Universal WE Manual EN

operating manual
universal we
(600/900) touch
Universal WE (600/900) Touch
IDENTIFICATION
MAGNAFLUX GmbH, Bahnhofstraße 94-98, 73457 Essingen, Germany
Manufacturer
T: +49 7365 81 0 F: +49 7365 81 449 E: info@magnaflux.com.de W: www.eu.magnaflux.com
Machine type Universal WE (600/900) Touch
Machine number
Customer
Location
Order
Year of manufacture
machine equipment
Individual limits of the machine
Maximum length of work pieces 70 - 900 mm
Maximum diameter of work pieces 450 mm
Maximum weight of work pieces 100 kg
Aviation cycle Relative ED 60%, absolute ED max. 6 s ON/ 4 s OFF at 50% of nominal power
Magnetising (magnetising currents variably adjustable from 10% up to the individual maximum value)
Circumferential magnetising by axial current flow or field flow with inserted or attached
Magnetising circuit 1
conductor (circumferential magnetising).
Magnetising circuit 2 For divided sleeves (option)
Magnetising circuit 3 Longitudinal magnetising by yoke magnetising.
Magnetising circuit 1 max. 2,000 A AC (effective value)
Magnetising circuit 2 For divided sleeves (option)
Magnetising circuit 3 max. 15,000 AW AC (effective value)
Spraying
Hand-held hose
Hand-held shower with push button
Large-area shower
UV light
UV hand lamp Type:
UV surface lamp Type: Magnaflux LED TYPE 365/30 (option)
UV surface lamp Type: Magnaflux UV Superlight 400 W (option)
Special equipment
Two-hand controls (option)
Control panel with touch screen
T-Code parameter memory (option)
Dark booth (option)
Fan for dark booth (option)
contents
Section Pg Section Pg
1 Notes for users 1 4 Description of workflows and 11
1.1 Information about your machine 1 functions
1.2 Purpose of the operating manual 1 4.1 Individual test workflow 11
1.3 Symbols used 1 4.2 Home position of the machine 11
1.3.1 Action instructions 1 4.3 Workpiece clamping devices 11
1.3.2 Safety instructions 1 4.4 Spraying the workpiece 11
1.4 Location references in the operating manual 2 4.5 Magnetising the workpiece 12
4.5.1 Constant current control 12
2 Machine description 2 4.5.2 Current flow monitoring 12
2.1 Intended use 2 4.5.3 Magnetising types in accordance with EN ISO 12
9934-1
2.1.1 Specification of the workpieces 3
4.5.4 Demagnetising of workpieces 13
2.1.2 Limits of the machine 3
4.6 Lighting at the workstation 14
2.2 Technical data 3
4.7 Visual inspection 14
2.2.1 Dimensions and weights 3
4.8 T-Code parameter memory (option) 15
2.2.2 Electrics 3
2.2.3 Magnetising circuits 4
2.2.4 Clamping devices 4 5 General safety instructions 16
2.2.5 Pneumatics 4 5.1 Hazards when handling the machine 16
2.2.6 Test liquid system 4 5.2 Magnetic loads at the workplace 16
2.2.7 UV-LED-Lamp (Option) 4 5.3 Emergency measures 17
2.2.8 Ambient conditions 4 5.4 Duty of the operating company 17
2.2.9 Emissions 4 5.5 Duty of the personnel 17
2.3 Structure of the machine 5 5.6 Personnel training 17
2.4 Optional special equipment (ordered) 5 5.7 Personal protection equipment (PPE) 18
2.5 Safety features 6 5.8 Defective protective and safety features 18
2.6 Operator work stations 6 5.9 Alterations or modifications 18
2.7 Type plate 6 5.10 Spare/ wear parts and consumables 18
2.8 Labels on the machine 6

2.9 Test liquid system 6 6 Transport 19
2.10 Pneumatic maintenance unit 7 6.1 Transport preparation 19
6.2 Transport in original packaging 19
3 Touch panel at the main operating 8 6.3 Unpacking the machine 19

console 6.4 Machine transport 20
3.1 Screen “Automatic” (start screen) 8 6.4.1 Transporting the magnetising station with a 20
forklift
3.2 Screen “T-Code Select” (option) 8
6.4.2 Transporting the magnetising station with a 20
3.3 Screen “T-Code Edit” 9
crane
3.4 “Diagnosis” screen 9
3.5 Screen “User management” 10
3.6 Screen “Service” 10
contents
Section Pg Section Pg
7 Installation 21 11 Maintenance 31
7.1 Setting up the machine 21 11.1 Maintenance schedule 31
7.2 Connecting the power supply 21 11.2 Inspection instructions 31
7.3 Connecting the test liquid pump 22 11.2.1 If available: Checking the EMERGENCY 31
STOP button
11.2.2 Measuring the magnetising field strength 31
8 Commissioning 22
11.2.3 Magnetising testing 32
8.1 Preparatory tasks 22
11.2.4 Checking the test liquid concentration 32
8.2 Checking functions and magnetising 22
11.2.5 Verifying the test liquid indication capability 33
11.2.6 Checking UV intensity 33
9 Preparing for operation 23
11.3 Maintenance instructions 34
9.1 Filling the test liquid tank 23
11.3.1 Draining the compressed air/ water separator 34
9.2 Overview of setting tasks 23
11.3.2 Topping up the oil in the dosing oiler 34
9.3 Set the distance between the sleeves 23
11.3.3 Cleaning the magnetising contacts 34
9.4 Reconstruction / adjustment of workpiece 24
support 11.3.4 Cleaning the contacts of the high-current 34
connections
9.5 Replace magnetising mandrel 24
9.6 Setting the magnetising parameters 25
9.6.1 Machines without T-Code 25
12 Decommissioning and disposal 35
12.1 Safety instructions for decommissioning 35
9.6.2 Machines with T-Code (option) 26
12.2 Temporary machine decommissioning 35
12.3 Final machine decommissioning 35
10 Operation 27
12.4 Final machine disposal 35
10.1 Safety instructions 27
10.2 Switching the machine ON and OFF 27
- EC/EU Declaration of Conformity 36
10.2.1 Emergency shut-down 27
10.2.2 Before switching the machine ON 27
10.2.3 Switching the machine ON 27
10.2.4 Reactivating the machine after an emergency 27
stop
10.2.5 Switching the machine off for a short time 27
10.2.6 Switching the machine off for a longer time 28
10.3 Select operating mode 28
10.3.1 Manual operation 28
10.3.2 Automatic mode 28
10.4 Home position of the machine 28
10.5 Testing the workpiece in automatic mode 28
10.6 Demagnetising the workpiece 29
10.7 Testing the workpiece in automatic mode 29
with T-Code
10.8 Machine cleaning 29
10.9 Replacing the test liquid 30
10.10 Clean the test liquid tank 30
10.11 What to do in the event of a fault 30
Universal WE (600/900) Touch 1
1 NOTES FOR USERS
1.1 Information about your machine 1.3 Symbols used

The crack detecting machine is designed to provide excellent 1.3.1 Action instructions
work results with ease of use. To make best use of the wide
All tasks of the operating personnel are presented in a
range of possible applications, we offer additional equipment
numbered list. The sequence of actions must be adhered to.
tailored to each individual application, which allows for the
System responses to each operating action are marked by
work on the machine to be even more comfortable.
an arrow. Example:
1 Operating action step 1
You can find information on the machine’s identification and
2 Operating action step 2
intended use and all technical data in Chapter 2.
 System response to operating action 2
Important: Read and observe these operating instructions

1.3.2 Safety instructions
before first use of the machine. For general safety notes see
Chapter 5. Safety instructions:
• warn of immediate or possible hazards;
• inform about hazard prevention measures;
1.2 Purpose of the operating manual • describe measures for minimising risk;
This operating manual:
• offer important information for safety-conscious behaviour.
• describes the function, operation, maintenance and
disposal of the machine; Safety instructions are denoted by a pictogram and a signal
word.
• provides important information for the safe and efficient
• The pictogram describes the type of hazard.
use of the entire system and its individual components;
• The signal word describes the severity of the hazard
• must be stored freely accessible for the operating and
maintenance personnel; Comply with safety instructions to avoid injury to yourself, to
others, and damage to material assets.
• must be handed over with the machine in case of a
location change or change of ownership.
Signal words:
• DANGER: Immediate danger to life and health of
Tips for using this manual:
personnel (severe injury or death).
Read the notes for users first. This is where the symbols
• WARNING: Possible danger to life and health of
used in the operating manual are explained.
personnel (severe injury or death).
When installing, operating, or maintaining the machine, read • CAUTION: Possibly dangerous situation. Possible danger
the component and function descriptions in chapter 2 and 4 of injury to personnel or material damage.
first, and then the instructions for the relevant task. This will
• ATTENTION: Possibly dangerous situation. Possible
give you a better understanding of the system, and will be
danger of material damage.
better able to judge the hazards of the task at hand.
Symbols/pictograms:
You must read the general safety instructions. They form
the basis for safe operation. Specific warnings and safety
instructions are provided before each individual task instruc-
Warning of immediate or possible dangers.
tion.
The instructions do not contain assembly or functional

descriptions, but will show you step-by-step how to achieve Rule: Requirement for a specific behaviour
your goal. Make sure that you read all information regarding or activity. Measures to be absolutely
requirements and tools, and all warnings and safety instruc- observed!
tions. Follow the prescribed sequence of actions.
Prohibition: Prohibits certain activities or

conduct.
2 Universal WE (600/900) Touch
1 NOTES FOR USERS 2 Machine description
1.4 Location references in the operating 2.1 Intended use

manual Operational safety of this machine/system can only be
All directional and location references given in this manual guaranteed for the intended use.The machine/installation is
refer to the main workstation at the front of the machine. intended solely for materials testing:
• of specified workpieces;
• using the magnetic particle test method as specified in
EN ISO 9934-1;
• when stationary;
• within the limits specified below.
Please contact the manufacturer with any questions regard-

ing optimised machine utilisation.
[1] rear Obligations of the operating company

[2] right
The operating company must ensure that workpieces are
[3] front
checked and fed into the magnetising station properly. The
[4] left
operating company must supply all required equipment and
ensure appropriate measures to eliminate hazards due to
moving or hoisted workpieces.
The operating company must also ensure that no personnel

is present below lifted loads during the loading or unloading
of workpieces.
Use contrary to intended use

