detect faults in workpieces reduc-
es significantly with the decreasing quality of the test
liquid. The quality and ecacy a of test liquid depends
on the individual inspection task and the condition of
the workpieces. Check your test liquid at regular inter-
vals and replace if necessary.
2.9 TEST LIQUID SYSTEM
The test liquid unit comprises:
• the test liquid tank
• the connecting lines
• a hand-held hose or spray.
The test liquid flows in a closed circuit through the test
liquid collector tray and a dirt filter, back into the test
liquid tank.
1. Test liquid flow to the Universal SW
2. Feed opening with lid
3. Test liquid tank
4. Test liquid pump
5. Dirt filter
6. Test liquid return from the Universal SW
8
2.10 PNEUMATIC MAINTENANCE UNIT
1. Compressed air outlet to the pneumatic system
2. Regulator screw and oil gauge
3. Oil container
4. Pneumatic connection
5. Condensate trap with drain plug
6. Air pressure gauge
7. Air pressure regulator
2.11 LIGHTING YOUR UNIVERSAL SW
The lighting you use with your Universal SW unit
depends on several parameters:
• The type of workpiece and its surface
• The test liquid being used
• Existing lighting at the location.
Avoid blinding lights and reflections from shiny surfac-
es through badly positioned light sources.
When using fluorescent test liquids, evaluate under
UV light only, wherever possible. Ensure the UV light
intensity never falls lower than 1000 μW/cm² and check
your UV lamps regularly.
When using visible test liquids - i.e. those without flu-
orescent colouring agents - you should ensure lumi-
nance of at least 500 Lux on the workpiece.
ST700 Stationary Inspection LED UV Lamp
2.12 VISUAL INSPECTION
Visually inspection is the most commonly used form of
evaluating a workpiece. The operator visually inspects
the workpiece, either while it is in the machine, or at a
specially designed inspection station.
By using fluorescent test liquids and UV lights you can
easily spot test liquid accumulations which indicate
cracks or other flaws in the workpiece. Ambient light
should be blocked from shining on the workpiece by
using a blackout booth.
1. Blackout booth
2. ST700 overhead UV LED lamp
3. EV6000 portable UV LED lamp (optional)
4. Magnetised workpiece
9
3. OVERVIEW OF CONTROLS
1. Main operating console (control cabinet)
2. Tap for hand-held hose
3. Switch for overhead UV light
4. Clamping lever on the sleeve carriage
5. Right control panel
6. Two-hand control (option)
7. Left control panel
8. Emergency stop button
9. Main switch
3.1 MAIN SWITCH
WARNING: The main switch fulfills an
important safety function as a discon-
nection device. Ensure unimpeded
access at all times.
Function: switches the power supply on and o.
Position 0: power supply o
Position 1: power supply on
3.2 EMERGENCY STOP BUTTON
Function: stops the machine in an emergency.
If the emergency stop button has been pressed, it
must be unlocked manually. Before unlocking, deter-
mine and fix the cause of the emergency stop, and
make sure all hazards are eliminated.
Unlocking:
Depending on the version of the emergency stop but-
ton, either:
• Turn the button a quarter-turn clockwise.
• Pull the button upwards.
3.3 MAIN OPERATING CONSOLE
NOTE: as an alternative to the controls described be-
low, the Universal SW can be equipped with a T-Code
Touch Panel. See separate instructions for how to use
the T-Code system.
1. Operating elements for magnetising circuit 1 (circular
magnetisation current flow)
2. Operating elements for magnetising circuit 2 (
longitudinal magnetisation, coil magnetising)
3. Selector switch for operating mode (manual/auto-
matic)
4. Selection switch for demagnetising
5. Indicator light: control on
6. Illuminated push-button: Malfunction and Reset
7. Selector switch for continuous spraying: on/o
8. Push-button: control on
9. Push-button: control o
10.
11. Switch/speed controller for the extraction fan in the
blackout booth (option)
10
Operating elements of the magnetising circuits
a. Digital display of magnetising current/field flux
b. Switch to turn magnetisation circuit on/o
c. Potentiometer intensity
a. Digital display of magnetising current/field flux
Function with current flux (circular magnetising)
Displays the eective actual value of the magnetising
current. Unit depends on the amperage; A or kA.
