Magnaflux Universal 320 SW Operating instructions

Brand: Magnaflux

Model: Universal 320 SW

Type: Operating instructions

This manual is also suitable for

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)

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

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)

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

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 ecient 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)

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 diers 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.

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.

2. FUNCTIONS AND PROCEDURES

2.1 OVERVIEW OF TEST PROCEDURES

Dierent 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 dierently.

• 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.

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 eective 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

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 99341

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 eects 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.

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 sucient 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

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 ecacy 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

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

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)

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 eective 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

b c

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 sucient 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 eects 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

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.

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

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.

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: Insucient 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.

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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Magnaflux Universal 320 SW Operating instructions

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Model: Universal 320 SW

Type: Operating instructions

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