Technical Order - Magnetic Particle Inspection.pdf

TO 33B2-65-1

IDENTIFYING TECHNICAL PUBLICATION SHEET

FOR

COMMERCIAL MANUAL

1 MAY 2005

Published Under Authority of the Secretary of the Air Force.

22 SEPTEMBER 2013

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DISTRIBUTION STATEMENT B - Distribution authorized to U.S. Government Agencies only (Proprietary Information) (3 November 2013). Other requests for this document shall be referred to 406 SCMS/GUEE, Robins AFB, GA 31098-1670. Questions concerning technical content shall be referred to 404 SCMS/GUEE.

1. PURPOSE: This Identifying Technical Publication Sheet is issued for the purpose of identifying an authorized commercial manual for Air Force use and for providing supplemental information thereto.

TITLE: OPERATION AND MAINTENANCE INSTRUCTIONS - MAGNETIC PARTICLE INSPECTION UNIT

STATIONARY WET METHOD, MAGNE-TECH

PUBLICATION DATE: 1 MAY 2005

ADDITIONAL IDENTIFICATION:

2. ADDITIONAL INFORMATION: NSN: 6635-01-366-6791

See SUPP D

33B2-65-1

Operation and Maintenance Instructions

Magnetic Particle Inspection Unit Stationary Wet Method

NSN 6635-01-366-6791

May, 2005

Publication No. GB-3509A-01-CTM Rev. 2

May,2005

Identifying Technical Publication Sheet for

Commercial Manual

1. Purpose: This identifying technical publication sheet is issued for the purpose of identifying an authorized commercial technical manual for Air Force use and for providing supplemental information thereto.

Delivery Order: 0001 Equipment: Magnetic Particle Inspection Unit

Stationary Wet Method Model No. GB-3509A-01

Title: Operation and Maintenance Instructions Date: May, 2005

2. Additional Copies: Additional copies are available from

3. File Location: The above described commercial manual is filed in__________________.

4. Authority Notice, Distribution Statement, Disclosure Notice Notice.’Reproduction for non-military use ofthe information or illustrations contained in publication identified above is not permitted. The policy for military use reproduction is established for the Air Force in AFR 205-1.

Table of Contents

Section Page

I. Introduction and Description 1-1 Identification........................................................................................^ -3 Purpose and Function of Equipment -7 Characteristics of Equipment -14 Power Connection -18 Items Furnished -20 Environmental Requirements -22 Items Required 1-24 Storage Data 1-26 Tools and Test Equipment 1-28 Warranty 1-35 Safety Precautions 1-36 Electrical Hazards 1-37 Chemical Hazards 1-38 Compressed Air

II Preparation for Use and Installation Instructions 2-1 Preparation for Use 2-3 Unpacking 2-4 Leveling 2-5 Electrical Connections 2-6 Air Supply 2-7 Checkout Procedure 2-8 AC Demag Checkout Procedure 17 2-9 DC Demag Checkout Procedure 2-10 Remote Control Operation 2-11 Bath Preparation

III General Theory of Operation 3-1 General 3-3 DC Power Circuit 3-4 AC Magnetization Control Circuit 3-5 AC Demagnetization Control Circuit 3-6 DC Magnetization Control Circuit 3-7 DC Demagnetization Control Circuit 3-8 Module Circuits 3-9 Black Module

(Continued)

Section Page

III General Theory of Operation (cont.)

3-10 Green Module 3-11 Purple Module 3-12 Red Module 3-13 White Module

IV Operating Instructions 4-1 Control Indicators 4-2 Black Light Hood 4-4 Startup / Shutdown 4-6 Normal Operation 4-7 Magnetization Procedures 4-15 Demagnetization Procedures 4-17 AC/DC Demagnetization

V Maintenance Instructions 5-1 Daily Procedure 5-2 Weekly Procedure 5-3 Monthly Procedure 5-4 Trouble Shooting 5-7 DC Power and Logic System Checkout 5-8 AC Power and Logic System Checkout 5-9 General Repair Procedures 5-12 Cleaning

VI Calibration Procedures and Adjustments

6.1 Equipment Calibration

6.2 Ammeter Accuracy

6.3 Ammeter Adjustment

6.4 Machine Timer Control Check

6.5 Magnetizing Time Adjustment

6.6 Quick Break Check

VII Bill of Materials Listing

(Continued)

Section Page

VIII Appendix A Diagrams 8-1 Magnetic Particle Inspection Unit (Sht 1) 8-2 Magnetic Particle Inspection Unit (Sht 2) 8-3 Coil and Carriage Assembly 8-4 Tailstock Assembly 8-5 Fan Console Assembly 8-6 Headstock Assembly 8-7 Hood Assembly 8-8 SCR Stack, Primary 8-9 SCR Stack, Secondary 8-10 Wiring Diagram

Section I

Introduction and Description

1-1 Identification

1-2 This instruction manual describes the function, operating procedures, installation, maintenance and parts information ofthe Wet Method Magnetic Particle Inspection Unit manufactured by

The manual is organized to present first a basic familiarization ofthe system’s functions, then the detailed procedures for installing, operating and maintaining the equipment.

Notes, Cautions, and Warnings accompany the text throughout this manual. A Note indicates an operating procedure or condition that is essential to highlight or which provides an explanation for a given procedure. A Caution indicates operating procedures or practices that, if not strictly observed, may result in damage to, or destruction of equipment. A Warning indicates operating procedures or practices that can result in bodily injury or loss of life if not correctly followed.