Function with field flux (longitudinal magnetising)
Displays flux as a product of the actual magnetising
current and the number of turns of the magnetising
coil. Unit depends on the amperage; AW or kAW.
b. Switch
Function: switches the magnetising circuit on and o.
Position 0: magnetising circuit o
Position 1: magnetising circuit on
c. Intensity potentiometer
Function: use to set nominal value of magnetising
current.
Note: At a nominal value of less than 10% of the max-
imum value, it is not possible to monitor the current
flow. Therefore ensure that the nominal value is great-
er than 10% of the maximum value.
Option: a step switch for setting the nominal value of
the magnetising current is also available. If installed,
the adjustment range of the intensity potentiometer is
limited to the range set on the step switch.
Selector switch for operating mode
Function: sets the operating mode of the machine
Position 0: manual mode active
Position 1: automatic mode active
Selector switch for demagnetising
Function: switches on/o the demagnetising in auto-
matic mode
Position 0: demagnetising o
Position 1: demagnetising on
Switch/speed controller for extraction fan (option)
Function: switches on/o the extractor fan in the black-
out booth, and adjusts its speed
Position 0: extractor fan o
Position 1: extractor fan on
3.4 LEFT OPERATING PANEL
1. Emergency stop button
2. Indicator light: Home position
3. Push-button: Rotate workpiece
4. Push-button: Magnetising
5. Push-button: Demagnetising (manual mode)
6. Push-button: Unclamp
Emergency stop button
Function: stops the machine in an emergency.
If the emergency stop button has been pressed, it
must be unlocked manually. Before unlocking, deter-
mine and fix the cause of the emergency stop, and
make sure all hazards are eliminated.
Unlocking: depending on the version of the emergen-
cy stop button, either:
• Turn the button a quarter-turn clockwise.
• Pull the button upwards.
Indicator light: Home position
Function: signals whether the machine is in home
position
Position 0: machine in home position
Position 1: machine not n home position
a
b c
11
Push-button: Magnetising
Function: turns on the magnetisation as long as the
button remains pressed.
Prerequisite: workpiece clamped
Push-button: Demagnetising
Function: starts demagnetisation
Button pressed:
• In automatic mode: demagnetisation is controlled
by PLC.
• In manual mode: the workpiece is magnetised with
the set intensity. For sucient magnetisation, press
and hold the button for 5 seconds.
Button released: the magnetising current is controlled
to zero along an e-function.
Prerequisite: workpiece clamped.
Push-button with indicator light: Clamp (option)
Function of button: clamps the sleeves
Light on: workpiece clamped
3.5 RIGHT OPERATING PANEL
1. Push-button: Rotate workpiece
2. -
3. -
4. -
4. GENERAL SAFETY INFORMATION
4.1 HAZARDS WHEN USING THE MACHINE
WARNING: This manual must be
kept with the machine and must be
freely accessible for operating and
maintenance personnel at all times.
WARNING: High magnetic field
strengths during magnetising can
cause damage to health and have
negative eects on medical implants.
• Always comply with the applicable accident
prevention regulations
• Keep a safe distance from the machine during
magnetisation.
WARNING: Ultraviolet radiation can
damage skin and eyes.
• Never look directly into an UV lamp.
• Avoid skin contact.
• Ensure that only authorised personnel are allowed
within the danger zone.
• Operate UV lamps only if fitted with an undamaged
and properly mounted filter.
• If required, wear eye and skin protection.
CAUTION: Heavy workpieces can
crush hands. Do not reach between
workpieces and machine components
during loading and unloading. Use
hand protection.
CAUTION: Fire hazard: test oils are
highly flammable. Only use flame-
retardant test oils with a flash point >
100°C.
When using oily test liquids:
• have suitable fire extinguishers nearby,
• keep magnetising contacts clean at all times,
• observe the instructions provided by the test liquid
manufacturer.
When using the Universal SW, you must be aware of
hazards for:
• the life and limbs of the operator and other personnel
• the machine itself
• other assets
12
The basis for safe handling and trouble-free operation
of this machine is the knowledge of the safety and user
information in this manual.
Serious injuries to person and damage to property
are possible with:
• incorrect installation
• improper use
• removing coverings or safety devices.
In addition, observe the general and local regulations
for accident prevention and environmental protection.