Use contrary to intended use can lead to injury or damage.
The system must not be operated:
• in potentially explosive environments
• for mechanical or thermal processing of workpieces.
These types of use constitute a misuse of the system.
The operating company is solely responsible for any

consequences:
• from use other than intended use
• from actions not described in the operating manual.
The manufacturer accepts no liability for consequential

damage. If used for any other than the intended use, all
warranty claims against the manufacturer become null and
void.
Work location
The system meets the requirements of the following
standards with regards to electromagnetic compatibility:
• DIN EN 61000-6-4 VDE 0839-6-4:2011-09: Interference
emission standard for industrial environments
• DIN EN 61000-6-2 VDE 0839-6-2:2006-03: Emission
resistance standard for industrial environments
With regards to interference emission, the system is not

suitable for use in residential and small trade environments.
2 Machine description
2.1.1 Specification of the workpieces 2.2 Technical data

Only workpieces complying with the following specification 2.2.1 Dimensions and weights
may be tested with the machine using the magnetic particle
Magnetising unit in standard design with 600 mm clamp-
inspection method:
ing length
Workpieces Workpieces made of ferromagnetic Width 1760 mm
materials with a magnetic conductivity
of >100 µ Depth 730 mm
Clamping length 70 - 900 mm Height 1900 mm (without dark room)
Diameter max. 450 mm Weight 520 kg
Weight 100 kg Weight of test liquid tank 20 kg
Flammability Not self-igniting under pressure, friction
and heat Magnetising unit with expansion unit with 900 mm
clamping length
Explosivemess Not self-exploding under pressure,
friction and heat Width 2100 mm
Weight 550 kg
Please contact the customer service department of the
manufacturer with any questions regarding the products to Dark room (optional)
be tested.
Width 2600 mm
2.1.2 Limits of the machine Depth 2000 mm
Field strength in the > 32 A/cm Height 2300 mm

workpiece Height with fan 2450 mm
Magnetising circuit 1 Variably adjustable up to max. Weight 200 kg
2000 A AC (effective value)
Magnetising circuit 3 Variably adjustable up to max. Space requirement for entire system
15,000 A AC (effective value)
Width 2600 mm
Aviation cycle Relative ED 60%, absolute ED
Depth 3000 mm
max. 6 s ON/ 4 s OFF at 50% of
nominal power
Throughput/h Depending on loading/unloading All measurements are approximate. See installation plan for
times, magnetising times, and obligatory dimension specifications.
assessment times
Permissible min. 10°C, max. 35°C 2.2.2 Electrics
temperature range
Supply voltage AC 3x 400 V / 50 Hz
for operation
Power input approx. 59 kVA
Service life Control voltage 230 VAC, 24 VDC
A comprehensive safety inspection by the manufacturer is re- Construction-side 63 A inert
quired after 10 years of operation. Please contact the manu- fuse protection
facturer’s customer service department in good time. Activation time Relative ED 60%, absolute ED
max. 6 s ON/ 4 s OFF at 50% of
Testing area nominal power
The workpiece will be tested across its entire surface. Test
area is the entire shell surface of the workpiece without the
face pieces. Crack indication is restricted or even impossible:
• in the case of workpieces that deviate substantially from
the specification,
• in the area of the bearing and contact regions of the work-
piece,
• if an unsuitable test liquid is used,
• in severely contaminated workpieces.
2.2.3 Magnetising circuits 2.2.6 Test liquid system

Circumferential magnetising (current flow) Test liquid tank capacity 40 litres
Magnetising Axial current flow or field flow with Supply voltage test liquid AC 400 V / 50 Hz
inserted or attached conductor pump
(circumferential magnetising) Power supply for test liquid Socket in dug-out under-
Current type Alternating current (AC) pump neath the magnetising
station on the base frame;
Magnetising current Variably adjustable up to max. 1.5 m connection cable on
2000 A AC (effective value) the pump; CEE-form plug,
Open-circuit voltage 3.2 V 16 A, 5-pin
Short-circuit current 2920 A AC (effective value)
2.2.7 UV-LED lamp (option)
Longitudinal magnetising (yoke magnetising)
See separate documentation of the UV light; technical data
Magnetising Yoke magnetising at this point are not binding information.
Current type Alternating current (AC)
Manufacturer and type Magnaflux UV-LED surface
Flow Variably adjustable up to max.
lamp TYPE 365/30
15.000 AW AC (effective value)
Supply voltage 85-265 V AC / 47-63 Hz
Power consumption ca. 70 W
2.2.4 Clamping devices
Wavelength 365 nm ± 5nm
Standard design with safety short-stroke UV-A Intensity max. 65 W/m² (6.500 µW/cm²)
Type of left sleeve Pneumatic driven in 400 mm distance
Clamping distance 7 mm UV-B/C emission no emission
Clamping power 940 N White light part < 8 Lux
Type of right sleeve Pneumatic driven Width approx. 640 mm
Clamping distance 7 mm (safety short-strke) Depth approx. 300 mm
Clamping power 940 N Height approx. 215 mm

Weight 11,5 kg
Extended clamping distance:
25 mm, combined with two-hand-control 2.2.8 Ambient conditions
Operating temperature 5 to 45 °C
2.2.5 Pneumatics Storage temperature 5 to 55 °C
Air pressure 6 bar Humidity during operation max. 90% relative humidity
Air quality Dry, oil-free, filtered (non-condensing)
Compressed air Hose coupling, NW 7.2 mm Humidity during storage max. 90% relative humidity
connection (non-condensing)
Oil capacity of dosing 250 ml
oiler 2.2.9 Emissions
Oil type for dosing oiler Hydraulic oil compliant with EMC Suitable for industrial applications in accordance
DIN 51524 Part 2, viscosity 32 with the EMC Directive and current EMC
mm²/s at 40°C (HLP 32) standards.
Recommended oil Festo specialist oil OFSW-32, Noise Workplace related emission value at normal
types for dosing oiler ARAL Vitam GF 32, ESSO Nuto operation: 75 dB (A). Measured in accordance
32, MOBIL DTE 24, BP Energol with DIN EN ISO 3744:2011-02
HLP–HM 32
2.3 Structure of the machine 2.4 Optional special equipment (ordered)
[1] Optional expansion unit for clamping distance [1] Pneumatically driven tailstock
600900 mm
[2] Pneumatically activated clamping device for the rear
[2] Pneumatic clamping unit at the right sleeve half of the sleeve
[3] Manual valve of the pneumatic clamping unit for the [3] Pneumatically activated clamping device for the front
sleeve carriage half of the sleeve
[4] Right hand sleeve carriage [4] Divided right sleeve (contact sheets of both halves of
the sleeve)
[5] Yoke coil at the right sleeve
As an option, the right sleeve can be designed divided
[6] Workpiece receptacle and magnetising contact for
horizontally or vertically. For divided sleeves
axial current flow
• these can be clamped individually
[7] Test liquid tank
• the yoke is effective on both halves of the sleeve
[8] Foot switch for clamping/unclamping of the workpiece • Two separate magnetising circuits are available for
[9] Pneumatic service unit with pneumatic port magnetising the circuit
[10] Main switch Allocation of the magnetising circuits:

• Rear sleeve is magnetising circuit 1.
[11] Transformer cabinet
• Front sleeve is magnetising circuit 2.
[12] Tray for tangential field strength measuring device FSM-2
[5] Touch control panel for T-Code parameter memory
[13] Pneumatic clamping unit at the left sleeve
[6] Control panel elements for 3 magnetising circuits, e.g.
[14] Yoke coil at the left sleeve
for divided sleeve
[15] Control cabinet with touch panel (main control console)
[16] Large-area shower
[17] Optional pneumatic drive of the large-area shower
[18] Optional UV lamp
2.5 Safety features 2.7 Type plate

The type plate of the machine is mounted near the main
WARNING: Only operate the equipment switch on the control cabinet. It contains important informa-
with all protection and safety features in tion about the machine, the power supply, and the manufac-
place and fully functional. turer.
Check safety and protection features periodically.

2.8 Labels on the machine
The machine is equipped with the following safety and
CE label: indicates conformity with applica-
protection features: ble EU regulations regarding the product,
which require a separate CE label.
Danger due to electric current. Work on the

electric system must only be carried out by
certified electricians.
Danger due to hot surfaces, e.g. on work-

pieces or system components. Wear suit-
able protective gloves.
Hazards due to UV radiation. Suitable PPE

(safety goggles and skin protection) is
required, and specific work instructions
must be complied with.
Danger due to magnetic fields. Access

prohibited for specific groups of people. See
general safety instructions.
[1] Main switch (mains isolation) on the control cabinet
[2] EMERGENCY STOP button on control cabinet and at
the operating console at the work station (option) Danger of interference with medical
implants. Access is prohibited for personnel
[3] Two-hand controls for the activation of pneumatic or with medical implants.
electro-motor drives (option)
2.6 Operator work stations

The machine must only be operated by one person. The
work station for standard operation is at the front of the
machine.
2.9 Test liquid system Test liquid circuit
Layout and function

The test liquid unit consists of:
• the test liquid tank,
• the connecting lines,
• the hand-held hose or shower.
The test liquid flows in a closed circuit via the test liquid
collection basin and a dirt trap back to the test liquid tank.
Note: Depending on machine model, some of the test
liquid cannot be collected in the basin during the test [2] Pump
process, which means it cannot be returned to the test liquid [3] Stopcock, mounted on the test liquid tank (optional)
tank. Ensure that escaping test liquid is collected and [4] Solenoid valve
disposed of in accordance with regulations. An additional
[5] Stopcock at the workstation or the magnetising station
test liquid collection basin underneath the machine may be
(option)
required or sensible.
[6] Test liquid nozzle
[7] Test liquid collection basin
Test liquid tank
[8] Return flow from the magnetising station with dirt trap
2.10 Pneumatic maintenance unit
[1] Test liquid feed line to the magnetising station