1-3 Purpose and Function of Equipment

1-4 The is designed for rapid detection of defects in magnetic metals which otherwise could not be seen by the inspector. This unit provides general purpose inspection by the wet method process. An iron oxide suspension is flowed over the work piece while the part is in a magnetized condition. The magnetic particles are attached to, and concentrate at the defects in the work piece, making the defects clearly visible to the inspector.

1-5 Discontinuities detected by magnetic particle inspection may be inherent in materials from which parts are made. Cracks may be the result of fatigue or excessive service stress. Discontinuities are considered defects if their presence is considered detrimental to the use ofthe part.

1-6 Parts to be magnetic particle inspected may be clamped between the tailstock and headstock to achieve circular magnetization. Current passed directly through the part will produce a circular magnetic field, disclosing longitudinal discontinuities. Longitudinal magnetization may also be used instead of, or in addition to circular magnetization by use ofthe coil. When current is passed through the coil, a longitudinal magnetic field is induced in the part, disclosing transverse discontinuities. On cylindrical parts a circular magnetic field may be induced by placing a copper bar through the part, clamping the bar between the headstock and tailstock, and energizing the machine. The current passing through the bar will then induce a circular magnetic field in the part.

To allow inspection of large/or irregular parts, difficult to inspect in the unit, remote inspection accessories are provided.

1 -7 Characteristics of Equipment (See Table 1 -1)

1-8 The equipment covered in this manual consists of a basic, wet method magnetic particle inspection unit and several accessories. The unit incorporates 6,000 ampere DC magnetizing and demagnetizing, as well as 5,000 ampere AC magnetizing and demagnetizing features. An AC-DC switch selects the mode of operation. The magnetizing procedure for AC or DC operation is essentially the same. AC inspection will disclose only discontinuities on the surface ofthe part being inspected. DC inspection provides for a deeper penetration of the magnetic field into the part being inspected and can disclose discontinuities such as inclusions below the surface ofthe part.

1-9 A metal cabinet houses the basic system. An accessory hood arrangement envelops the unit. This provides a light tight enclosure permitting maximum visibility and contrast of indications during inspections using black light and fluorescent particles.

1-10 The tailstock moves on rails and may be secured any place within its travel range. Pressure on the part being inspected is required to ensure good electrical contact. This is supplied by a movable plate located on the headstock. It is activated by a foot switch controlled air cylinder. A tank containing the wet bath medium is covered with hardwood grilles. The grilles allow the bath medium to drain into the tank while preventing small parts from entering it. The bath medium is applied with a hand held hose and nozzle. An electric motor driven pump recirculates the bath medium and also creates pressure to the hand nozzle. A sump screen is installed in the tank to prevent damage to the pump from foreign objects.

1-11 The magnetizing coil is movable along the rails and may be locked in the desired position. The coil provides a means for magnetizing parts longitudinally. It is made up of five full turns of copper strip. The product of five turns times the reading on the ammeter will give coil output in ampere turns.

1-12 The headstock is fixed in position, and contains an air operated cylinder for clamping parts between the headstock and tailstock. On the headstock are controls for the air cylinder, air pressure gage and air filter.

1-13 The front left (control) panel of the unit contains the bulk of the operator controls. These include switches selecting the mode of operation (magnetizing or demagnetizing), selecting coil or contact use, and the main current control potentiometers.

1-14 Power Connection

Warning

Dangerously high voltage potentials are present within the cabinet. To prevent electrical shock, use caution when installing, operating, or performing maintenance on this equipment.

Table 1-1

Specifications

Item Characteristic

Magnetizing Output Current (maximum): 5000 Amperes AC, 6000 Amperes DC Control Setting: Infinite adjustment Regulation: State ofthe art electronics Rectification: Silicon Controlled

Rectifiers (SCR’s) Demagnetization Output

AC Mode: 5000 Amperes (maximum) ramped to zero amperes

DC Mode: 6000 Amperes (maximum) alternating polarity ramped to zero amperes

Range of Automatic Timer AC Magnetization: 1/6 to 1-1/2 seconds (1/2 second normal) AC Demagnetization: 2 to 10 seconds (10 seconds normal) DC Magnetization: 1/6 to 1-1/2 seconds (1/2 second normal) DC Demagnetization: 15 to 40 seconds (30 seconds normal)

Manual Timing: Remote cable is be used for non timed operation.

Duty Cycle At 100% Rated Output: 5 seconds ON, 4 minutes OFF AT 40% Rated Output: 10 seconds ON, 3 minutes OFF

Thermal Cut Out: Disables unit if overheated, automatically resets after cool down.