4.2 MAGNETIC FIELDS IN THE WORKPLACE
WARNING: Magnetisation may inter-
fere with pacemakers and other
medical implants, e.g. insulin pumps.
The following individuals must keep a minimum
distance of 5m from the Universal SW at all times:
• people wearing magnetisable implants
• pregnant women
• people under the age of 16
The specified safety distance is based on the limits
stated in the German Accident Prevention Regulation
BGV B11, version June 2001, of the occupational expo-
sure limits specified for changing electrical, magnetic
and electromagnetic fields (ICNIRP), version 1998.
The machine is assigned to exposure area 1 in accor-
dance with the Unfallverhütungsvorschrift BGV B11
(German accident prevention regulation BGV B11).
When working with the Universal SW, always maintain
the following safety distances from the machine:
• People without active medical implants: s=500 mm
• People with active medical implants (e.g. a pace-
maker): s=5000 mm
Areas of increased exposure
The grey shaded area marks the area of increased ex-
posure. BGV B11 advises spending only short periods
of time in this area.
The operator of the machine is required to identify,
document and mark areas of increased exposure.
S/he must ensure that:
• only authorised and trained personnel work in these
areas, and
• the defined values for short-term and partial bodily
exposure are not exceeded, or that
• personal protective equipment is worn to prevent
excessive exposure.
Important: magnetic fields can penetrate walls!
The requirements stated in BGV 11 must be strictly
complied with when working in areas with increased
exposure.
Since 'areas of increased exposure' depend on the
actual situation on-site, we recommend prohibiting
access to all rooms where strong magnetic fields are
present, for people with medical implants (e.g. pace-
makers), pregnant women, and people under the age
of 16.
4.3 IN CASE OF EMERGENCY
In an emergency, push the emergency stop button
or immediately disconnect the machine from the
power supply by turning the main switch to the OFF
position (marked with “0”).
The main switch can be locked in the OFF position by
means of a padlock.
4.4 RESPONSIBILITIES OF THE OWNER
The owner must only allow people to work on the
Universal SW who:
• are familiar with basic requirements regarding safety
at work and accident prevention;
• have been trained in the operation of the machine;
• have read and understood this manual.
4.5 RESPONSIBILITIES OF OTHER PERSONNEL
Before working with this machine, all personnel must:
• comply with basic requirements regarding safety at
work and accident prevention;
• read and understand the instructions provided in
this manual.
Please contact the manufacturer with any questions.
13
4.6 TRAINING
The Universal SW must only be operated by trained
personnel. Personnel in training must be supervised at
all times when working with the machine.
Transport and installation, power supply connections,
commissioning, maintenance and repair work must
only be performed by qualified specialist personnel
with machine-specific training.
4.7 PERSONAL PROTECTIVE CLOTHING
The following personal protective clothing. (PPE) must
be worn when operating the Universal SW:
• protective gloves
• safety boots
• a skin-protecting agent
The owner is required to prove PPE for all personnel.
4.8 FAULTY PROTECTIVE AND SAFETY DEVICES
Faulty safety devices can lead to dangerous situations.
If a safety device develops a fault:
1. Switch of the machine immediately.
2. Secure it against restarting.
3. If necessary, disconnect from mains power.
4.9 MODIFICATIONS TO THE MACHINE
Any additions or modifications the Universal SW are
not permitted without the written agreement of the
manufacturer, Magnaflux GmbH. If you want to make
any changes, please contact Magnaflux GmbH first.
4.10 SPARE PARTS AND CONSUMABLES
The use of spare parts supplied by third party man-
ufacturers can be hazardous. Only use original parts
or parts approved by Magnaflux GmbH. Magnaflux
GmbH does not accept any liability for damage caused
by non-approved spare parts or consumables.
5. TRANSPORT
5.1 EQUIPMENT FOR TRANSPORT
To transport the Universal SW, the following means are
required:
• a crane with two trolleys and suitable rope harnesses
• a forklift truck or manually-operated forklift.
WARNING: Lifted loads can fall and
cause serious personal injury and
property damage.
• Only use transport equipment that is suitable for the
weight and the dimensions of the machine. Check
the information in section 1.2: Technical Data.
• Insert forklift prongs only in the intended admission
points in the undercarriage. Other attachment points
are not permitted.