[2] Filler opening with cap
[4] Test liquid pump [1] Compressed air output to the pneumatic system
[5] Dirt trap [3] Oil container
[6] Return flow from the magnetising station [4] Compressed air connection
[5] Water separator with drain screw
[6] Manometer
[7] Pressure regulator
[8] Setting screw and sight glass on dosing oiler
3 Touch panel at the main operating console
3.1 ‘Automatic’ screen (start screen) 3.2 ‘T-Code Select’ screen (option)
Important: Activate this screen for workpiece testing in

Important: For workpiece testing in automatic mode with automatic mode with T-Code. For workpiece testing without
T-Code, see ‘T-Code Select’ screen. T-Code see screen “Automatic”.
Call Call
The screen appears automatically after the control has been Tap T-Code button; the T-Code screen
switched on. From all other screens, the screen can be appears.
called up with the Return button.
Display
Circular Display of actual value of magnetising
magnetisation current in magnetising circuit 1 in kA.
Tap Select Dataset button.
Longitudinal Display of actual value of current flow
magnetisation in magnetising circuit 2 in kAW.
Close screen, display T-Code screen.
Shower time Display of current set value for shower
time (magnetising with spraying).
Display
Input fields Circular Display of actual value of magnetising
Important: The input fields for the set values are displayed magnetisation current in magnetising circuit 1 in kA.
only if the respective magnetising circuit is preselected. Longitudinal Display of actual value of current flow
Current set value Nominal value of the magnetising
current: Functions
• for magnetising circuit 1 in kA
Recipe Name Display/selection of the formulation
• for magnetising circuit 2 in kAW
where the T-Code datasets are stored.
Post-magnetising Set value for the magnetising time Note: Generally all datasets are stored in
time after spraying. formulation 1. A selection is not possible.
Shower time Set value for shower time (magnetis- Data Record Display/selection of the currently loaded
ing with spraying). Name dataset. Also refer to the instructions for
setting up the magnetising parameters in
Functions chapter 9.
Select Selection of magnetising circuits. Transfer parameter values from the
currently selected dataset into the
Manu/Auto Selection of operating modes (see 10.3) machine controller. In automatic mode,
Select demag. Selection demagnetising on/off. these parameter values are used for
Permanent Permanent spraying on/off (test liquid testing the workpieces.
spraying pump on/off). Reset Acknowledge active error message or
Reset Acknowledge active error message or cancel running demagnetising.
cancel running demagnetising.
3.3 ‘T-Code Edit’ screen Functions

Recipe Name Display/selection of the formulation
where the T-Code datasets are stored.
Note: Generally all datasets are stored in
formulation 1. A selection is not possible.
Data Record Display/selection of the currently loaded
Name dataset. Also refer to the instructions for
setting up the magnetising parameters in
chapter 9.
Transfer parameter values from the cur-
rently selected dataset into the machine
controller. In automatic mode, these
parameter values are used for testing the
workpieces.
Transfer parameter values from the
Use this image to input the magnetising parameter for the machine controller into the currently
workpiece check. You can save up to 100 data records with selected dataset. Important: The values
workpiece-specific parameter values. previously saved in the dataset will be
overwritten!
Activate the screen “T-Code select” for workpiece testing in Creating a new data set.
automatic mode with T-Code. For workpiece testing without
T-Code see screen “Automatic”.
Save current parameter values in the
Call currently selected dataset.
Tap T-Code button; the T-Code screen
Delete currently selected data set.
appears.
Reset Acknowledge active error message or

cancel running demagnetising.
Tap Edit new Dataset button. 3.4 ‘Diagnosis’ screen

Close screen, display T-Code screen. Displays of the history of fault messages
Display
Circular Display of actual value of magnetising
magnetisation current in magnetising circuit 1 in kA.
Call
Tap Diagn button.
Close screen, display Automatic screen

(start screen).
3.5 ‘User management’ screen 3.6 ‘Service’ screen
Call Call
Tap User Administration button. Tap Service button.
Close screen, display Automatic screen Close screen, display Automatic screen
(start screen). (start screen).
Groups Display
You must assign each created user to a group. The following Circular Display of actual value of magnetising
groups are available: magnetisation current in magnetising circuit 1 in kA.
Unauthorized No rights magnetisation in magnetising circuit 2 in kAW.
Users Testers who can select datasets in
T-Code but cannot create or edit these.
Input fields
Programmers Set-up personnel who can select
Important: The input fields for the set values are displayed
datasets in T-Code but cannot create
only if the respective magnetising circuit is preselected.
or edit these.
Supervisor Set-up personnel who can select Preset value Set values for magnetising current in
datasets in T-Code but cannot create magnetising circuit 1 and current flow in
or edit these. magnetising circuit 2.
Service Service engineers who have access to
internal machine data.
Functions
Administrator Administrators with all rights who can
also create new users Select Selection of magnetising circuits.
Enable current Switch on magnetising currents of the
preselected magnetising circuits.
4 Description of workflows and functions
4.1 Individual test workflow 4.4 Spraying the workpiece

The machine can magnetise the workpiece with alternating
current (AC). CAUTION: fire hazard - test oils are highly
flammable.Only use flame-retardant test
In AC operation, the axial current flow (circumferential oils with a flash point > 100°C.
magnetising) and the yoke magnetising (longitudinal
magnetising) can be run concurrently. Workpieces are there- When using oily test liquids:
fore checked for cracks in longitudinal direction, as well as
• have fire extinguishers at hand,
for cracks around the circumference.
• ensure compliance with instructions provided by the test
liquid manufacturer.
The machine operator feeds the workpiece manual or via
a client-side transport system (hoisting equipment) into
Check the test liquid regularly and if necessary replace it.
the workpiece receptacle in the machine. The workpiece
is clamped between two pneumatically driven sleeves
If the system is not used for more than one hour, but should
(see overview of the machine equipment). The two contact
remain in operation, it is necessary that the test liquid flows
surfaces for axial current flow make contact with the work-
in the circuit. Otherwise:
piece. The machine is ready to commence the magnetising
process. • the test liquid heats up.
• the quality of the test liquid reduces.
Spray time starts with the activation of the magnetising • the test oils could become self-igniting at higher tempera-
current and the spray function. The spray function stops tures.
and remagnetising commences, once the spray time has
elapsed. The magnetising current is deactivated once the Open the tap on the hose and place this in the test liquid
remagnetising time has elapsed. The machine operator can collection basin. Then switch on the constant spraying at the
now assess the workpiece. main control console.
Test liquid
4.2 Home position of the machine
The correct concentration of test liquid is a decisive factor
• Sleeves unclamped in the detection of faulty workpieces. Please comply with
• Magnetising current and spray function switched off. mixing ratio instructions provided by the manufacturer.
• Large-area shower in rear position
The test liquid for magnetic particle testing is a suspension
• No active fault. containing:
• a magnetising powder and
• a carrier medium, e.g. water or oil.
4.3 Workpiece clamping devices
The workpieces are inserted by a worker or a suitable device The test powder is frequently mixed with fluorescent dye. As
into the workpiece supports and are removed after inspection. a result, the ac-cumulation of test liquid in cracks becomes
clearly visible under UV light.
Workpiece supports
Besides stationary workpiece supports the following options Using the test liquid
are also available: A sufficient quantity of the test liquid must be evenly applied
• roller block with manual drive to the workpiece. Therefore:
• stationary supports and additional workpiece turning unit • ensure accurate mixing ratio of test powder and carrier
medium,
• thoroughly mix the suspension before use,
• replace severely contaminated suspension.
Spraying with hand-held shower or hose 4.5 Magnetising the workpiece

You can spray the workpiece with test liquid manually, using 4.5.1 Constant current control
the hand-held hose or shower. The tap at the work station The strength of the actual magnetising current depends on
allows the machine operator to shut off the test liquid line the resistance in the circuit. The magnetic field strength in
to the hand-held hose/ hand-held shower, and to adjust the the workpiece is a result of the current output.
throughput volume individually.
The constant current control regulates the voltage in the
magnetising circuit as a function of the actual current. The
actual current value during the entire magnetising cycle is
maintained in accordance with the pre-selected nominal
value.
4.5.2 Current flow monitoring

During magnetising, the actual magnetising current value is
• continuously measured and
• compared to the pre-set nominal value.
A current flow fault is reported if current is absent or too low.