Convenience Outlet: 115 V AC, 60 Hz, 5 amperes

Maximum Length Capacity Distance between headstock and tailstock: 100 inches

Air Supply Requirements: 30 to 100 psig (60 psig nominal)

Table 1-1 (Continued)

Specifications

Item Characteristic

Bath Medium Tank Capacity: 15 to 30 gallons

Weight: 2500 pounds (approximate)

Dimensions (overall) Inspection Station Length: 124 inches Width: 37" (hood open), 54" (hood closed) Height: 108" (hood open), 84" (hood closed)

Volume Inspection Station: 333 cubic feet (hood closed)

Center of Gravity: N/A

Table 1-2

Electrical Requirements

Line Amperes Fused Wire From Disconnect Momentary 0.5 SEC at Disconnect Switch to Unit for

Input Voltage 6000 Amperes Load Switch 100 Foot Run

3 Phase, 460 VAC 110DC/300AC 100 Ampere Four.No. 4AWG 50/60 Hz

3 Phase, 230 VAC 220DC/600AC 200 Ampere Four No. AWG 50/60 Hz

Caution

Before connecting power to unit, insure that PUMP switch is in OFF position. Insure that connections have been made for correct voltage before operating unit. The phase control SCR gate drives used in this equipment are Phase Rotational Critical: AB C rotation only. Unit will not operate if wired in incorrect phase.

1-15 The unit can be operated with 230V or 460V AC line supply at 50 to 60 Hz. See table 1-2 for electrical requirements. Machine initial voltage connection is for 460 volt. See paragraph 2-6 for operation on 230 volt. If 50 Hz operation is required replace Red Modules Part #9N1903 with Red Modules Part #9N1917.

1-16 A phase rotation lockout device located in the unit interrupts the circuit when incorrect phasing occurs. To correct, reverse B and C lines.

Warning

Adequate protection for the unit and operating personnel must be provided.

1-17 Incoming power disconnect switching and over current protection are not supplied with this equipment. Provision for these features must be made external to the unit. Slow blow fuses or thermal circuit breakers must be used. Fast acting fuses or electronic/magnetic trip circuit breakers shall not be used.

1-18 Items Furnished

1-19 List of items furnished:

Qty. U/M Part Number Description

1 EA GB-3509A-01 Inspection Station 1 EA N520670 Hood Assembly, BH-100

EA N9X118001 Curtain set EA N9D1152001 Footswitch assembly EA N880-001 pound ofmag particles

1 EA N500199001 ASTM Centrifuge Tube 1 EA N500203001 Magnetic field indicator 1 EA N500201001 Stand, Centrifuge Tube 1 EA N9E5212001 90 Watt halogen white bulb 1 EA 63935T15 20" tank scrub brush 2 EA N500205001 Molded Neoprene V-Block with Pads

PR NC21OE-1PR 2/0 X 10’ Cables with 4/0 connectors on E/EO

1 PR NC415E-1PR 4/0 X 5’Cables with 4/0 connectors on E/E

1 EA N500328001 1" Dia. X 18" Long Copper Central Conductor

PR N500220001 contact clamps with EE connectors EA N500222001 Contact block with EE connectors

NOTE: Mag hose and nozzle, black light, black light rod and collars (3ea) are attached to the machine.

1-20 Environmental Requirements

1-21 Normal indoor shop ambient temperature and humidity are suitable for operation ofthe equipment described in this manual.

-22 Items Required

1-23 No separate equipment other than the accessories supplied is required for the use ofthe equipment covered in this manual.

1-24 Storage Data

1-25 Indoor room ambient conditions are required for long term storage ofthe equipment covered in this manual.

-26 Tools and Test Equipment

1-27 Common hand tools and electrical test equipment are required for maintenance ofthe equipment covered in this manual. No special tools or test equipment are required.

1-28 Warranty

1-35 Safety Precautions

1-36 Electrical Hazards. Dangerously high voltage potentials are present within the cabinet of this unit.

To prevent electrical shock, use caution when installing, operating, or performing maintenance on this equipment.

1-37 Chemical Hazards. The solvents used to clean this equipment may be toxic, flammable or both. Do not use solvents in the vicinity of open flame or other ignition sources. Use only in a well ventilated area. Wear eye protection when using. Avoid prolonged skin contact.

1-38 Compressed Air. Eye protection should always be worn when using compressed air. Do not exceed an air pressure of 15 psig when compressed air is used to dry parts. Do not direct an air stream towards self or other personnel.

Section II

Preparation for Use and Installation Instructions

2-1 Preparation for Use

2-2 Prior to installation, consider the following factors in locating the unit:

1. A suitable source of230V or 460 V, 50/60 Hz, 3 phase alternating current capable of supplying power in accordance with table 1-2.

2. A compressed air supply of 30 to 100 psig (60 psig nominal) shall be available.

3. A minimum oftwo feet shall be allowed at the rear and right side ofthe inspection station to assure adequate space for ventilation and servicing.

4. A firm, reasonably level floor capable of supporting the unit weight and the materials awaiting inspection is required. The floor should be sufficiently level to insure leveling of the coil and tailstock traverse rails with the minimum amount of shimming under the feet of the unit.

5. Adequate clearance above the unit is required to allow the opening and closing the hood frame.

6. Adequate space should be available for storage of materials and materials movement.

2-3 Unpacking. No special unpacking instructions are needed. Visually check the crating for shipping damage and subsequent damage internally. Ascertain that all accessories accompanying the system have been received.

2-4 Leveling. Level the traverse rails, shimming the legs as required.

2-5 Electrical Connections (ref: Table 1 -2)

CAUTION:

High voltage exists at this location. Turn all power off before performing voltage convergence.

1. This unit is equipped with a voltage convergence board which allows all necessary voltage changes to be performed at one location. The initial voltage connection is 460V AC, 60 Hz.

