P--150

00 S
SERIIES

Revvised July 2014

4
www.magnaflux.comm
Page | 1-0


TABLE OF CONTE NTS

GEN
NERAL SAFETY INSTR RUCTIONS
SEC
CTION 1 - EQ
QUIPMENT SPECIFICA ATIONS .......................... ....................................................... 1-3
al ....................................................... ....................................................... 1-3
Scope off this Manua
Purpose of the Equippment ............................................... ....................................................... 1-3
Equipme eristics ............................................... ....................................................... 1-3
ent Characte
Equipme ent Specifica ations ................................................. ....................................................... 1-5
SEC
CTION 2 - INSTALLATIO ON and STO ORAGE .......................... ....................................................... 2 2-1
General ...................
. ......................................................... ....................................................... 2
2-1
on ........................................................................ ....................................................... 2
Installatio 2-1
Preparation for Stora age or Shipm ment ............................... ....................................................... 2 2-4
SEC
CTION 3 - OP PERATING INSTRUCTIIONS ............................. ....................................................... 3 3-1
Operating Controls and a Indicatorrs ................................... ....................................................... 3 3-1
Shutdow wn ......................................................................... ....................................................... 33-2
Emergen ncy Shutdow wn ...................................................... ....................................................... 3 3-2
SEC
CTION 4 - MA AINTENANC CE .................................................... ....................................................... 4 4-1
General ...................
. ......................................................... ....................................................... 4
4-1
Daily Operator Mainttenance ............................................ ....................................................... 4 4-1
Weekly Operator
O Ma aintenance ........................................ ....................................................... 4 4-1
Periodic Internal Maintenance ......................................... ....................................................... 4 4-2
CTION 5 – DRAWINGS .......................................................... ....................................................... 5
SEC 5-1

Revvised July 2014

4
www.magnaflux.comm
Page | 1-1


GEN
NERAL SAF
FETY INST
TRUCTIONS
S

This manual pro ovides inform

mation on how
w to install, operate, and
d maintain yyour Magnaflux magneticc
particle inspectio
on machine.

Read arefully before operating or servic

d these insttructions ca cing your m
machine.

 Only trained personnel should operate or service this machine. Be familiar with your ffacility and local
procedurres as well as
a Lock Out/T
Tag Out req
quirements b
before workin
ng with this machine.

 Read this
s entire man
nual before operating
o this machine.

 Wear saffety glasses that conform

m to ANSI Standard Z87
7.1 while ope
erating this m
machine.

 Do not wear
w loose clothing or jew
welry while operating
o or servicing this machine.

 Inspect the machine daily for uns ons; replace any worn or broken parrts (see Section 4).
safe conditio

 Keep all unauthorize

ed personnell away from the machine
e operating a
area.

 According to the Am merican Confference of Governmenta

G al Industrial Hygienists (ACGIH) reccommendations,
inspectorrs with pacemakers should avoid ex xposure to D D.C. fields ovver 10 gausss; or 60 cyclle A.C. field over
ss. There are a variety of pacemak
1.0 gaus o magnetic fields. Wea
kers with diffferent suscceptibilities to arers
should discuss pacemaker limita ations with th
heir physicia
ans and learrn more exa actly what the
ey should avvoid,
and whetther they shoould be expo
osed to mag gnetic fields before operrating this eq quipment.

 When yo
ou are finishe
ed operating ne, turn off a ll power.
g the machin

 This mac chine was de esigned to help the end user complyy with ASTM
M E-1444-11. Calibration
n frequency
is dictate
ed by this sta
andard.

Revvised July 2014

4
www.magnaflux.comm
Page | 1-2


SECTION
N 1: EQUIP
PMENT SP
PECIFICAT
TIONS

SCO
OPE OF TH
HIS MANUA
AL

This manual pro

ovides all ess
sential inform
mation required for insta
allation, operration, and m
maintenance
e of the P-1500
Serie
es Power Pa
ack.

PUR
RPOSE OF THE EQUIPMENT

The equipment is used to inspect ferro omagnetic pa arts by meaans of the mmagnetic parrticle inspection method
d.
Magnetic particle inspection (MPI) is a non-destructive meth hod for revvealing surfa
ace, and, u under certain
n
cond
ditions, sub-s
surface discontinuities. It consists of
o three basi c operationss:

1
1. Applicatio
on of magne
etic particles
s.

2
2. Establish
hment of a suitable magn
netic field.

3
3. Inspectio
on and evalu
uation of partticle accumu
ulations.