Current flow monitoring:
• functions in manual and automatic operation
• does not function in an intensity range setting of 0 - 10%
On machines with hand-held shower: Press the push-but-

The magnetising cycle is repeated in the event of a current
ton in the shower handle for spraying.
flow fault. A fault is reported and the machine is stopped if
the nominal value is not reached.
Tip: The hand-held hose/hand-held shower is also
convenient for cleaning the machine. Rinse the work area
4.5.3 Magnetising types in accordance with EN ISO
inside the test liquid collection basin thoroughly before each
9934-1
test liquid change.
The magnetising types available on the machine depend on
the machine model and accessories installed.
Showering with Large Surface Shower (option)
Optionally, the machine can be equipped with a large sur- Contact Magnaflux GmbH sales department for information
face shower. regarding required machine components.
It enabkles you to shower the workpiece [2] comfortably and DIN EN ISO 9934-1 deals with magnetic particle inspection
evenly with test agent. On each shower head [1], a stop- in general, and covers the magnetising types available for
cock is installed, allowing you to adjust the individual flow workpiece magnetising.
volumes.
The most common magnetising types are described in the
following brief overview.
Axial current flow

Magnetising by axial current flow. Inherent current flow –
workpiece is in direct contact and behaves like an electrical
conductor.
• Circular magnetic field around the workpiece.
• Displays longitudinal cracks in the workpiece
[1] Large surface shower

[2] Workpiece
[3] Magnetisation equipment
Induction flow For demagnetising,

Magnetising by axial current flow. Circular workpiece forms • a field with alternating polarity must be present, and
the secondary winding (1 winding in short circuit) of a • field strength must continuously decrease towards zero.
transformer.
• Circular magnetic field around the workpiece cross-section. Electronic demagnetising works according to the following
• Displays longitudinal cracks in the workpiece principle:
• The workpiece is magnetised in a regular magnetising
Yoke magnetising (stationary system) cycle with a pre-set magnetising current.
Magnetising by way of field current flow. Workpiece in the • After spraying and at the end of the remagnetising time,
magnetic field between two yokes of an electromagnet. the magnetising current is gradually controlled towards
Displays transverse cracks in the workpiece. zero along an e-function.
Field current flow with inserted or attached conductor

Magnetising by current conductor (auxiliary flow). Magnetis-
ing mandrel in tubular or circular workpieces, or in parallel
contact with the workpiece.
• Circular magnetic field around the conductor and the
workpiece.
• Displays longitudinal cracks in the workpiece
Field current flow via a fixed coil

Magnetising via a conducting coil (field current flow).
• Circular magnetic fields around the conductors accumu-
late inside the coil to form a common longitudinal field.
• Displays transverse cracks in the workpiece
4.5.4 Demagnetising of workpieces

Course of magnetising current during demagnetising
After surface crack testing using the magnetic particle
inspection method, a residual magnetic force will remain in Where magnetising uses direct current, demagnetising uses
the workpiece. Eliminating this magnetic residue will help low frequency, pulsed direct current of alternating polarity.
avoid negative effects during later processing or when using
the workpieces.
The field strength in the workpiece may by reduced by two

methods:
• internally - the magnetising current is controlled towards
zero along an e-function. Demagnetising immediately
follows magnetising in the crack testing machine.
• externally - here the workpiece is demagnetised by an
external coil (see Magnaflux/Tiede products, type ETT).
The workpiece is continuously moved out of the magnetic
field.
Electronic demagnetising
A magnetising with alternating current must be followed
by an AC demagnetising. The electronic current control
unit continually controls the magnetising current along an
e-function towards zero.
4.6 Lighting at the workstation 4.7 Visual inspection

The lighting at the assessment workstation depends on a Visual inspection is frequently used as the method of inspec-
number of parameters: tion for the workpieces.
• Type of workpiece and workpiece surface
• Test liquid As a rule, the machine operator inspects the workpieces
• Lighting conditions at the workplace visually directly in the machine or at a special assessment
station.
Avoid glare from reflective surfaces on the workpiece and
unfavourably positioned light sources. The accumulations of test liquid typical for cracks in the
workpiece are clearly visible as a result of the fluorescent
test liquid and the UV lighting. It is best if external light is
shielded by a dark booth.
Magnaflux UV-LED365/30 lamp
If you are using test liquids without fluorescent dyes, an

illumination intensity of at least 500 lux on the workpiece is
recommended.
If you are using fluorescent test liquids, then

Visual inspection of the workpieces in the machine
• workpieces should only be inspected under UV light
• the UV light intensity should not be less than 1000 μW/cm² [1] Dark booth (optional)
• regularly inspect the UV lamps. [2] UV super lamp
[3] UV hand lamp (optional)
[4] Workpiece
4.8 T-Code parameter memory (option)

The magnetic particle inspection requires workpiece-specific
est parameters such as magnetisation currents and
magnetisation times. You can save the test parameters of up
to 1000 parts and simply select one in the T-code parameter
memory.
The configuration and selection of the magnetisation param-

eter occurs in the screen T-Code select via an individual part
number (workpiece).
Using T-Code
Tap T-Code button; the T-Code screen

appears.
Edit new Create new dataset or change an

Dataset existing dataset.
Select existing dataset for workpiece
Select Dataset
testing.
T-Code data set with magnetising parameter
Important: Activate this screen for workpiece testing in au-

tomatic mode with T-Code
5 GENERAL SAFETY INSTRUCTIONS
5.1 Hazards when handling the machine Dirty or corroded magnetising contacts (e.g. the folding coil)
will lead to excessive transition resistances at the contact
When using the machine, dangers can develop for:
points.
• life and limb of the operator or third party,
• the machine itself,
• other real assets.
The basis for the safe handling and trouble-free operation of

this machine is the knowledge of the safety and user infor-
mation in this manual.
Serious injuries to person and damage to property are

possible with:
• improper installation and setting,
• inappropriate use, The magnetising contacts must therefore be cleaned
• illegal removing of coverings or safety devices. regularly. Maintenance cycles are strongly dependent on
use. Adjust maintenance intervals according to your own
In addition, observe the general and local regulations of the experience.
accident prevention and environmental protection.
Skin irritation caused by test substances
Operating manual at the operating location Ingredients of the test substance may cause skin irritation
This operation manual must be stored at the operating or other health issues. Always comply with the instructions
location at all times. The manual must be freely accessible provided in the manufacturer’s safety data sheet when
for operating and maintenance personnel at all times. handling test substances.
Magnetic field strengths 5.2 Magnetic loads at the workplace

High magnetic field strengths during magnetising may cause WARNING: Magnetising may interfere with
damage to human health and have negative effects on the proper function of pacemakers and
medical implants. other medical implants, e.g. insulin pumps.
• Comply with general and location-specific accident
prevention regulations. Lingering in the vicinity of the machine
or within a perimeter of 5 m around the
• Maintain safety distance during magnetising.
magnetising station is prohibited for:
• persons wearing medical aids and
Risk of crushing due to heavy workpieces
magnetisable implants
Heavy workpieces can crush hands.
• pregnant women
• Do not reach between workpieces and machine compo-
• persons under the age of 16
nents during loading and unloading.
• Use hand protection.
The safety distance given complies with the threshold
High fire risk due to oily test liquids values provided in the German Accident Prevention
Regulation BGV B11 of June 2001, the international
Fire hazard: test oils are highly flammable. Only use
directive regarding exposure to electric, magnetic, and
flame-retardant test oils with a flash point > 100°C.
electromagnetic fields over time (ICNIRP - International
Commission on Non Ionizing Radiation Protection) of 1998.
When using oily test liquids:
• have fire extinguishers at hand, In accordance with the German Accident Prevention
• keep magnetising contacts clean at all times, Regulation BGV B11, the machine for magnetic crack
• ensure compliance with instructions provided by the test testing machine is associated with exposure range 1.
liquid manufacturer! Exposure range 1 applies to areas with controlled access,
e.g. production facilities.
Maintain the following safety distance from the magnetising 5.3 Emergency measures
device during operation (magnetising current active):
In the event of an emergency, press the emergency stop
• Persons without pacemakers: s=500 mm button (where available) or disconnect the machine from
• Persons with pacemakers: s=5000 mm mains power immediately.
The main switch isolates the machine from mains power.

• The OFF position is marked “0”.
• The ON position is marked “1”.
The machine is isolated from mains power when the main

switch is in the OFF position.
The main switch can be locked in OFF position with a pad-

lock.
5.4 Duty of the operating company

Areas of elevated exposure The operating company undertakes to ensure that the
machine is only operated by persons who:
Increased exposure will occur inside the marked areas
(safety distance). BGV B11 only permits a limited stay in • are familiar with basic requirements regarding work safety
these areas. and accident prevention;
• have been trained in the operation of the machine;
The operating company is required to determine, document
and mark areas of increased exposure. It must be ensured • have read and understood this manual.
that:
• only authorised and trained personnel work in these
areas, and 5.5 Duty of the personnel
• the permitted values for brief and partial bodily exposure Prior to starting work, all persons working on this machine
are not exceeded or are required to:
• personal protective equipment preventing unacceptable • comply with basic requirements regarding work safety
increased exposure is worn. and accident prevention;
• read and comply with the instructions provided in this
Important: magnetic fields penetrate walls! operating manual.
The requirements stated in BGV 11 must be strictly complied Contact the manufacturer with any other questions you have.
with when working in areas with increased exposure.
Since areas of increased exposure correlate directly with 5.6 Personnel training
local conditions, we recommend generally prohibiting
access to areas with strong magnetic fields for: The machine must only be operated by trained personnel.
Personnel in training must be supervised at all times when
• persons using medical implants, e.g. pacemakers,
working on the machine.
• pregnant women,
• persons under the age of 16.
Transport and set-up, supply line connections, commission-
ing, and maintenance and repair work must only be per-
formed by qualified personnel with machine-specific training.
5.7 Personal protection equipment (PPE)

The following PPE is required when operating the machine:
• Safety gloves
• Safety boots
• Skin protecting agents
The operating company is required to make available all

necessary PPE.
Ingredients of the test substance may cause skin irritation

or other health issues. Always comply with the instructions
provided in the manufacturer’s safety data sheet when
handling test substances.
5.8 Defective protective and safety features

Faulty or dismantled safety features may result in hazardous
situations. Therefore:
1. Switch off machine immediately.
2. Secure against reactivation.
3. If necessary, disconnect from mains power.
5.9 Alterations or modifications

Additions or modifications to the machine without prior
written approval of the manufacturer are not permitted.
Please contact the manufacturer if you are planning any
conversions.
5.10 Spare/wear parts and consumables

The use of spare/ wear parts supplied by third party manu-
facturers may be hazardous. Only use OEM parts or parts
approved by the manufacturer.
The manufacturer shall not accept any liability for damage

caused by non-approved spare parts, wear parts or consum-
ables.
6 TRANSPORT
6.1 Transport preparation 6.3 Unpacking the machine