3 phase from the factory unless otherwise specified. To change voltage, locate the voltage convergence board by removing the middle front panel ofthe machine. Open the hinged cover from front of convergence board by removing the left screw. Remove the 1/4 inch brass nuts from convergence board. Re-install the moveable section to left for 230 volt operation, to right for 460 volt operation. Re-install all 1/4 inch brass nuts, take caution not

To over tighten nuts causing brass studs to strip. Replace plastic cover. Located in upper left comer of convergence board is a push to test button. Press this button a amber light will light if 230 volts are selected. A red light will light if 460 volts are selected.

Note: 50 Hz. operation requires Red Modules P/N 9N1917. 60 Hz. operation uses Red Modules P/N 9N1903. Contact if proper Red Modules are needed.

Warning

Dangerously high voltage potentials are present within the cabinet. To prevent electrical shock, use caution when installing, operating, or performing maintenance on this equipment.

Warning

Before connecting power to unit, insure that PUMP switch is in OFF position.

Insure that connections have been made for correct voltage before operating unit.

The phase control SCR gate drives used in this equipment are Phase Rotational Critical: AB C rotation only. Unit will not operate if wired in incorrect phase. The internal black (phase rotation) module will have both LED’s lit if unit is phased correctly. To correct phase rotation exchange B and C phase line wires.

Adequate protection must be used on incoming power lines.

1. Incoming power disconnect switching and over current protections are not supplied with this equipment. Provisions for these features must be made external to the unit.

2-6 Air Supply

1. Connect the air line to the air filter located on the headstock. To unlock the pressure regulator pull knob outward. Make air pressure adjustments so that approximately 60 psig is registered on the headstock air pressure gauge. To lock pressure control knob push knob in.

This pressure (60 psig) is recommended for most applications.

2. The clamp piston speed control is located on the headstock below the air pressure regulator.

valve. Adjust the speed as required.

2-7 Mag Checkout Procedure

1. The following steps provide an initial checkout and performance verification procedure for the unit.

Caution

Observe the duty cycle limitations during checkout procedures or damage to the unit may result.

2. Before applying power to the machine, depress the "ENERGIZE MASTER" push-button on the front panel. The "Energize Master" push-button should be depressed whenever line power is applied or shut off.

3. Turn external disconnect switch on. The red LINE pilot light on the headstock shall illuminate, and the rectifier cooling fans shall operate.

4. Attach the foot switch to the receptacle on the left end panel.

5. Position tailstock so that the accessory copper bar can be placed between the tailstock and headstock, and lock tailstock into position. Depress foot switch. The air cylinder shall operate and clamp the copper bar firmly between headstock and tailstock.

6. Turn CONTACT/COIL switch to CONTACT. Turn MAG/DEMAG switch to MAG. Turn the AC/DC switch to DC. Turn CURRENT CONTROL potentiometer fully counterclockwise.

7. Pull the ENERGIZE MASTER button to energize the power transformer.

8. Press ENERGIZE push-button. The amber MAG indicator shall illuminate. The shot interval is timed at 1/2 second at the factory. The MAG indicator shall automatically extinguish at the end ofthe magnetization cycle.

9. Turn CURRENT CONTROL potentiometer clockwise, alternately pressing the ENERGIZE push-button, until a nominal current value of 1000 amperes is reached.

10. Press the ENERGIZE push-button and note reading on ammeter. Position the actuator of the left hand kickbar so that it engages the auxiliary energize push-button. Press the kickbar.

The ammeter shall register same reading. Position the actuator ofthe right hand kickbar so that it engages the auxiliary energize push-button. Press the kickbar. The ammeter shall register the same reading.

11. Turn CURRENT CONTROL potentiometer clockwise to maximum reading on dial plate.

Press ENERGIZE push-button and note reading on ammeter. If indicated current is not 6,000 amperes, adjust as follows:

a. If indicated current is too low due to low incoming voltage, turn DC HEAD MAX potentiometer (located on module board in power pack) clockwise to increase current. Repeat adjustment until ammeter indicates 6,000 amperes.

b. If indicated current is to high due to high incoming voltage, turn DC HEAD MAX potentiometer counterclockwise to decrease current. Repeat adjustment until ammeter indicates 6,000 amperes.

12. Turn CURRENT CONTROL potentiometer counterclockwise to zero reading on dial plate.

Press ENERGIZE push-button and note reading on ammeter. If ammeter indicates above 50 amp reading, turn DC HEAD MIN potentiometer counterclockwise. Repeat ENERGIZE cycle adjustment until ammeter reads between zero and 50 amps (.05 display on ammeter at a minimum current control setting.

13. Repeat steps 11 and 12 until ammeter reads 50 to 6,000 amperes full scale.

Note: Action ofCURRENT CONTROL potentiometer is not linear. Low setting to achieve maximum meter spread may be at a clockwise setting above zero on the dial plate.

14. Turn CONTACT/COIL switch to COIL. Repeat steps 11 and 12, adjusting DC COIL MAX potentiometer and/or DC COIL MIN potentiometer as necessary to achieve <50 to 3,000 minimum ampere full scale on ammeter (15,000 ampere turns).

15. Turn AC/DC switch to AC, turn CURRENT CONTROL potentiometer clockwise to maximum reading on dial plate. Press ENERGIZE push-button, and note reading on ammeter. If reading is not 3,000 amperes in COIL position, adjust AC COIL potentiometer full clockwise. Turn contact/coil switch to contact, energize and note ammeter reading. If it is not 5,000 amperes, adjust the AC/HEAD MAX and MIN potentiometers on module board as in Steps 11 and 12.