Disccontinuities may
m exist in raw materia al from which parts are made, or, th hey may occcur during p processing oro
fabrication of the parts, or, they may exist
e as crac
cks due to e
excessive se ervice stressses. Discon ntinuities are
e
conssidered defe ects if their existence
e is detrimental to the usefuulness of the
e part. Mag gnetic particle inspectionn
can readily and reliably locate discontinu uities revealing manufaccturing and/o
or service-in
nduced defeccts.

EQU
UIPMENT CHARACTE
C ERISTICS

The P-1500 is ana extremely y compact in ntegral unit of

o aluminum construction. All opera ating controls and outpu
ut
term
minals are loccated on the e front panel. Two carry ded. One is on the top of the coverr;
ying handless are provid
the o
other is a sw
wivel handle e located at the front of the cover. This handle e may be po ositioned unnder the unitt,
when o raise the frront panel to facilitate me
n desired, to eter reading and operatiion of contro
ols.

Currrent output is
s about 15000 amperes low voltage A.C.
A and ab
bout 1500 am
mperes half--wave D.C. The outputs
s
are b
based on the e use of 30 feet
f of 4/0 ca
able as a loa
ad.

Optioonal magne etizing cable

es can be equipped
e wiith prods fo
or circular m
magnetizatio
on. The cables can be e
wrap
pped around d parts to fo
orm a coil fo
or longitudin
nal magnetizzation. Demmagnetizatio
on is accom
mplished in a
simillar manner.

The P-1500 unitt is built to operate from several volttages (not in

nterchangea ably), typically 230 volts or 460 volts
s,
50/60 hertz, sing
gle-phase. Current at ra ated output is approxim mately 45 am mperes at 23 30 volts and 23 amperes s
at 46
60 volts. (Co
onsult “Data a Nameplate” on specific
c unit for corrrect operatin
ng voltage.)

Revvised July 2014

4
www.magnaflux.comm
Page | 1-3

Channge over froom one volta
age to another will neces
ssitate chan
nging certain
n componentts and wire connections
s.
Conssult factory for
f informatio
on.

An a
automatic res
set thermal overload
o rela
ay is provide
ed to preven
nt overheatin
ng of electriccal compone
ents.

The current con ntrol potentio

ometer, in conjunction
c with a speccial silicon ssolid state ccontrol syste
em, provides
s
infiniitely variable
e magnetizinng and dema agnetizing cu
urrent contro
ol.

The power trans

sformer, ope erating in con
njunction witth blower co
ooled silicon diodes, tran
nsforms the high voltage
e,
low amperage liine input, to
o low voltagee, high ampperage half-w wave D.C. ffor magnetizzing. Low vvoltage, highh
amperage A.C. is
i also furnis
shed for mag gnetizing and demagnettizing.

An issolation type er provides 115-volt curre

e transforme ent for the c ontrol circuittry.

The P-1500 pow wer transform

mer and rectifier are des
signed for in
ntermittent sservice at 15
500 amperess output. To
o
avoid ng and consequent dam
d overheatin mage, a maximum duty ccycle of 2 minutes “on” a and 2 minutes “off” mus
st
be adhered to when
w operatin
ng at rated output.
o

CAUUTION: Le ess than 30 feed of 4/0 0 cable in the magnetizi ng circuit w

will cause an excessive current draw
w
from
m the line and
d overheating of parts.

e.g., the unit’s serial number, electrrical specificcations, and duty cycle rating) may be found on
Pertiinent data (e n
the M
Magnaflux Data
D Plate, located on thhe power pa
ack.

Revvised July 2014

4
www.magnaflux.comm
Page | 1-4


EQU
UIPMENT SPECIFICA
S ATIONS

Weight and Diimensions

Tab
ble 1-1. Mach
hine Weight

pproximate Weight
Ap W (Dry)

Model No. nds

Poun Kilograms
s

P-1500 3
93 43

Tab
ble 1-2. Overrall Dimensio
ons

Descrription

P-1500 21 5/32” L x 9 11/3

32” W x 9 17/3
32” H

Revvised July 2014

4
www.magnaflux.comm
Page | 1-5


PAGGE LE
EFT B
BLAN
NK
INT
TENTTIONA
ALLY
Y

Revvised July 2014

4
www.magnaflux.comm
Page | 1-6
 SECTION 2: INSTALLATION AND STORAGE

GENERAL

This section contains information required for unpacking, inspecting, and setting up the magnetic particle
inspection unit. Information for preparing the inspection unit for shipment and storage is also included.