1. Decommission the machine prior to transport. 1. Cut and remove any shrink wrap.
2. Inspect the condition and load bearing capacity of the 2. Use a crowbar to open the crate.
floor at the intended installation location and along the
3. The machine components are bolted to the pallet and
entire transport route.
secured with straps. Unscrew the fastening bolts and
• The machine must only be installed on a level and firm carefully loosen the straps.
surface.
• Comply with relevant local regulations for work spaces. 4. Lift small parts and accessories off the pallet by hand.
• Take note of the technical information provided for the
machine.
6.4 Machine transport
3. Specify and mark the exact installation location.
The machine cannot be transported in a ready-to-operate
4. Specify the transport route and remove possible obstacles. state. Machine components, electric and pneumatic connec-
5. Keep unauthorised personnel away from the transport tions and safety features must be removed for transport.
route and installation location. Cordon off these areas, if
necessary. Machine disassembly, transport and subsequent reassembly
must only be carried out by relevantly trained technicians.
WARNING: Lifted loads can fall and result Please contact the Magnaflux service department with any
in severe injury or damage to material questions.
assets.
Transport instructions
Machines and machine components must only be lifted or • Take note of the instructions contained in the operating
transported with appropriate lifting equipment suitable for manual, the general safety instructions, accident preven-
the weight and dimensions of the machine. tion regulations and local requirements for transport.
• Secure the installation location against unauthorised
Transport, disassembly and assembly of the system must
access until all safety features of the machine have been
only be carried out by specifically trained personnel.
installed and are fully functional.
6.2 Transport in original packaging

The machine is delivered in its original packaging on a pallet
or crated, and should be transported in the same condition
as close as possible to the installation location.
The machine in its original packaging is bolted to the pallet

and secured with straps. Machines must not be tipped
over or tilted more than 10° from the horizontal. Relevant
warnings are attached in plain view to the packaging.
The gross weight of the machine including packaging is

stated in the shipping documents.
Procedure
1. Insert the forks of a suitable forklift into the transport
pallet at the marked positions.
2. Lift the machine slightly and with care.
3. Transport the machine close to the ground to the unpack-
ing location.
4. Lower the machine slowly and carefully. Do not reach
under the machine.
6 TRANSPORT
6.4.1 Transporting the magnetising station with a forklift 6.4.2 Transporting the magnetising station with a crane
Requirements
• No workpiece in the machine.
• Machine in home position.
• All moving parts are secured against movement.
• Main switch is off and all supply lines are disconnected.
• Test liquid tank is drained and detached from the
magnetising station. Mains cable of the test liquid pump is
unplugged.
• Floor fastening bolts have been removed. Transport eyes on the machine
If the control cabinet is not permanently fixed to the ma- Requirements

chine, disconnect all cable connections between the control • No workpiece in the machine.
cabinet and the magnetising station.
• Machine in home position. Carriage with sleeve in right-
If the transformer cabinet is not permanently fixed to the hand side end position.
machine, disconnect the high current connections between • All moving parts are secured against movement (straps).
the transformer cabinet and the magnetising station.
• Main switch is off and all supply lines are disconnected.
Procedure • Test liquid tank is drained and detached from the
1. Check and secure the transport route and remove magnetising station. Mains cable of the test liquid pump is
possible obstacles. unplugged.
2. Insert the forks of a suitable forklift as far as possible • Floor fastening bolts have been removed.
into the base. The forks must project at least 20 cm at the
rear of the machine. If necessary, use two forklifts to lift Procedure
the machine. 1. Insert the transport eyelets into the bores on the lower
3. Lift the machine carefully a small distance off the ground. frame and fasten them with nuts. Check the transport
Ensure centre of gravity adjustment! If necessary, correct eyes for secure fit before transportation.
the position of the forks until the machine is securely 2. Attach the lifting gear for transportation by crane to the
supported by the forklift. transport eyes marked red. Do not use other machine
4. Transport the machine to the installation location as close parts as slinging points. Make sure that the lifting gear
as possible to the ground. does not run over protection grilles or other attachments.
Use one travelling crab each for the two left-hand and the
5. Lower the machine slowly and carefully. two right-hand transport eyes.
6. Transport the test liquid tank with a fork-lift truck or hoist. 3. Lift the machine carefully a small distance off the ground. ~
If necessary, secure to a pallet. Ensure centre of gravity adjustment! If necessary, adjust
the rope length so that the machine is hanging straight
from the crane.
4. Transport the machine to the installation location as close
as possible to the ground.
5. Lower the machine slowly and carefully.
6. Remove the transport lugs and transport locks.
7 INSTALLATION
7.1 Setting up the machine Power supply
ATTENTION: Insufficient ventilation of control systems and Take note of the power supply data provided on the type
motors may lead to overheating. Place the machine where plate and in the switching diagram.
unrestricted air flow to the ventilation grilles is ensured. Note the following when connecting the power supply:
• On the construction side, only inert fuses must be used.
Installation must only be carried out by relevantly trained
• Implement appropriately dimensioned lines in terms of
personnel. Please contact the Magnaflux service department
length and power supply conditions.
with any questions.
The cable entries are located on the underside of the control

The correct set-up positions of the individual components is
cabinet.
documented in the installation plan.
Compressed air supply

Operate the machine:
The machine requires a 6 bar pneumatic connection and a
• in enclosed, dry spaces
7.2 NW hose coupling for the compressed air supply.
• on a level surface only
The compressed air connection is located on the mainte-

Bolt the machine to the floor to achieve sufficient stability.
nance unit at the rear of the magnetising unit.
1. Set the machine down at it final location.
Procedure
2. Mark the position of bore holes on the floor through the 1. Feed the supply line into the control cabinet through the
bores in the attachment plates. screw fitting on the underside of the control cabinet.
3. Move the machine slightly to the side. 2. Connect the supply line to the relevantly marked terminal
4. Drill the holes into the floor and insert appropriate plugs. strip in the control cabinet.
5. Set the machine down at it final location. 3. Check the power supply:
6. Insert the bolts through the attachment plates into the • Voltage must match the type plate information
floor plugs. • Clockwise field rotation
7. Tighten all bolts. 4. Connect compressed air supply line to the maintenance
unit via its hose coupling.
5. Activate the compressed air supply.
7.2 Connecting the power supply
6. Check proper seal of the connection.
7. Adjust the pressure via the pressure regulator on the
WARNING: High voltages can cause lethal
maintenance unit. See chapter Technical data.
electric shock and burns.
Electric connections must be created:

• in accordance with the wiring diagram and the information
provided on the type plate
• only by certified electricians
• in compliance with applicable standards at the installation
location.
The device socket inside the control cabinet remains electri-

fied even after the main switch is switched off.
7 INSTALLATION 8 commissioning
7.3 Connecting the test liquid pump CAUTION: Initial machine commissioning
may only be carried out by specifically
The test liquid pump is installed next to the test liquid tank
trained and certified personnel. Read
and comes equipped with a plug-in supply line. The socket
and comply with the operating and safety
[1] for the test liquid pump is located in the dug-out that also
instructions provided for the machine and
contains the test liquid tank.
third-party components!
8.1 Preparatory tasks

5. Remove unauthorised personnel from the vicinity of the
machine.
6. Carry out a visual inspection of the entire machine.
7. Check power supply.
8. Check the fill levels of lubricants and consumables.
9. Set up the machine.
Procedure 10. Close all safety gates and covers.
1. Position the test liquid tank in its specified location. See
machine installation diagram.
8.2 Checking functions and magnetising
2. Set the test liquid pump onto the tank.
Check machine function with a known faulty workpiece, or
3. Insert the line plug [2] for the test liquid pump into the one that has had a fault introduced purposely.
socket [1].
4. Route the cable so that there is no tripping hazard and the Procedure
cable cannot be damaged. 1. Activate the compressed air supply.
2. Switch on the machine at the master switch.
3. Return the machine to its home position.
4. Set up machine to receive the workpiece. Ensure that
the distance of the sleeves is set in such a way as to
ensure the secure seating of the workpiece on the supports.
5. Select manual mode in start screen. Set the mode
selector switch in position 0.
6. Set current strengths and magnetising times. Switch
demagnetising OFF.
7. Insert the faulty workpiece.
8. Use hand-held shower to spray the workpiece with test
liquid and magnetise.
9. Visually inspect the workpiece for cracks and measure
the field strength.
10. Demagnetise workpiece in manual operation.
11. Measure the residual field strength in the workpiece.
12. Preselect automatic mode. Leave demagnetising
function deactivated.
13. Use hand-held shower to spray the workpiece with test
liquid and start the magnetising cycle.
14. Visually inspect the workpiece for cracks and measure
the field strength.
15. Demagnetise the workpiece.
16. Measure the residual field strength in the workpiece.
9 Preparing for operation
9.1 Filling the test liquid tank CAUTION: Parts of the carriage and the
cable harness of the high current cables
The test liquid tank must be filled with appropriate test liquid
may pose a crushing hazard for hands and
before operation. It is imperative that you read and comply
fingers.
with the manufacturer instructions and data sheet provided.
• Do not reach into the area of the carriage track rollers.
If you have already added test liquid, verify the concentration • Personnel is not permitted at the rear of the machine near
and indication capability of the test liquid before running the the cable harness which the carriage is in motion.
test operation. See also the chapter “Maintenance”.
By using the moveable sleeve carriage, a large clamp-
Procedure ing range is possible. Adjust the position of the carriage to
1. Clean the machine before adding new test liquid. attitude of the sleeves distance.
2. Switch off the machine controls.
3. Open the cap on the test liquid tank.
4. Fill test liquid tank. Do not overfill the tank.
5. Replace the cap.
9.2 Overview of setting tasks