Note: Machines with larger coils may have less then 3000 amps AC for its maximum output.

16. Time Adjustments

AC time adjustments are made on the AC Module Board (part number 9N2022). Mag time is normally set at 0.5 seconds and the AC Demag time is 8 to 10 seconds.

DC time adjustments are on the DC Module Board (part number 9N2017). Mag time is normally set at 0.5 seconds and the DC Demag time is 25 to 30 seconds.

Warning

Do not exceed duty cycle in Table 1-1. (5 seconds "ON" and 4 minutes

"OFF.")

2-8 AC Demag Checkout Procedure

1. Magnetize a steel part, rod or wrench that is less then 18 inches in length in AC, Coil, Mag mode at approximately 1/2 output on current control.

2. Check the ends of the part with a field indicator to assure part is magnetized.

3. Select AC, Coil, Demag operation on selector switches. Turn current control clockwise to approximately 3/4 of scale.

4. Depress Energizer push-button. During the AC Demag cycle the current is ramped down to zero in approximately 5 to 10 seconds.

5. Using a field indicator measure ends of the test part. Residual field shall be less then 3 gauss.

2-9 DC Demag Checkout Procedure

1. Magnetize a 18 inch maximum length steel part, rod, or wrench in DC, Coil, Mag mode at approximately 1/2 output.

2. Check the ends ofthe part with a field indicator to assure part is magnetized.

3. Select DC, Coil, Demag on selector switches. Increase current control to approximately 3/4 ofthe scale.

4. Depress Energize push-button. Output current will pulse at reversing polarities and decay to zero during its approximately 25 to 30 second cycle.

5. Residual field left in test part shall be less than 3 gauss.

6. If proper demag has not occurred, an adjustment may be needed, Refer to the purple module (part number 9N1922) paragraph 3-22 in Section III.

2-10 Remote Control Operation

Caution

Observe duty cycle limitations during remote operations.

If a remote control is to be used with the unit, plug the remote control cable into the socket provided on the control panel, and snap to lock into place. Set the controls to give a nominal magnetizing shot and press the remote ENERGIZE switch. The MAG indicator shall illuminate when the magnetization cycle starts and extinguish automatically when the remote switch is deactivated. Set the controls to give a nominal demagnetization shot press and release the remote ENERGIZE switch. The DEMAG indicator shall illuminate at the start of the demagnetization cycle and automatically extinguish at the end of the cycle. Also see paragraph 4-12.

2-11 Bath Preparation Caution

Do not operate the pump without liquid in the tank or without the sump screen in place, as damage to the pump may result.

1. Clean tank and pump filter of any debris accumulated during shipment or installation. Flush tank if necessary.

2. Before filling the tank, make sure the drain valve is closed.

3. Prepare the bath concentration (see manufactures mixing instructions for the magnetic particles).

4. Fill tank with required bath solution (approximately 3" above agitation tube).

5. Allow pump to thoroughly agitate the suspension to assure uniform particle distribution.

This requires at least five minutes after turning on the pump.

6. Run suspension through the applicator for at least one minute. This is to assure the suspension in the system is fresh and agitated.

7. Fill the centrifuge tube with agitated suspension to the 100 ml level.

8. Demagnetize the suspension in the tube to reduce clumping.

9. Place tube in the stand and allow suspension to settle for 30 minutes in a vibration free location.

10. Observe the total level of settled particles at the end ofthe 30 minute period. The graduations read directly in milliliters (ml). The level of contaminates must be subtracted from the total level to obtain concentration ofthe particles.

11. Illuminate the tube and suspension with the black light. Only the particle layer should fluoresce. Fluorescence in the liquid or contaminant layer indicates solution breakdown and requires draining and replacement.

12. If the level of magnetic particles is above the established range (0.25 to 0.30 for fluorescence), calculate and add the amount of bath medium necessary to obtain the desired level. If the magnetic particle level is too low, add magnetic powder as required. Because magnetic particles are continually being carried off in inspected parts, excessively high settled particle readings are usually attributable to dirt washed from parts during inspection.

The operator must determine whether to add bath medium or magnetic particles or to discard a dirty bath and mix a new one based on the test results, the observation of particles during operation, the color of particles and bath, the volume of materials inspected since the last bath change, and experience with the equipment. Repeat the above procedure after making corrections.

Section III

General Theory of Operation

3-1 General

3-2 The following paragraphs provides a general description ofthe electronic circuitry and logic controls ofthe unit.

3-3 DC POWER CIRCUIT. In the DC mode of operation, incoming three-phase power feeds power transformers T-l, T-2 and T-3.

1. The center tap outputs of transformers T-l, T-2, and T-3 are directly connected to the tailstock contact, and to one side ofthe coil. This is a permanent, high-amperage, low-voltage, common return connection.

2. Positive DC for the system is rectified by secondary SCR stack, which constitutes a three-phase, full-wave, center-tapped bridge. As well as providing rectification, the secondary SCRs are used as contactors for the positive, high-amperage, low-voltage DC signal feed to the headstock or coil. Choice of headstock or coil energization is controlled by the CONTACT/COIL switch, which closes the contactor to energize the headstock, or the contactor to energize the coil.

3. Negative DC for the system is rectified by secondary SCR stack. The secondary SCRs are switched on only when MAG/DEMAG selector switch is in the DEMAG position, and AC/DC selector switch is in the DC position. These SCRs provide negative, high amperage, low voltage DC for the reversing DC demagnetization.