CAUTION: Transport, dismantling and
installation of the Universal SW must
only be carried out by specially trained
personnel.
5.2 PREPARING FOR TRANSPORT
1. Decommission the machine prior to transport.
2. Inspect the condition and load bearing capacity of
the floor at the intended installation location and
along the entire transport route.
• The machine must only be installed on a firm,
level surface.
• Comply with relevant local regulations for work
spaces.
• Take note of the technical information provided
in this manual.
3. Determine and mark out the exact installation site.
4. Determine the transport route and remove any
potential obstacles.
5. Keep unauthorised personnel away from the trans-
port route and installation location. Cordon o the
area, if necessary.
6. Check the securing devices on the machine and
attach them if necessary.
• Fix the sleeve carriage
• Fix the magnetising coil
• Fix the UV lamp
14
5.3 TRANSPORT IN ORIGINAL PACKAGING
The machine will be delivered on a pallet, a transport
base or in a crate, and should be transported in this
condition as close as possible to the installation site
The machine is fastened with bolts and screws to the
floor of the packaging, and fixed with tension straps.
Do NOT drop, overturn or tilt the machine more than
10° from the horizontal.
The gross weight of the machine including packaging
can be found in the delivery note.
1. Line up the forks of a suitable fork lift with the mark-
ings on the transport pallet.
2. Raise the machine carefully and gradually, a little at
a time.
3. Transport the machine as close as possible to the
installation site.
4. Lower the machine slowly and carefully. Do not reach
under the machine while lowering.
5.4 UNPACKING THE MACHINE
1. Cut and remove plastic wrapping, if present.
2. Use a crowbar to open the crate.
3. The machine components are bolted to the pallet
floor and secured with tension straps. Unscrew the
fastening bolts and carefully loosen the straps.
4. Take small parts and accessories o the pallet by
hand.
5.5 TRANSPORTING AN UNPACKED MACHINE
Prerequisites:
• No workpiece in the machine.
• Machine in home position.
• All moving parts secured against moving.
• Main switch is o and power supply disconnected.
• Test liquid tank is drained and detached from the
magnetising station. Power supply unplugged from
the test liquid pump.
• Fixing bolts removed from the floor.
• For units with a stand-alone control cabinet: remove
all cable connections between the cabinet and the
magnetisation station.
• For units with a stand-alone transformer cabinet:
disconnect the high-current cables between the
transformer cabinet and the magnetisation station.
Transport with a forklift
Procedure:
1. Determine the transport route and remove any
potential obstacles.
2. Insert the forks of a suitable forklift under the base
of the machine and drive the forklift as close to the
machine as possible. The forks must project at least
20 cm at the rear of the machine. If necessary, use
two forklifts to lift the machine.
3. Lift the machine carefully a small distance o the
ground. Pay attention to the centre of gravity; if
necessary, correct the position of the forks so that
the machine is securely supported by the forklift.
4. Transport the machine to the installation site as
close to the ground as possible.
5. Lower the machine slowly and carefully.
6. Transport the test liquid tank on its pallet using a
forklift truck or hoist. If necessary, secure it to the
pallet.
Transport with a crane
Procedure:
1. Move the sleeve carriage to the right-end position and
fix it there.
2. Insert eyelets into the holes in the base frame and
fasten them with nuts. Check eyelets are securely
fixed in place before transport.
3. Attach rope harness for crane transport to the red
eyelets.
• Do not use attach lifting gear to any other parts
of the machine.
• Make sure that the ropes do not run over protec-
tive grids or other attachments.
• Use one trolley of the crane for the two left eye-
lets and one trolley for the right eyelets.
4. Lift the machine carefully a small distance o the
ground. Pay attention to the centre of gravity; if
necessary, adjust the ropes so that the machine is
hanging level on the crane.
5. Transport the machine to the installation site as
close to the ground as possible.
6. Lower the machine slowly and carefully into place.
7. Remove the eyelets.
15
Transporting the control cabinet
Only necessary if the control cabinet is not fixed to
the machine.
Procedure:
1. Check eyelets are securely fixed in place.
2. Attach rope harness for crane transport to the eye-
lets on top of the cabinet.