The following setting tasks are required for the machine:
• Set the distance between the sleeves. Position the carriage
with the right-hand side sleeve in such a way as to ensure
secure seating of the workpiece on the supports and [1] Workpiece length
secure clamping. [2] Workpiece
• Refit and set the workpiece supports. This procedure [3] Distance between the sleeves
depends on the individual version of the supports - see [4] Manual valve for clamping the tailstock
description and instructions provided by the relevant
manufacturer. Procedure
• Configure the magnetising parameters on the touch panel. 1. Return the machine to its home position.
2. Remove all workpieces from the machine.
9.3 Set the distance between the sleeves 3. Switch off the main switch and secure against unauthor-
ised reactivation.
WARNING: Very heavy workpieces can fall 4. Pull the lever of the manual valve to the front.
off the supports and cause severe injury to
personnel or material damage. 5. Manually adjust the position of the tailstock. Set the
distanceof the two tailstocks about 5 mm larger than the
• Never move the sleeve carriages with a workpiece in place. length of the workpiece. On an expanded clamping stroke
• Do not adjust settings on the sleeve carriages with a work the distance must be set larger.
piece in place. 6. Push the lever of the manual valve to the rear.
• Insert workpiece with utmost care and avoid impact shock ´´The tail-stock is now clamped again.
on the workpiece supports.
7. Adjust the workpiece supports accordingly as needed.
• Do not step underneath hoisted loads when inserting
workpieces. 8. Insert the workpiece and check the setting. Correct as
necessary.
9.4 Reconstruction/adjustment of workpiece 9.5 Replace magnetising mandrel

support
The workpiece supports [3] are usually prismatically CAUTION: A heavy magnetising mandrel
arranged and attached to the sleeves [1]. can crush hands and fingers.
Depending on the workpiece dimensions and the shape of

the workpiece ends, various supports may be required. • Hold the magnetising mandrel securely with both hands.
• Where a magnetising mandrel is to be lifted with hoisting
Adjust the workpiece supports on the sleeves to the work- equipment, ensure that appropriate slinging gear is used for
piece diameter. safe transportation.
• Remove unauthorised personnel from the vicinity of the
machine.
Depending on the size of the workpiece, an appropriate

magnetising mandrel must be attached. See the separate
configuration table for magnetising mandrel sizes.
Depending on machine version, the magnetising mandrel is

attached to the sleeve by way of stud bolts or threaded bolts.
For the replacement of larger magnetising mandrels,
two people and/or appropriate hoisting equipment will be
Example of a workpiece support on the sleeve
required.
Procedure
1. Remove the workpiece from the machine.
2. Switch off machine.
3. Unscrew the fastening bolts of the workpiece support.
4. Adjust the position of the workpiece supports for a
centred clamping position in the sleeve.
5. Remove workpiece support as needed and replace with
matching support for the workpiece.
6. Retighten the two fastening bolts on the workpiece
supports.
7. Insert workpiece, clamp and check contact.
Mounting the magnetising mandrel (various models)
[1] Clamping screw with counter nut

[2] Magnetising mandrel
[3] Fastening bolts
9.6. Setting the magnetising parameters

Set the magnetising parameters at the operating panel.
Ensure that sufficient field strength is achieved in the work-
piece. Check settings and crack detection using a workpiece
with a known fault.
See also chapter 4 for the specific test workflow and the
operating instructions for the machine in chapter 10.
Current flow monitoring during magnetising will work only for

Magnetising mandrel with spray nozzle for test equipment nominal values > 10% of max. value. Always enter a nominal
value greater than 10%.
[1] Left or right magnetising sleeve
[2] Valve for test material (optional) 9.6.1 Machines without T-Code
[3] Spray nozzle for test material (optional)

[4] Magnetising mandrel
[5] Fastening bolt for holding the magnetising mandrel
[6] Fastening bolts for the magnetising mandrel
Procedure
1. Return the machine to its home position.
3. Switch off the main switch and secure against unauthor-
ised reactivation.
4. Dismount the magnetising mandrel. Hold magnetising
mandrel and carefully loosen the clamping screw on the
Magnetising parameter in automatic mode without T-Code
rear side of the sleeve plate. Hold the magnetising
mandrel with both hands and pull it up and away from the
The input fields for the set values are displayed only if the
sleeve.
respective magnetising circuit is preselected.
5. Mount the new magnetising mandrel. Place magnetising
mandrel on sleeve. Tighten the fastening bolts. Tighten The table below details the available actions and proce-
the counter nut on the fastening bolts. dures.
Action Parameter(s) Procedure

Select magnetising circuits Preselect circular magnetization Preselect the desired magnetising circuits
Preselect longitudinal magnetization via the parameters with values YES/NO.
Intensity (nominal value for Preset value circular magnetization Set the desired nominal magnetising value
magnetising current) Preset value longitudinal magnetization. for each activated magnetising circuit via
the parameters.
Postmagnetisation (Preset Postmagnetization circular magnetization Set the duration of magnetising after
value of postmagnetising Postmagnetization longitudinal magnetization spraying of the workpiece in automatic
time) mode via the parameters
Shower time Shower time Set the duration of magnetising and spray-
ing of the workpiece in automatic mode via
the nominal value Shower time.
Demagnetising Preselect demagnetization Preselect automatic demagnetising directly
after the magnetising process via the
parameter with values YES/NO.
9.6.2 Machines with T-Code (option) Procedure

You can save the test parameters of up to 1000 parts and Tap T-Code button; the T-Code screen
simply select one in the T-code parameter memory. appears.
Set the magnetising parameters in the screen T-Code Edit.
Tap Edit new Dataset button.
Save current parameter values in the

currently selected dataset.
Transfer parameter values from the

currently selected dataset into the
machine controller. In automatic mode,
these parameter values are used for test-
ing the workpieces.
Action Parameter(s) Procedure

Select magnetising circuits Preselect circular magnetization Preselect the desired magnetising circuits
Preselect longitudinal magnetization via the parameters with values YES/NO.
Intensity (nominal value for Preset value circular magnetization Set the desired nominal magnetising value
magnetising current) Preset value longitudinal magnetization. for each activated magnetising circuit via
the parameters.
Postmagnetisation (Preset Postmagnetization circular magnetization Set the duration of magnetising after
value of postmagnetising Postmagnetization longitudinal magnetization spraying of the workpiece in automatic
time) mode via the parameters
Shower time Shower time Set the duration of magnetising and spray-
ing of the workpiece in automatic mode via
the nominal value Shower time.
Demagnetising Preselect demagnetization Preselect automatic demagnetising directly
after the magnetising process via the
parameter with values YES/NO.
10 operation
10.1 Safety instructions 10.2.2 Before switching the machine ON
CAUTION: Machine operation is reserved Procedure

for trained personnel only. Read and comply 1. Remove unauthorised personnel from the vicinity of the
with the operating and safety instructions machine.
provided for the machine and third-party 2. Carry out a visual inspection of the entire machine.
components!
3. Check the fill levels of lubricants and consumables.
4. Remove all workpieces from the machine.
CAUTION: Fire hazard! - test oils are highly 5. Unlock all emergency stop buttons.
flammable.
6. Check the set-up of the machine.
• Only use flame-retardant test oils with a flash point > 100°C. 10.2.3 Switching the machine ON
• Keep all contact surfaces clean. Procedure
• Carefully adjust the contact points of the workpiece 1. Activate the compressed air supply.
(distance of the sleeves) 2. Switch on the machine at the master switch.
3. Unlock emergency stop buttons as needed.
When using oily test liquids:
• have fire extinguishers at hand, 10.2.4 Reactivating the machine after an emergency stop
• ensure compliance with instructions provided by the test
CAUTION: Before reactivating the machine
liquid manufacturer.
after an emergency stop:
• determine the cause for the emergency
The detectability of faults on workpieces decreases with stop,
diminishing quality of the test liquid. The service life of test • eliminate any hazards,
liquids depends on the inspection task and the condition of • Remove workpiece from the machine as
the workpieces. needed.
Procedure
Check test liquids regularly and replace as needed. 1. Determine the cause for the EMERGENCY STOP. Check
whether all dangers have been eliminated.
Magnetising time limitation:
2. Unlock the pressed emergency stop button. Depending
Maximum. magnetising time is 30 seconds. A forced shut-
on model, Turn the button head one quarter-turn clock-
down will occur after that time. The machine will be locked
wise or pull the top of the button upwards.
down for 1 minute following a forced shut-down. A relevant
error message is displayed on the control panel. 3. Switch on the main switch.
4. Select manual mode.
5. Return the machine to its home position. Remove work-
10.2 Switching the machine ON and OFF piece from the machine as needed.
10.2.1 Emergency shut-down 6. Repeat the interrupted inspection sequence.
In addition to a controlled shut-down, the machine can be 10.2.5 Switching the machine off for a short time
switched off immediately (forced shut-down) in case of
emergency: Do not use the emergency stop button to stop the machine
during normal operation. Carry out the operating tasks and
• Immediately switch off the main switch. All movement will use the control elements provided for that purpose.
stop immediately, and the magnetising current is shut off.
• Attach a padlock and warning sign to the main switch. Procedure
1. Complete the inspection of a workpiece.
• Notify a relevantly qualified service technician.
• Ensure that all hazards have been remedied before re- 3. Switch off the machine via the main switch.
activating the machine.
10 operation
10.2.6 Switching the machine off for a longer time magnetising process. Touch the button Select demagnetising.
A prolonged interruption would occur over the weekend or
during annual holidays. 10.3.2 Automatic mode
The test workflow is started in automatic mode by clamping
Procedure the workpiece via the pedal switch. Depending on the pre-
1. Complete the inspection of a workpiece. set magnetising parameters, magnetising and spraying will
activate first. The spray function stops and remagnetising
time commences, once the spray time has elapsed. With
3. Switch off the machine via the main switch. demagnetising active, the workpiece is subsequently
4. Deactivate the compressed air supply. demagnetised after magnetising.
5. Drain and dispose of the test liquid inside the test liquid
tank.
6. Clean the machine.
10.4 Home position of the machine
• Sleeves unclamped in rear position.
• Magnetising current and spraying switched off.
10.3 Select operating mode • No malfunction active.
Open the screen Automatic.
10.5 Testing the workpiece in automatic mode
WARNING: High magnetic field strengths

and powered components may cause
personal injury.
• Only one person must operate the machine and inspect the
workpieces.
• No other personnel is permitted in the immediate vicinity of
the machine during magnetising.
• Remove unauthorised personnel from the vicinity of the
machine.
• Do not reach into the work area of the machine during
Selecting the operating mode operation.
Manual operation Note on magnetising: Magnetising time must not exceed

Mode selector switch Automatic in position 0 maximum activation time. A fault will be generated once
a magnetising time of 30 seconds is exceeded; after that,
Automatic operation
magnetising will be locked for 1 minute (cool-down time).
Mode selector switch Automatic in position 1
The preselection of the magnetising circuits and magnetis- Also see description of the machine in Chapter 2 and the
ing currents is independent of Manual/ Automatic mode, and description of the sequences in Chapter 4.
applies for both.
10.3.1 Manual operation Ensure the correct set-up of the machine before commenc-
ing a workpiece test and double-check the operating mode
The workpiece can be magnetised or demagnetised in manual
selection. Actuating the clamping device depends on the
mode at any time independent of the pre-set spray or remag-
clamping distance and the equipment of the machine:
netising time.
• Clamping distance < 7 mm: Pedal switch
Spraying and magnetising • Clamping distance > 7 mm: Two-hand switching or push
Select the desired magnetising circuits via the button Select. button
Demagnetising
You can preselect automatic demagnetising directly after the
10 operation
10.7 Testing the workpiece in automatic mode

with T-Code
For editing the test parameters, see chapter 9.
Open the screen Automatic and select the automatic mode.