4. In the DC demagnetization mode, when ENERGIZE switch is actuated, secondary SCR’s are energized at the level set by the CURRENT CONTROL potentiometer. This initiates a ramp down in voltage at a predetermined rate. While the ramp is decreasing, the secondary SCRs are switching and rectifying power from the three-phase transformers, producing positive and negative signals with a predetermined dwell interval between the pulses. The dwell interval is set at the factory and is not adjustable in the field.

5. AC POWER CIRCUIT. In the AC mode of operation, single-phase incoming power is fed to the primary SCR stack, which feeds power transformer T-4. When AC/DC selector switch is in the AC position, AC lookout contactor is closed, connecting one secondary terminal of T-4 to the contact and coil contactor. The other secondary terminal of T-4 is connected to common bus of transformers T-l, T-2 and T-3.

3-4 AC MAGNETIZATION CONTROL CIRCUIT. In the AC mode of operation, with the MAG/DEMAG selector switch in the MAG position, AC/DC selector switch in AC position, when the ENERGIZE switch is actuated, a timer in the White module is started. This, in turn, fires the red modules of the AC primary SCR stack at a level determined by the Current Control potentiometer located on the control panel. After the time cycle is complete the circuit shuts down.

3-5 AC DEMAGNETIZING CONTROL CIRCUIT. In the AC mode of operation, with the MAG/DEMAG selector switch in the DEMAG position, AC/DC selector switch in AC position, when the ENERGIZE switch is actuated, a timer in the White module is started. This, in turn, fires the red modules ofthe AC primary SCR stack at a level determined by the Current Control potentiometer located on the control panel. The White module automatically ramps down from the preset current to 0 amperes over a preset operating time and then the circuit shuts down. CR-5 Relay is energized whenever any magnetization or demagnetization cycle is occurring. This relay illuminates the appropriate function indicator light located on the headstock.

3-6 DC MAGNETIZATION CONTROL CIRCUIT. In the DC mode of operation, with MAG/DEMAG selector switch in MAG position, AC/DC selector switch in DC position, and CONTACT/COIL selector switch in either position, when ENERGIZE switch is actuated, a magnetization timer is activated in Green module. Magnetization timer duration is controlled by TIMER MAG DC potentiometer. This timer energizes Red modules. Simultaneously, the Green module causes Red modules to fire the secondary SCR’s at a level determined by the setting ofthe CURRENT CONTROL potentiometer.

3-7 DC DEMAGNETIZATION CONTROL CIRCUIT. In the DC mode of operation, with MAG/DEMAG selector switch in the DEMAG position, AC/DC selector switch in DC position, and CONTACT/COIL selector switch in either position, when ENERGIZE switch is actuated, a demagnetization timer is activated in Green Module. Demagnetization timer duration is controlled by TIMER DEMAG DC potentiometer. This timer activates the Green module which activates Purple module. The Green module ramps down, lowering the current. The Purple module reverses polarity by switching on Red modules alternately, with a 200-millisecond dwell time between on cycles. The dwell interval and ramp time is set at the factory and is not adjustable in the field. At the conclusion of the timed demagnetization cycle. Green module is automatically switched off.

CR-6 Relay is energized whenever any magnetization or demagnetization cycle is occurring. This relay illuminates the appropriate function indicator light located on the headstock and also prevents the AC function from operating during DC mode.

3-8 Module Circuits

Caution

Electrical power to the unit must be disconnected when removing or installing modules, or damage to module circuitry may occur.

3-9 Black Module, Part No. 9N1901. The Black (Phase & Power) module provides a +15V DC regulated power supply for the rest ofthe system. It contains light emitting diode (LED) indicators that indicate operation, and also phase loss or phase rotation.

1. Pin connections on the Black module are as follows:

PIN

NO. Function

1 Ground 2/3 14V AC input 4 ....................................................................+15V DC regulated output 5 +20V DC (approx.) unregulated output 6.................................................................................Switchable ground 7 Phase C input 8 Phase B input 9 Phase A input 10 Plugged for mechanical interlock 11/12......................................................................................... Not used

2. The switchable ground at pin 6 is wired through a power transistor which lifts ground to the firing modules in the system in the event ofphase loss or phase rotation, thereby making the machine inoperative.

3. Input to pins 7,8 and 9 is 20 to 240V AC from the primaries ofthe control transformers. Pin 10 is mechanically plugged to prevent accidental installation of a different module into the socket for the Black module.

4. Two LED indicators are located at the top ofthe Black module cover. The left hand LED illuminates when the module is energized and functional. The right hand LED illuminates when phase rotation is correct and all three phases are equal in voltage. A phase loss or phase rotation will cause the right hand LED to extinguish or to glow weakly. With input power correctly phased and equal in voltage, both LED indicators will glow with equal intensity.

3.10 Green Module, Part No. 9N1902. The Green (DC Ramp and Timing) module controls the timing of the energize and ramp functions in the DC mode, as well as the ramp down voltage. The Green module contains its own separate power supply, and is therefore independent of and isolated from any electrical noise originating in the Black module. The Green module contains two light emitting diode (LED) indicators to verify proper functioning and when the module is energized.