3. Lift the control cabinet carefully a small distance o
the ground. Pay attention to the centre of gravity; if
necessary, adjust the ropes so the cabinet hangs
level on the crane.
4. Transport the machine to the installation site as
close to the ground as possible.
5. Lower the machine slowly and carefully into place.
6. INSTALLATION
6.1 SET UP THE MACHINE
CAUTION: Insucient ventilation of
controls, motors and transformers can
lead to overheating. Set up the ma-
chine in such a way to ensure free air
flow through the ventilation grilles.
Prerequisites:
• Take the exact installation positions of the individual
components from the floor plan.
• Install the machine on a level surface in a closed,
dry room.
Procedure:
1. Set the machine down at its final location.
2. Mark the positions of the drilled holes through the
holes in the screw-on plates on the floor.
3. Move the machine slightly to the side.
4. Drill holes in the floor and insert suitable dowels.
5. Move the machine back to its final position.
6. Insert screws through the mounting plates into the
dowels in the floor
7. Tighten the screws.
6.2 CONNECT THE POWER SUPPLY
DANGER: High voltages can cause
lethal electric shock and burns.
Electric connections should only be created:
• in accordance with the wiring diagram and the infor-
mation provided on the type plate
• in compliance with applicable standards in your
country.
• by a qualified electrician.
Power supply
Observe the information about the power supply on
the machine's type plate and in the circuit diagram.
When connecting the power supply:
• Use only delay fuses
• Use cables of appropriate length and suitable for
the power supply conditions.
The cable entry point is located on the underside of
the control cabinet.
16
Compressed air supply
For the supply of compressed air, the Universal SW
requires a pneumatic connection with 6 bar and hose
coupling NW 7.2.
The compressed air connection is located on the
control cabinet on the rear of the magnetisation unit.
Procedure:
1. Feed the supply line through the fitting on the
underside of the control cabinet.
2. Connect the supply line to the marked terminal
inside the control cabinet.
3. Check the power supply:
• Voltage must match the type plate information
• Clockwise rotation field.
4. Connect the compressed air supply line to the
hose coupling on the control cabinet.
5. Turn on the compressed air supply.
6. Check connection seal for leaks.
7. Adjust the pressure via the pressure regulator on
the control cabinet. For set values, see section 1.2:
Technical Data.
6.3 CONNECT THE TEST LIQUID PUMP
The test liquid pump is installed directly on the test liq-
uid tank and comes with a plug-in supply line.
The socket [1] for the test liquid pump is located on the
underside of the base of the magnetising station.
Socket and plug-in supply line for the test liquid pump
1. Install test liquid tank in its designated position (see
machine floor plan).
2. Install test liquid pump on the tank
3. Insert plug of test liquid pump [2] into socket [1.]
4. Lay the cable, ensuring it does not create a tripping
hazard and is not likely to get damaged.
7. COMMISSIONING
Before starting up the machine, complete the following
tasks:
• Check power supply.
• Fill with test agent.
• Test all functions.
• Set up the machine.
• Check the magnetisation.
7.1 SAFETY INFORMATION
CAUTION: Initial commissioning of the
system must be carried out by trained
specialist personnel. Observe the
operating and safety instructions for
the machine and its parts.
7.2 PREPARATION
1. Keep unauthorised persons away from the machine.
2. Carry out a visual inspection of the entire machine.
3. Check the power supply.
4. Check filling levels of lubricants and consumables.
5. Set up the machine.
6. Close all safety doors and protective covers.
7. If present: Unlock all emergency stop buttons.
7.3 SWITCH ON THE MACHINE
1. Switch on the main switch.
2. Switch on the control unit.
3. Make sure machine is in home position.
4. Select the magnetisation circuits.
5. Set current levels.
6. Set time values (option)
7. Select automatic mode.
8. Start the machine.
7.4 TEST THE MACHINE FUNCTIONS
You can test the machine functions by using a defective
part. To do this, proceed as follows:
1. Move the machine to its home position.
2. Adjust the machine for the chosen workpiece.
3. Switch o the demagnetisation unit.
4. Insert the defective workpiece.
5. Start the magnetisation cycle.
6. Inspect the workpiece for visible cracks and
measure the field strength.
7. Replace the workpiece in the machine.
8. Demagnetise the workpiece.
9. Measure the residual field strength in the workpiece.
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