INSTALLATION

Location of Unit

Consider the following requirements before selecting a permanent location for the inspection unit:

1. A power source of the proper voltage, frequency and phase (as designated on the Magnaflux Data
Plate) capable of providing current per the nameplate for the power pack.

2. A minimum of two feet is required at both ends and the rear of the inspection unit to ensure adequate
space for servicing and ventilation.

3. A firm, reasonably level floor capable of supporting the inspection unit and the materials awaiting
inspection.

4. Adequate space to accommodate a black light inspection canopy (Optional), material storage, material
movement and access to the materials.

Unpacking

No special unpacking process is necessary. Observe normal precautions to prevent damage to inspection
unit, and adhere to standard practices for the removal of crating material, protective barrier materials and
preservatives.

Visually inspect the machine and Optional accessories for any apparent shipping damage, and to ascertain
that all accessories ordered have been received. If shipping damage is found, please contact the freight
company to report the damage before contacting Magnaflux Customer Service via phone at 847-657-5300, or
via e-mail at CS@magnaflux.com.

Revised July 2014

www.magnaflux.com
Page | 2-1
Electrical Connections

The power pack unit as supplied is internally wired for operation from a power source as designated on the
Magnaflux Data Plate. When connecting the unit all local codes should be followed. External wiring directions
for operation on the designated voltage are as follows:

1. With current control in “Off” position, connect the power pack to the purchaser provided fused
disconnect switch of proper rating. (Consult “Data Nameplate” on back of unit for correct operating
voltage.)

2. For both voltage type units, connect “Green” ground lead to a suitable electrical ground. Check ground
with ohmmeter to be assured of proper ground. If a ground lead longer than the line cord is required,
use “Green” line size wire.

3. Set current control to some position other than off. Red pilot light will glow indicating that power to the
unit is “on”.

4. Connect 30 feet of 4/0 cable to output terminals at the front of the unit. Plug in prod control cable and
check operation of unit for both A.C. and half-wave D.C. output.

For maximum output on either A.C. or half-wave D.C. it is necessary to reduce the INDUCTIVE loop of the
external cables as much as possible; that is, the spacing between the external 4/0 cables must be kept at a
minimum. If possible the first 10 feet of cables should be bound or taped together for optimum current
conditions.

NOTE: When cables are used as a coil with A.C. current, ammeter reading will be below 1000 amperes due
to coil inductance.

CURRENT CONTROL AND RED PILOT LIGHT

This is the main switch, located next to ammeter on front panel and controlling current into the unit. With the
current control in any position other than off, the red pilot light will glow indicating that the unit is ready for
operation. Current values will be indicated on the ammeter when the external magnetizing circuit is complete.

OVERLOAD RELAY

This control, located inside of unit, is an automatic resetting type overload relay. It will interrupt the current
flowing to the power transformer whenever the rated duty cycle is exceeded.

AMMETER

The ammeter, located on front panel, registers the amperage flowing in the magnetizing circuits. An automatic
solid state switching circuit allows a single meter to provide accurate current readings for both A.C. and half-
wave D.C. magnetizing current.

Revised July 2014

www.magnaflux.com
Page | 2-2
OUTPUT TERMINALS

Half-wave D.C. is obtained by connecting the cables to the common and HW outlets as indicated. A.C. current
is obtained from the A.C. and common outlets.

CONTROL CABLE RECEPTACLE

This receptacle, located below the current control, connects to the prod control cable.

PROD CONTROL SWITCH

The prods (optional) have a control switch built into the handle. It is connected through a 20 foot cable and
three prong twist lock plug to the control cable receptacle. It controls the flow of magnetizing current through
the prods.

REMOTE CONTROL CABLE SWITCH

This switch (optional) is attached through a 15 foot cable and three prong twist lock plug to the control cable
receptacle.

Revised July 2014

www.magnaflux.com
Page | 2-3
PREPARATION FOR STORAGE OR SHIPMENT

Limited Storage

When the inspection unit will not be used for a period up to 30 days, it should be covered up to avoid dust and
dirt build up.

Long Term Storage and/or Shipment

Disconnect power from the power pack unit by placing the external disconnect switch in the off position.