Open the screen T-Code select and choose the data set via
the Data Record Name.
The input fields for the set values are displayed only if the
respective magnetising circuit is preselected.
Requirements
• Machine is switched on and set-up in accordance with the
workpiece type.
• Machine is in home position.
• The right sleeve carriage is in position.
Transfer the parameter values of the select-
ed data set to the control of the machine.
Procedure
For testing the workpiece in automatic
1. Set to Automatic mode. Set the mode selector switch to 1. mode, see chapter 10.5.
2. Check the preselection of the magnetising circuits.
3. Check position of the sleeve carriage and the sleeves. 10.8 Machine cleaning
4. Insert the workpiece. Clean the machine:
5. Start the magnetising cycle. Press the pedal switch. • when switched off
 The sleeves clamp and the magnetising cycle starts, • using either spent test liquid, and/or water and a hose
spraying and magnetising commence. with a low pressure spray nozzle;
6. Inspect the workpiece under UV light after magnetising • never use compressed air or solvents,
has been completed. • always clean the machine before replacing the test liquid.
7. If necessary (heavy workpieces): Secure the workpiece
with appropriate lifting equipment and unclamp the sleeves. Procedure
1. Convey the workpiece away from the lifting equipment.
8. Convey the workpiece away from the machine.
2. Clean all components (with the exception of sensors) in
the work area of the machine with the hand-held shower
10.6 Demagnetising the workpiece or the hand-held hose.
Demagnetising in automatic mode 3. When cleaning with water from an external source, the
If demagnetising was preselected, demagnetising will auto- cleaning water will run into the test liquid tank. Make sure
matically commence in automatic mode after magnetising. that the tank does not overflow.
4. Rub off stubborn dirt with a cloth. Do not use any metallic
Manually controlled demagnetising tools.
Press and hold the push- Magnetising ON. 5. Drain and clean the test liquid tank.
button Demagnetise.
6. Fill with fresh test liquid.
Release the push-button Start demagnetising cycle.
Demagnetise.

10 operation
10.9 Replacing the test liquid 10.11 What to do in the event of a fault
Establish a safe condition
WARNING: Severe injury hazard - powered
The machine will be automatically brought to a safe condition
components in the area of the lifting equip-
and testing operation is stopped if the controls detect a fault.
ment may snag and crush extremities.
There are, however, a number of faults and errors that can-

Before accessing the dug-out: not be detected by the controls, or it may no longer possible
• Remove workpiece from the lifting equipment to establish an entirely safe machine state.
• Lower lifting equipment into its home position
Should a hazardous situation arise, then immediately:
• Deactivate master switch and secure against unauthor-
ised reactivation • press the emergency stop button
• switch off the main switch
Never close grille as long as personnel is present inside the • if necessary, secure the main switch against reactivation
dug-out.
• attach a warning sign to the machine.
Dirt particles washed off the workpieces by the test liquid will • investigate the cause
collect in the test liquid tank. Contaminated test liquid will
impair crack detection. Detected faults are displayed on main control panel.
Procedure
1. Completely evacuate and clean test liquid tank.
2. Refill the tank with fresh test liquid. Select the quantity
according to the specifications on the test liquid packaging.
3. Add the specified amount of water.
4. Mix test liquid and water thoroughly.
5. Close the stopcock for the hand-held hose.
6. Dispose of the old test liquid according to regulations.
10.10 Clean the test liquid tank

You will find fault descriptions and relevant remedies in this
Clean the test liquid tank each time the test liquid is replaced. operating manual.
Procedure Notify as needed:

1. Drain the test liquid tank fully using the test liquid pump. • trained service personnel authorised to carry out repairs
2. Deactivate main switch. • the customer service department of the manufacturer.
3. Remove the cover and the test liquid pump from the test
Errors must be acknowledged by pressing the button Error/
liquid tank.
Reset. Operational and warning messages are acknowl-
4. Pour some water into the tank. edged automatically, once the cause has been remedied.
5. Clean the tank with a cloth. Do not use any tools.

6. Empty the tank again completely.
7. Replace the test liquid tank cover and test liquid pump.
8. Clean the dirt screen inside the tank cover. Replace
screen if you detect any damage (Magnaflux part number
62600-009126).
11 MAINTENANCE
Maintenance includes all technical and administrative Inspection and maintenance interval 3
actions to maintain and re-establish the machine’s functional
Magnetising Disconnect the high-current cables,
state. equipment clean the contact points, and coat
with contact grease.
Carry out the described tasks periodically at the intervals
Control cabinet Clean the filters and renew the filter
specified in the inspection and maintenance schedule. and transformation mats if necessary.
cabinet
11.1 Maintenance schedule
Overview maintenance intervals 11.2 Inspection instructions
Interval Period Operating hours 11.2.1 If available: Checking the EMERGENCY STOP
1 daily 8h button
2 weekly 40 h Procedure
3 quarterly 500 h 1. Activate the controls.
2. Press the EMERGENCY STOP button  The control
Carry out the maintenance tasks at the intervals recom-
system must deactivate immediately.
mended above. Adjust the maintenance intervals according
to individual usage conditions as needed. 3. Where available: Repeat steps 1 and 2 for each
EMERGENCY STOP button.
Safety-relevant parts of the machine are designed for a
4. Deactivate the machine immediately and secure main
service life of 10 years. After 10 years, the operating
switch against unauthorised reactivation if one of the
company is required to have a safety inspection carried out
EMERGENCY STOP buttons does not function correctly.
by the manufacturer.
Notify maintenance personnel.
Inspection and maintenance interval 1

11.2.2 Measuring the magnetising field strength
Entire machine Carry out visual inspection. The ma-
The intensity and characteristics of the magnetic field are
chine must not be used if any dam-
age is detected; notify service per- important parameters for magnetic particle inspection.
sonnel as needed. Check magnetising when setting up the machine for new
workpieces.
Test liquid Check test liquid concentration and
display ability, replace as needed.
The tangential field strength measuring device FSM-2 is
Test liquid system Clean test liquid tank.
used for tangential measurements of the magnetic field
strength. The display of the FSM-2 can be switched to show
the field strength in A/cm as an actual or peak value. For
Inspection and maintenance interval 2
more information about the FSM-2:, see documentation
Entire machine Clean with a mild industrial detergent, provided by the manufacturer.
no solvents or acids and alkaline
solutions. Requirements
Workpiece Visual check for damage. Replace Tools required: tangential field
supports any damaged parts as needed. strength measuring device FSM-2
Magnetising Check magnetising by measuring the Magnaflux GmbH part number:
workpiece field strength in the workpiece. 133 032.
Magnetising Clean magnetising contacts with steel
contacts wool and coat with contact grease. Procedure
UV lamps (where Measure light intensity; visual check 1. Magnetise workpiece.
included in the of the filter disk. Replace defective 2. Place measuring probe on the workpiece.
system) filters as needed.
3. Read magnetic field strength in A/cm on display.
Pneumatic Evacuate compressed air/water
maintenance unit separator; top up oil in proportional
oiler (if present)
11 MAINTENANCE
11.2.3 Magnetising testing 11.2.4 Checking the test liquid concentration

Professor Berthold’s test block is a simple test device for The detectability of faults on workpieces decreases with
determining display sensitivity during magnetic particle diminishing quality of the test liquid. The service life of test
inspections, as well as the directionality of the magnetic field. liquids depends on the test type and the condition of the
workpieces.
The test device consists of a flat, remanence-free circular
shield into which a soft-iron cylinder is inserted. The soft iron The indicating capability of the test liquid must therefore be
consists of four section. These sections are separated by verified periodically. Replace the test liquid as needed.
non-magnetising slits and form two perpendicular air gaps.
Magnetic particle suspensions in pump circuits must not be
For more information about the test block, see the documen- tested using the ASTM bulb. Dirt particles in the test liquid
tation provided by the manufacturer. will falsify indications.
Requirements For optimised fault detection on workpieces, the test liquid

Tools required: Prof. Berthold’s test block concentration must exactly match manufacturer specifica-
Magnaflux GmbH part number 135 005 tions.
Checking the test liquid concentration:

• after replacing the test liquid,
• after prolonged work interruptions.
Requirements
Procedure Tools required: ASTM bulb
1. Magnetise workpiece. Magnaflux GmbH part number: 135 015
2. Place test block on the workpiece  Some of the field

lines will flow through the soft-iron core of the test block.
3. Wet the test block with test liquid.
´´Depending on field directionality, one or the other of
the gaps of the crosswise slits will be mapped on the
test block.
´´The magnetic field runs perpendicularly to the gap
mapped.
4. Turn the base of the test body’s enclosure in such a way
that the distance to the workpiece increases. Turn until
the magnetic particle indication disappears. The greater
the distance, the more sensitive the display achievable
with the test method.
Procedure
1. Fill the ASTM bulb with freshly mixed test liquid.
2. Allow the ASTM bulb to settle for 30 minutes.
3. Check the settled magnetic particles against the gradua-
tion marks on the ASTM bulb.
11 MAINTENANCE
11.2.5 Verifying the test liquid indication capability 11.2.6 Checking UV intensity
The detectability of faults on workpieces decreases with The detectability of workpiece defects can be considerably
diminishing quality of the test liquid. The service life of test increased by fluorescent test liquid and UV light. The light
liquids depends on the inspection task and the condition of intensity of the UV lamp plays a significant role.
the workpieces.
Light intensity can decrease noticeably with increasing age
The indicating capability of the test liquid must therefore be of the lamp. The light intensity of all UV lamps must therefore
verified periodically. Replace the test liquid as needed. be checked periodically, and lamps be replaced as needed.
Requirements The light intensity should be approximately 1000 µW/cm².

