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Magnaflux CSV Series Operation Manual Download Page 4

 

 

Revised January 2020 

www.magnaflux.com 

Page   |   1-3 

 

 

SECTION 1: EQUIPMENT SPECIFICATIONS 

 

 
SCOPE OF THIS MANUAL

 

 
This  manual  provides  essential  information  required  for  installation,  operation,  and  maintenance  of  standard 
Magnaflux CSV Series Stationary Power Pack Magnetic Particle Inspection Machines. 
 

PURPOSE OF THE EQUIPMENT

 

 
The  equipment  is  used  to  inspect  ferromagnetic  parts  by  means  of  the  magnetic  particle  inspection  method. 
Magnetic  particle  inspection  (MPI)  is  a  non-destructive  method  for  revealing  surface,  and,  under  certain 
conditions, sub-surface discontinuities.  It consists of three basic operations: 
 
 

1.  Application of magnetic particles. 

 
 

2.  Establishment of a suitable magnetic field. 

 
 

3.  Inspection and evaluation of particle accumulations. 

 
Discontinuities may exist in raw material from which parts are made, or, they may occur during processing or 
fabrication  of  the  parts,  or,  they  may  exist  as  cracks  due  to  excessive  service  stresses.    Discontinuities  are 
considered defects if their existence is detrimental to the usefulness of the part.  Magnetic particle inspection 
can readily and reliably locate discontinuities revealing manufacturing and/or service-induced defects. 
 

EQUIPMENT CHARACTERISTICS

 

 
Stationary  power  pack  magnetic  particle  inspection  units  consist  of  a  power  pack  that  provides  low-voltage, 
high-amperage  3-phase  full  wave  direct  current  for  magnetization,  and  reversing  3-phase  full  wave  direct 
current for demagnetization on output 1.  Demagnetization on outputs 2 and 3 is an Optional Feature. 
 
The output current levels are governed by 3 separate current controls.  Selection of outputs 1, 2, and 3 is done 
through a color touch screen operator interface.  A push button next to the operator interface initiates the timed 
magnetizing current “shot.” 
 
A  digital  ammeter  provides  a  reading  of  the  magnetizing  current.    The  reading  is  held  until  the  next  current 
“shot” is initiated.   
 
Pertinent data (e.g., the unit’s serial number, electrical specifications, and duty cycle rating) may be found on 
the 

Magnaflux Data Plate,

 located on the front side of the unit. 

 
 
 
 

 

Summary of Contents for CSV Series

Page 1: ...Revised January 2020 www magnaflux com Page 1 0 CSV SERIES...

Page 2: ...eparation for Storage or Shipment 2 19 SECTION 3 OPERATING INSTRUCTIONS 3 1 Operating Controls and Indicators 3 1 Daily Start Up and Operation Check List 3 2 Normal Set up 3 25 Magnetizing Procedures...

Page 3: ...vicing this machine Inspect the machine daily for unsafe conditions replace any worn or broken parts see Section 4 Keep all unauthorized personnel away from the machine operating area According to the...

Page 4: ...tresses Discontinuities are considered defects if their existence is detrimental to the usefulness of the part Magnetic particle inspection can readily and reliably locate discontinuities revealing ma...

Page 5: ...uty Cycle Multiplication Factors for Resistance Welders NPFA National Electric Code 2011 Table 1 1 Electrical Input Model Series Input Volts AC Phase Load Amperes Recommended Line Fuse Amp eres CSV 10...

Page 6: ...eries Maximum Current Amperes Current Control Demag CSV 10 10 000 Continuously Variable In all cases Reversing Decaying DC on Output 1 CSV 15 15 000 Continuously Variable In all cases Reversing Decayi...

Page 7: ...ary 2020 www magnaflux com Page 1 6 EQUIPMENT WARRANTY The Equipment Warranty Statement can be found on our Web site at the following link https www magnaflux com Files Corporate Equipment Warranty St...

Page 8: ...Revised January 2020 www magnaflux com Page 1 7 PAGE LEFT BLANK INTENTIONALLY...

Page 9: ...rm reasonably level floor capable of supporting the inspection unit and the materials awaiting inspection 4 Adequate space to accommodate material storage material movement and access to the materials...

Page 10: ...d be located on the back right corner of the unit WARNING Turn off and lock out the external disconnect switch not normally supplied before opening the right side panel Failure to disconnect incoming...

Page 11: ...ction unit Test ground fault interrupt for proper operation Figure 2 2 below shows the outlets 2 If using the optional 600086 BLACK LIGHT with the integral mag shot button plug the mag shot cable into...

Page 12: ...middle red button called MASTER ON as shown in Figure 2 4 below This is located on the front side of the unit When the unit is powered on the POWER ON light which is the far left button lights up If...

Page 13: ...it is ready to operate The unit can be operated in Manual or Recipe mode When the main screen appears the MANUAL ON green colored button should appear in the bottom center of the screen Figure 2 6 If...