Use the original shipping materials if possible. If the original packaging is not available, fabricate a shipping
container with sufficient blocking, bracing, and bolting to protect the contents during shipment and long-term
storage. For overseas shipping, the shipping crate must be lined with sealed case liners. For commercial level
packing, fabricate a shipping container in accordance with Consolidated Freight Classification Rules that will
insure safe transportation to the point of delivery. Estimated shipping dimensions and weight are listed in
Tables 1-1 and 1-2. Mark the crate(s) clearly to identify the contents and denote which side is to be up.

Revised July 2014

www.magnaflux.com
Page | 2-4
PAGE LEFT BLANK
INTENTIONALLY

Revised July 2014

www.magnaflux.com
Page | 2-5
 SECTION 3: OPERATING INSTRUCTIONS

OPERATING CONTROLS AND INDICATORS

DUTY CYCLE WARNING: Operating the unit at or near the maximum duty cycle will cause cables to
heat. Appropriate PPE is recommended when handling heated cables. Heated cables
should not come into contact with flammable materials. The life expectancy of
components will decrease if the unit is operated at or near maximum duty cycle for
extended periods of time, resulting in increased maintenance and repairs. Operators
should identify and specify cables that meet their current draw and duty cycle
requirements. Use of the unit at less than maximum duty cycle on a consistent basis will
reduce exposure to elevated temperatures and extend the life expectancy of the unit.

WARNING: Do not operate this machine until you are familiar with all the electrical and mechanical
controls. Check controls for proper functioning before operating machine.

COIL MAGNETIZATION

1. Attach (2) 10-foot lengths of 4/0 cable to the appropriate connectors on front panel. For “A.C.”, attach
one length to “common” and the other length to “A.C.”. For “H.W.”, attach one length to “common” and
the other length to “H.W.”. Special attention is called to paragraph No. 4 of “Connection”.
2. Wrap three turns of third 10-foot cable around or through part to be inspected. Connect it in series with
other cables to form a 30-foot closed circuit.
3. Plug remote control cable into “Control Cable” receptacle. Use switch to control magnetizing current.
Prod control cable can also be used for this function.
4. Turn current control to position that gives desired current level. Red light will glow.
5. Apply Magnaflux powder or bath to surface to be inspected while current is flowing. Inspect for lines of
magnetic particle build-up indicating defects.

PROD MAGNETIZATION

1. Attach two 15-foot lengths of 4/o cables to appropriate connectors on front panel. For “A.C.”, attach
one length to “common” and the other length to “H.W.”. Attach prods to cables. Special attention is
called to paragraph No. 4 of “Connection”.
2. Plug prod control cable into “Control Cable Receptacle”.
3. Turn current control to position that gives desired current level. Red light will glow.
4. Make prod contacts with clean surface of part. (Place prod tips about six inches apart on either side of
line of suspected defect.) Press prod handle switch to start magnetizing current flow. Ammeter will
indicate amount of magnetizing current.
5. Apply Magnaflux powder or bath to surface to be inspected while magnetizing current is flowing.
Inspect for indications of defects.
6. Release prod handle switch to stop flow of magnetizing current through prods. Remove prods from
part.

Revised July 2014

www.magnaflux.com
Page | 3-1
DEMAGNETIZATION

Demagnetization can be accomplished in a number of different ways with this unit.

1. Connect a formed coil to the A.C. and common output terminals. Set the current control to desired
current level. Depending upon the size of the part involved, it is either passed through the coil, or the
coil is passed completely over the part and slowly withdrawn while current flows in coil. As the part or
coil is withdrawn, the diminishing intensity of the A.C. field completes the demagnetization. When coil
face is at least 12” from the part, current in coil can be interrupted using switch on unit. If the line
switch is turned off while in close proximity to part, incomplete demagnetization may result.
2. Connect a formed coil to the A.C. and common output terminals. Set the current control to desired
current level. Place the coil over the part to be demagnetized. Depress and hold the control cable
button to cause current to flow through the coil. Slowly rotate the current control toward the off position
until the current drops to zero. Release the control cable button and remove coil from part.
3. If the part has been magnetized circularly by means of the direct contract method, demagnetization can
be accomplished as follows:

Connect the cables with prods to the A.C. and common output terminals.

Make prod contacts with clean surface of part. (Place prod tips about six inches apart, on either side of line of
defect.) Press prod handle switch to start magnetizing current flow through the part. Slowly rotate the current
control toward the off position until the current drops to zero. Release the control cable button.

SHUTDOWN

Disconnect power from unit by turning external disconnect switch to OFF or unplug from outlet for 115V
version.

EMERGENCY SHUTDOWN

To shut off the machine in an emergency, disconnect the power by turning OFF the external disconnect switch.
Lock Out unit as required.