Tools required: Comparison block 1 in accordance with EN Deviations from this guide value may occur depending on
ISO 9934-2 (Magnaflux GmbH part number 135 011). individual test conditions and ambient light.
Check the of the UV light intensity with manual UV meter

readings.
Requirements
Tools required: J221 UV meter
Magnaflux GmbH part number 134 001
Comparison block with fault pattern

Left: Good indication Right: Test liquid spent
capability of the test liquid
Procedure
1. Spray test block evenly with test liquid.
2. Hold the test block by the edge and inspect under a UV
light.
Procedure
3. Compare indications on the test block with the illustra-
1. Switch on UV light.
tions in the test block manual.
2. Wait about 10 minutes for the lamp to reach maximum
light intensity.
3. Hold the sensor of the UV meter under the lamp.
4. Check the intensity reading.
11 MAINTENANCE
11.3 Maintenance instructions The magnetising contacts must therefore be cleaned

regularly. Maintenance cycles are strongly dependent on
11.3.1 Draining the compressed air/ water separator
use. Adjust maintenance intervals according to your own
Depending on the quality of the compressed air, more or less experience.
water will collect in the water separator of the compressed
air maintenance unit. Requirements
Tools required:
Check the fill level of the water separator:
• Tungrease VC563 contact grease (Magnaflux GmbH part
• periodically in accordance with the maintenance schedule, number 71100-140483)
• at intervals determined from experience.
• Steel wool, medium fine
Empty the tank as needed.

Procedure
Check the fill level of the water separator in the compressed 1. Switch off machine and secure against unauthorised
air maintenance unit: reactivation.
• periodically in accordance with the maintenance schedule, 2. Clean the contact points with steel wool.
• at intervals determined from experience. 3. Apply a thin coat of contact grease to the contact points.
Procedure 11.3.4 Cleaning the contacts of the high-current connec-

1. Hold a container under the compressed air maintenance tions
unit. Clean all connection points (current transitions) between the
2. Open the drain screw on the water separator. high-current transformer, high-current cable, high-current
3. Drain condensate completely. switch and magnetising units regularly.
4. Retighten the drain screw.
11.3.2 Topping up the oil in the dosing oiler
CAUTION: Spilled oil may result in injuries

due to slipping
Pay attention to cleanliness when handling oil.

• Wipe up any spillage immediately.
• dispose of oily rags according to regulations.
[1] High-current connection [2] Contact area
The dosing oiler enriches the compressed air with oil. Read
chapter “Technical data” for oil specifications. Requirements
Tools required:
1. Periodically check the oil fill level in the container on the
compressed air maintenance unit. • Tungrease VC563 contact grease (Magnaflux GmbH part
number 71100-140483)
2. If the oil level is below the minimum mark, detach the oil
container • Steel wool, medium fine
3. Top up with oil to the maximum mark.

Procedure
4. Carefully replace the oil container.
1. Switch off machine and secure against unauthorised
reactivation.
11.3.3 Cleaning the magnetising contacts 2. Undo the connections on the high current cables.
Dirty or corroded magnetising contacts (e.g. the folding coil) 3. Clean the contact points with steel wool.
will lead to excessive transition resistances at the contact 4. Apply a thin coat of contact grease to the contact points.
points. 5. Re-establish the connections.
12 Decommissioning and disposal
12.1 Safety instructions for decommissioning 12.4 Final machine disposal

Requirements
WARNING: High voltages can cause lethal Check before disposal that all supply lines to the machine
electric shock and burns. have been disconnected.
Request information regarding locally applicable disposal

Power terminals on drive controllers may continue to store
regulations.
dangerous voltages up to 3 minutes after disconnecting.
Separate machine components by:
Work on the electrical system:
• Metals
• must only be carried out by certified electricians
• Plastics
• in compliance with applicable standards at the installation • Composite materials
location. • Electric assemblies
• Consumables (e.g. lubricants, etc.)
The device socket inside the control cabinet remains electri-
fied even after the main switch is switched off. Rechargeable batteries, dry-cell batteries, button cell
batteries, paints, varnishes, chemicals (e.g. solvents, clean-
ing agents, etc.), adhesives, fluorescent tubes, energy
12.2 Temporary machine decommissioning saving lamps, waste oil and oil filters are hazardous waste.
1. Drain consumables and dispose in accordance with local These items and substances are harmful to health and the
regulations. environment.
Contact the manufacturer with any questions.
3. Shut off the compressed air supply to the machine.
4. Secure the machine against unauthorised reactivation. Procedure
5. Clean the machine. 1. Decommission the machine.
2. Dismantle the machine from the top assemblies down.
3. Separate the machine components by material.
12.3 Final machine decommissioning
4. Dispose of all parts accordance with local regulations.
1. Drain consumables and dispose in accordance with local
regulations.
3. Shut off the compressed air supply and disconnect supply
line.
4. Disconnect power supply at the feed-in point or unplug
power line.
5. Roll up supply cables and secure them on the machine.
EC/EU declaration of conformity
for Tiede standard machines
for the purpose of the machines guidelines 2006/42/EC appendix II A
We hereby explain that the following machine corresponds to the subsequent EC regulations
of conception and of type as well as the execution brought by us into traffic. The machine was
checked and the test is OK. During changes to the machine without our written approval, this
declaration loses its validity.
Valid EC/EU regulations:

EC Regulation Machines, state 2006/42/EC appendix II A
EU regulation Electromagnetic Compatibility, state 2014/30/EU
Machine designation: Universal WE (600/900)

MAGNAFLUX GmbH Comm.-No:
S/N:
Applied harmoniser standards: DIN EN ISO 12100:2011, DIN EN ISO 13849-1:2016,

DIN EN ISO 13849-2:2013, DIN EN 60204-1:2014,
DIN EN ISO 9934-3:2002
Other applied standards and VDE 0100-410:2007, VDE 0113-1:2014, BGV B11,
specifications: ICNIRP
Authorised person for documentation: Mr. Georg Koch, Quality Management Officer
Address: Magnaflux GmbH, Bahnhofstr. 94-98, D-73457 Essingen,
Germany
Date: 12.07.2016
Responsible employee: Mr. Silvio GEORGI, Sales/Design Manager
Signature:

Universal WE Manual EN

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operating manual

2.2.6 Test liquid system 4 5.2 Magnetic loads at the workplace 16

2.2.7 UV-LED-Lamp (Option) 4 5.3 Emergency measures 17

2.2.8 Ambient conditions 4 5.4 Duty of the operating company 17

2.2.9 Emissions 4 5.5 Duty of the personnel 17

2.3 Structure of the machine 5 5.6 Personnel training 17

2.5 Safety features 6 5.8 Defective protective and safety features 18

2.6 Operator work stations 6 5.9 Alterations or modifications 18

2.7 Type plate 6 5.10 Spare/ wear parts and consumables 18

2.8 Labels on the machine 6

3 Touch panel at the main operating 8 6.3 Unpacking the machine 19

1 NOTES FOR USERS

1.1 Information about your machine 1.3 Symbols used

Important: Read and observe these operating instructions

The instructions do not contain assembly or functional

Prohibition: Prohibits certain activities or

1 NOTES FOR USERS 2 Machine description

1.4 Location references in the operating 2.1 Intended use

Please contact the manufacturer with any questions regard-

[1] rear Obligations of the operating company

The operating company must also ensure that no personnel

Use contrary to intended use

These types of use constitute a misuse of the system.

The operating company is solely responsible for any

The manufacturer accepts no liability for consequential

With regards to interference emission, the system is not

2.1.1 Specification of the workpieces 2.2 Technical data

Field strength in the > 32 A/cm Height 2300 mm

2.2.3 Magnetising circuits 2.2.6 Test liquid system

Clamping distance 7 mm UV-B/C emission no emission

Clamping power 940 N White light part < 8 Lux

Type of right sleeve Pneumatic driven Width approx. 640 mm

Clamping distance 7 mm (safety short-strke) Depth approx. 300 mm

Clamping power 940 N Height approx. 215 mm

2.3 Structure of the machine 2.4 Optional special equipment (ordered)

[10] Main switch Allocation of the magnetising circuits:

2.5 Safety features 2.7 Type plate

Check safety and protection features periodically.

Danger due to electric current. Work on the

Danger due to hot surfaces, e.g. on work-

Hazards due to UV radiation. Suitable PPE

Danger due to magnetic fields. Access

2.6 Operator work stations

2.9 Test liquid system Test liquid circuit

Layout and function

2.10 Pneumatic maintenance unit

[1] Test liquid feed line to the magnetising station

3 Touch panel at the main operating console

Important: Activate this screen for workpiece testing in

3 Touch panel at the main operating console

3.3 ‘T-Code Edit’ screen Functions

Reset Acknowledge active error message or

Tap Edit new Dataset button. 3.4 ‘Diagnosis’ screen

Tap Diagn button.

Close screen, display Automatic screen

3 Touch panel at the main operating console

3.5 ‘User management’ screen 3.6 ‘Service’ screen

Tap User Administration button. Tap Service button.

4 Description of workflows and functions

4.1 Individual test workflow 4.4 Spraying the workpiece

4 Description of workflows and functions

Spraying with hand-held shower or hose 4.5 Magnetising the workpiece