1. Pin Connections on the Green modules are as follows:

PIN

NO. Function

1 Ground(common) 2/3 14V (Approx.) AC input 4 ....................................................................+15V DC regulated output 5 Energize ramp down 6 ....................................................................................System Energize 7 ...................................................+15V DC energize/ramp down signal 8 ............................................................................Relay energize output 9 Control output to Red modules 10 Remote energize input 11 .............................................Connection for external energize timing adjustment potentiometer (DC MAG TIMING) 12 Connection for external ramp down timing adjustment potentiometer (DC DEMAG TIMING)

2. When pin 5 is connected to pin 1 (ground), it energizes the ramp down function of the module.

When pin 6 is connected to pin (ground) it energizes the system energize function of the module.

Pin 7 provides a signal of approximately +15V DC when the module is in system energize or rampdown modes, this signal also lights the right hand LED on the top ofthe module case. Pin 8 goes to ground (low) with respect to positive when the system is energized, or in the ramp down modes. This causes a power transistor to close a relay, which operates the pilot light on the front panel. Pin 9 is the control output for the Red (Firing) modules. Pin 9 output is approximately +7V DC at the start of the ramp down mode, decreasing over time as the module ramps voltage down.

Illumination of the left hand LED on the top ofthe module case indicates the ramp down cycle.

When pin 10 is connected to pin 4 (positive), an external relay is closed, turning on the system energize circuit at full power, permitting the system to operate in the remote mode. Pin 11 takes a 50 K potentiometer, the wiper ofwhich is connected to pin 4; varying the voltage at pin 11 varies the system energize timing. Pin 12 takes a 50 K potentiometer, the wiper ofwhich is connected to pin 4; varying the voltage ofpin 12 varies the ramp down timing. System energize timing range is from approximately 15 to 40 seconds (typically 30 seconds). If greater lengths oftime are needed, an additional resistor may be mounted externally on the circuit board.

3-11 PURPLE MODULE, PART NO. 9N1922. The Purple (Toggle Logic) module determines which of the secondary SCR’s will be turned on, the positive bank or the negative bank. In the ramp down mode, this module switches the SCR output from positive to negative with a fixed delay time between the polarity swings. This alternating-polarity DC voltage is used during the DC demagnetization cycle.

1. Pin connections on the Purple module are as follows:

PIN NO. FUNCTION

...........................................................................................................Ground 3 Ground to energize Purple module +15V DC to de-energize Purple module

4............. ................................................................+15V DC regulated input 5 ..............................................................Negative SCR bank output 6 Positive SCR bank output 9............. .............................................................................SCR bank supply 2/8/10/11/12.......................................................................................Not used

2. Pin 3 is the energize input for the Purple module, the signal for which comes from the Green module. When the Purple module is energized, pin 3 goes from approximately +15V DC to ground potential.

3. Pin 4 requires +15V DC regulated input to power the module, since the Purple module has no internal power supply. Pin 7 is normally at ground potential; a +15V DC signal from the Green module to pin 7 causes the ramp on sequence to be started.

4. Duration of the positive pulse, negative pulse, and the delay times between is nominally 50 milliseconds on, 200 milliseconds off. Adjustments for these times are preset within the module, and are not adjustable in the field.

5. Pin 9 is connected to Pin 6 during the "Mag" cycle. During the Demag cycle pin 9 alternately connects between Pins 6 and 5. This toggles the negative and positive SCR banks to achieve a reversing D.C. output for the demag cycle.

6. Located through top ofthe purple module cover is a plastic adjustment knob. This is the balance adjustment of the negative and positive SCR banks. By turning this adjustment it allows more output out of either SCR stack. The optimum adjustment will allow parts being demagnetized to have a zero residual field.

7 To adjust balance adjustment you must magnetize then D.C. demagnetize a simple shape part i.e. 1" steel rod <18". (A wrench or screwdriver can be used.) Check residual field with a field indicator. Turn purple module adjustment in small increments. Remagnetize and demagnetize part. If residual field has increased turn the purple adjustment the opposite direction. The test part must be magnetized, demagnetized, and checked after each incremental adjustment. Keep repeating until a zero residual field is obtained.

Too far of an adjustment will start leaving a residual field ofthe opposite polarity.

When a residual field on the left end of the part before adjustment was + 5 gauss. Then after adjustment the left end leaves a -5 gauss. This indicates that the adjustment has gone too far.

You have now adjusted the neg SCR bank much higher than the Pos SCR bank.

Note:

This purple module adjustment cannot compensate the output when a module has failed or loss of an SCR in either of the output SCR stacks.

3-12 Red Module, Part No. 9N1903. The Red (Firing) module controls the operation ofthe SCRs, which operate on the secondary high amperage, low voltage circuit. The Red modules control the synchronization of SCR firing during machine operation. The module contains light emitting diode (LED) indicators to verify proper function and when the module is energized.

1. Pin connections on the Red module are as follows:

PIN

NO. Function

1 ...................................................................................Common Ground 2 ................................................................................+1 V to +5 V input 3 ....................................................................................Gate feed SCR 1 4 ..........................................................................Cathode to feed SCR 5/6............................................................................. 14V AC sync input 7/8 .........................................................14V AC input for SCR 2 circuit 9 ................................................................................Gate to feed SCR 2 10 ........................................................................Cathode to feed SCR 2 11/12.....................................................14V AC input for SCR 1 circuit

Note

No internal adjustment to the Red modules are possible in the field. Misadjustment ofthe Red modules could result in burning out of one or all of the power transformers.