Revised July 2014

www.magnaflux.com
Page | 3-2
PAGE LEFT BLANK
INTENTIONALLY

Revised July 2014

www.magnaflux.com
Page | 3-3
 SECTION 4: MAINTENANCE

GENERAL

The following tables contain periodic visual and operational inspections designed to prevent or discover
malfunctions and defective parts. Many of these checks are based on ASTM E-1444. Do not operate the
inspection unit if it is found to be in need of repair or unsafe. Report problems to the designated authority. Do
not remove any cover panels. Inspections or maintenance requiring removal of cover panels are to be
performed by a qualified technician. A list of Authorized Magnaflux Service Centers is located
at www.magnaflux.com

DAILY OPERATOR MAINTENANCE

Table 4-1. Daily Operator Checks

Item Action

Cable and bus bar connec- Check bus bar and cable connections. Tighten as necessary. Check wires
tions and cables for worn or frayed insulation.

Locking devices Check tailstock and coil lock.

Leaks (bath) Check tank, hoses and nozzle for leakage.

Power indicator Check that indicator lights when power is supplied to inspection unit.

Push-buttons Check push-buttons for proper operation.

Ammeter Check ammeter readout

Automatic current control Check for smooth and proper operation.

Black light assembly Check for missing or broken filter or lamp. Check for damaged cord.

WEEKLY OPERATOR MAINTENANCE

Table 4-2. Weekly Operator Checks

Item Action

Ground Fault Interrupt Check for proper operation of Black Light.

Revised July 2014

www.magnaflux.com
Page | 4-1
PERIODIC INTERNAL MAINTENANCE

NOTE: The following procedures should be performed by a qualified maintenance technician.

WARNING: Turn off and lock out the external disconnect switch before removing cover panels. Failure to
disconnect incoming power could result in severe electrical shock or death.

WARNING: For cleaning, do not use compressed air greater than 30 psi. Wear eye protection. Use
cleaning solvents only in well ventilated areas.

Table 4-3. Periodic Checks

Item Action

Rectifier stack Blow accumulated dirt from rectifier heat sinks and fan blades. Do not use
cleaning solvents.

Control panel wiring Check wiring for discoloration or burnt insulation, connectors for security.

Lower unit wiring Check wiring for discoloration or burnt insulation, connectors for security.

Transformers Check transformers for discoloration and pungent order.

Connections Check and tighten all connections, bus bars, cables and wires.

Ammeter and “Mag” shot time Check for accuracy every 6 months.

Revised July 2014

www.magnaflux.com
Page | 4-2
PAGE LEFT BLANK
INTENTIONALLY

Revised July 2014

www.magnaflux.com
Page | 4-3
 SECTION 5: DRAWINGS

GENERAL

The drawings provided describe major equipment groups, assemblies, sub-assemblies, and detail parts of the
Magnaflux Magnetic Particle Inspection Units. Depending on your options package, certain parts may have
been substituted.

FIGURE AND INDEX NUMBER COLUMN

The first number identifies the corresponding drawing. The number after the hyphen identifies a component on
the associated illustration.

PART NUMBER COLUMN

On each drawing is a bill of material located in the lower right corner. Magnaflux part numbers are used to
identify all parts except common commercial hardware. Commercial hardware is identified with a full
identification in the DESCRIPTION column. Material and coating for commercial hardware is zinc plated steel
except where noted.

DESCRIPTION COLUMN

A brief description is provided for each item. The descriptions to the right indicate assembly-sub-assembly-
part relationship. The Magnaflux part number is included in the description.

UNITS PER ASSEMBLY COLUMN

The quantities listed are for that assembly only. The abbreviation "REF" is used to indicate that the quantity
has been shown in a previous listing. The abbreviation "A/R" (as required) is used when a precise quantity
cannot be specified.

HOW TO ORDER A PART

Contact your local Authorized Magnaflux Service Center or Distributor to order the part. Provide the model and
serial number of the unit, and the part number requested.

Revised July 2014

www.magnaflux.com
Page | 5-1
PAGE LEFT BLANK
INTENTIONALLY

Revised July 2014

www.magnaflux.com
Page | 5-2
155 Harlem Avenue, Glenview, Illinois 60025 USA Telephone:
(847) 657-5300 Fax: (847) 657-5388
Web: www.magnaflux.com E-mail: cs@magnaflux.com

Revised July 2014

www.magnaflux.com
Page | 5-3