Page 14: ...wn in Figure 2 8 below This sets the unit so that only one cycle will be performed after the Mag button is pushed The cycle is dependent on which outputs are turned on and off which will be detailed n...

Page 15: ...ed in the bottom left corner of the screen in the Setup Screens section This is shown in Figure 2 10 below Figure 2 10 The screen below shown in Figure 2 11 will appear and the parameters for Outputs...

Page 16: ...d push the box located next to Mag Power on the screen and a keypad will appear as shown below in Figure 2 12 The operator would enter a value of 20 and then push the blue ENT button The keypad will d...

Page 17: ...cables are connected to the bus bars of output 1 the operator would push the Mag button located next to the color touch screen interface This button is shown in Figure 2 13 below Figure 2 13 On the m...

Page 18: ...n parallel with double 30 4 0 for CSV 15 to the bus bars on output 2 as shown in Figure 2 17 and remove the cables from output 1 All three outputs and bus bars are shown below in Figure 2 17 Output 1...

Page 19: ...be turned off by pushing the OUTPUT OFF button Output 2 should show Output On and be the only one in the lighter shade of green Figure 2 19 With only Output 2 activated the Mag Power needs to be set...

Page 20: ...s done by pressing the box next to Mag Shot Time The operator would enter a value of 0 5 seconds and then press the blue ENT button After these parameters are set for Output 2 only as this is the only...

Page 21: ...ure for Output 2 located on the main screen which is located in the bottom center of the screen and shown below in Figure 2 23 During demagnetization a message will appear as shown in Figure 2 24 belo...

Page 22: ...0 of 1000 MCM in parallel with double 30 4 0 for CSV 15 to the bus bars on output 3 as shown in Figure 2 25 Figure 2 25 From the main screen the operator would push the Current Type button located in...

Page 23: ...pushing the OUTPUT OFF button Output 3 should show Output On and be the only one in the lighter shade of green Figure 2 27 With only Output 3 activated the Mag Power needs to be set The operator woul...

Page 24: ...essing the box next to Mag Shot Time The operator would enter a value of 0 5 seconds and then press the blue ENT button After these parameters are set for Output 3 only as this is the only activated o...

Page 25: ...center of the screen and shown below in Figure 2 31 During demagnetization a message will appear as shown in Figure 2 32 below Once the demagnetization cycle is complete the message will disappear and...

Page 26: ...ect the ground conductor from the brass grounding screw 2 Disconnect the black light Optional Pack and store in a plastic bag or carton 3 Remove the mounting screws and shims securing the inspection u...

Page 27: ...Revised January 2020 www magnaflux com Page 2 19 PAGE LEFT BLANK INTENTIONALLY...

Page 28: ...h when depressed de energizes the master control relay which in turn de energizes the rectifier fans and all control circuitry Depressing this push button during a magnetizing or demagnetizing sequenc...

Page 29: ...ARNING Lens on the black light may be extremely hot Let the unit cool before cleaning or replacing bulb The front panel of the unit is shown below in Figure 3 1 When the unit is powered on the POWER O...

Page 30: ...elds across the top of the screen show the respective value of the magnetizing currents generated on the last magnetizing shot The attained value for each output is stored and displayed until the next...

Page 31: ...N button lit the operator would then push the CURRENT TYPE button located on the bottom left section of the main screen This can be seen in Figure 3 5 below as it is located in the Setup Screens secti...

Page 32: ...nd then push the blue ENT button The keypad will disappear and the screen will go back to showing all the outputs Figure 3 7 For outputs that have the demagnetization optional feature such as Output 1...

Page 33: ...This can be adjusted from 0 5 to 2 seconds The operator would push the box located next to Mag Shot Time and the keypad would appear again as shown in Figure 3 7 on the previous page Then the operator...

Page 34: ...s shown below in Figure 3 10 on the main screen the operator would push any of the four cycle modes based on what is required The CYCLE 1 ON button would run the cycle through one time the CYCLE 2 SEL...

Page 35: ...three bus bar outputs on the front of the unit as shown below in Figure 3 11 the other end of the cables will go to the part and be connected via a cable wrap prods or clamps Figure 3 11 Once this is...

Page 36: ...wn in Figure 3 14 below Once the demagnetization cycle is complete the message will disappear and the main screen will appear again Confirmation of the part being demagnetized can be done using a cali...

Page 37: ...reen the operator can push the PROCESS PARAMETERS button to set what parameters to show on the report This button is shown below in Figure 3 16 and located in the bottom left of the main screen Figure...

Page 38: ...ct a parameter push on the box with the green check mark and the green check mark will disappear meaning it is not selected Figure 3 18 Next to the Lot Report is a box that is shown below in Figure 3...

Page 39: ...and a USB cable from a printer connects to the back side of the display Once connected the PRINT LOT REPORT can be pressed and the report would print When done printing remove the USB cable and fold t...

Page 40: ...om Page 3 13 Figure 3 21 The Utilities screen can also be accessed from the main screen as shown below in Figure 3 22 in the bottom left corner in the Setup Screens section The operator would again pu...

Page 41: ...Figure 3 23 below would appear The supervisor can now change additional settings by pressing the EDIT OPERATOR LOGIN SETTINGS button located in the bottom center of the screen Figure 3 23 The Edit Log...

Page 42: ...as shown in Figure 3 26 below The supervisor would enter the name using numbers if necessary Once complete the supervisor would press the Enter button and the keyboard would disappear and the name wou...

Page 43: ...Level is broken down as shown below in Figure 3 27 Figure 3 27 The passwords break down is shown below in Figure 3 28 For the Basic Operator the unit is shipped with the password set at 1111 The next...

Page 44: ...keypad would appear where this 4 digit number would be entered Then press the blue ENT button and that would select the password and the keypad would disappear Figure 3 29 Once the passwords are set t...

Page 45: ...hing the HELP button the Edit Login Help Screen below will appear as shown in Figure 3 32 Based on the level of access the person has they can push the LOGIN button located on the lower left corner of...

Page 46: ...4 To enter a lot number push the box in the top center of the screen and a keyboard will appear Enter the lot number and then press Enter This can be used if a batch of parts is desired to be tracked...

Page 47: ...ould confirm which mode the unit is in From the screen shot shown in Figure 3 35 below the MANUAL ON button is shown so that button would need to be pushed to change it to show RECIPE ON Figure 3 35 A...

Page 48: ...e screen in the Setup Screens section as shown below in Figure 3 37 Figure 3 37 After pushing the RECIPE SELECT button the Recipe Selection Screen will appear as shown below in Figure 3 38 From this s...

Page 49: ...on the white box and a keyboard will appear Type in the name of the recipe and then press Enter A close up of this section of the screen is shown in Figure 3 39 below Figure 3 39 After the recipe nam...

Page 50: ...perator would push the SAVE CHANGES button The GO TO MAIN button would then be pushed and if this recipe was still highlighted it would now be reflected as the active recipe on the main screen If the...

Page 51: ...Troubleshooting before proceeding Figure 3 42 Another alarm that may appear on the main screen as shown in Figure 3 43 below would is a Low Output alarm The one below indicates it is occurring on Out...

Page 52: ...ly the magnetizing current by pushing and releasing the magnetizing push button located next to the color touch screen interface 5 The digital read out above each output on the color touch screen will...

Page 53: ...have holes through them it may be desirable to circularly magnetize them with a central conductor rather than passing current directly through the part This method has the advantage of disclosing defe...

Page 54: ...Revised January 2020 www magnaflux com Page 3 27 PAGE LEFT BLANK INTENTIONALLY...

Page 55: ...ian A list of Authorized Magnaflux Service Centers is located at www magnaflux com DAILY OPERATOR MAINTENANCE Table 4 1 Daily Operator Checks Item Action Cable and bus bar connections Tighten as neces...

Page 56: ...ompressed air greater than 30 psi Wear eye protection Use cleaning solvents only in well ventilated areas Table 4 4 Periodic Checks Item Action Rectifier stack Blow accumulated dirt from rectifier hea...

Page 57: ...Revised January 2020 www magnaflux com Page 4 3 PAGE LEFT BLANK INTENTIONALLY...

Page 58: ...om Page 5 1 SECTION 5 TROUBLESHOOTING Refer to the corresponding wiring diagram as a supplement to the troubleshooting chart when tracing an electrical problem Check supplementary drawings for options...

Page 59: ...No output current at any of 3 outputs Thermo shutdown Turn off disconnect wait until unit cools Continuous mag shot on any of 3 outputs Shorted SCR Call Authorized Service Center Main fuse to unit bl...

Page 60: ...Revised January 2020 www magnaflux com Page 5 3 PAGE LEFT BLANK INTENTIONALLY...

Page 61: ...mmon commercial hardware Commercial hardware is identified with a full identification in the DESCRIPTION column Material and coating for commercial hardware is zinc plated steel except where noted DES...

Page 62: ...magnaflux com Page 6 2 SPARE PARTS LIST CSV 10 CSV 15 CSV 20 Part Number Description 521328 Relay 115V 521454 Relay 24V 623505 HMI Maple Display 622996 Firing board only for Rectifier Stack 521095 SCR...

Page 63: ...Revised January 2020 www magnaflux com Page 6 3 PAGE LEFT BLANK INTENTIONALLY...

Page 64: ...Revised January 2020 www magnaflux com Page 7 1 SECTION 7 HOOD INSTALLATION Not Applicable...

Page 65: ...Revised January 2020 www magnaflux com Page 7 2 PAGE LEFT BLANK INTENTIONALLY...

Page 66: ...Revised January 2020 www magnaflux com Page 7 3 3624 West Lake Avenue Glenview Illinois 60026 USA Telephone 847 657 5300 Fax 847 657 5388 Web www magnaflux com E mail cs magnaflux com...

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