2. Normal operation of Gate and Cathode for SCR is indicated by illumination of the left LED.

Normal operation of Gate and Cathode for SCR 2 is indicated by illumination of the right LED. Pins 5 and 6 carry an input 14V AC synchronizing control signal for the module. These pins power the logic control to synchronize the module firing with the AC line, and provide the output signal to the firing board within the module to fire the SCRs at the correct time during the cycle. Pins 7 & 8 carry the AC input to the firing board to power Gate and Cathode for SCR 2. Pins 11 and 12 carry the AC input to the firing board to power Gate and Cathode for SCR 1.

3-13 White Module, Part No. 9N1113 The White (AC Ramp and Timing) module controls the timing of the energize and ramp functions in the AC mode, as well as the ramp down voltage. The white module contains its own separate power supply. The white module contains two light emitting diode (LED) indicators to verify proper functioning and when the module is energized.

1. Pin connections on the White module are as follows:

PIN

NO. Function

1 Ground(common) 2/3 14V (Approx.) AC input 4 ....................................................................+15V DC regulated output 5 Energize ramp down 6 ....................................................................................System Energize 7 ...................................................+15V DC energize/ramp down signal 8 ............................................................................Relay energize output 9 Control output to Red modules 10 Remote energize input 11 .............................................Connection for external energize timing adjustment potentiometer Rl (AC MAG TIMING)

12 ....................................................Connection for external ramp down timing adjustment potentiometer

R2 (AC DEMAG TIMING)

2. When pin 5 is connected to pin (ground), it energizes the ramp down function ofthe module.

When pin 6 is connected to pin 1 (ground) it energizes the system energize function of the module. Pin 7 provides a signal of approximately +15V DC when the module is in system energize or ramp down modes, this signal also lights the right hand LED on the top ofthe module case. Pin 8 goes to ground (low) with respect to positive when the system is energized, or in the ramp down modes. This causes a power transistor to close a relay, which operates the pilot light on the front panel. Pin 9 output is approximately +6VDC at the start of the ramp down mode, decreasing over time as the module ramps voltage down. Illumination ofthe left hand LED on the top of the module case indicates the ramp down cycle. When pin 10 is connected to pin 4; varying the voltage at pin 11 varies the system energize timing. Pin 12 takes a 50K potentiometer, the wiper ofwhich is connected to pin 4; varying the voltage at pin 12 varies the ramp down timing. System energize timing range is from approximately 1/6 second to 1-1/2 seconds (typically 1/2 second). Ramp down timing range is from approximately 2 to 10 seconds (typically 7 seconds). If greater lengths oftime are needed, an additional resistor may be mounted externally on the circuit board

Section IV

Operation Instructions

4-1 Controls and Indicators

Nomenclature Location Type Function Fan Control Panel Toggle Switch Turns ventilation fans on/off

White Light Control Panel Toggle Switch Turns white lights on/off

Black Light Control Panel Toggle Switch Turns black light on/off Valve Headstock Valve Controls speed of air cylinder Regulator Headstock Regulator Controls air pressure to air cylinder Ammeter, digital Control Panel Meter Indicates mag/demag current level Air pressure Headstock Gage Indicates air pressure to air cylinder Demag Control Panel Amber Pilot Indicates demag cycle in operation Mag Control Panel Amber Pilot Indicates mag cycle in operation Line Control Panel Red Pilot Indicates line voltage is connected to unit

Pump Front Panel Toggle Switch Turns pump on/off Contact/Coil Control Panel Selector Switch Selects contacts or coil for mag/demag operation Mag/Demag Control Panel Selector Switch Selects mag or demag mode AC/DC Control Panel Selector Switch Selects AC or DC mode Energize Control Panel Push-button Starts mag/demag cycle Current Control Control Panel Potentiometer Adjust mag/demag current

Timer Mag DC Module Board Potentiometer Adjusts duration ofDC mag shot Timer Demag DC Module Board Potentiometer Adjusts duration ofDC demag shot AC Head Max Module Board Potentiometer Adjusts DC maximum contact duration AC Head Min Module Board Potentiometer Adjust AC zero contact AC Coil Max Module Board Potentiometer Adjust AC maximum coil current

AC Coil Min Module Board Potentiometer Adjust AC zero coil current DC Head Max Module Board Potentiometer Adjusts DC maximum contact current DC Head Min Module Board Potentiometer Adjusts DC zero contact current

DC Coil Max Module Board Potentiometer Adjusts DC maximum coil current

DC Coil Min Module Board Potentiometer Adjusts DC zero coil current

Hip Bar Front ofUnit Hip Bar Starts Mag/Demag cycle Foot Switch Connected to Foot Switch Controls front panel jack Headstock Clamping Power Disconnect External to Unit Switch Switches incoming 3 phase 460/230V

AC power on/off

Circuit Protection External to Unit Provides over current protection for unit

4-2 Black Light Hood

4-3 When parts are to be inspected with black light, semi-darkness for viewing is required. The folding hood of the machine provides this semi-darkness. The hood consists of a steel frame assembly covered with fire retardant, vinyl-coated nylon curtains. The hood is attached to the unit and folds back from the bath area to permit the use of overhead cranes to handle heavy parts into and out of the unit. Ventilation, white light and black light controls are provided on the console panel.

4-4 Startup/Shutdown

4-5 Push the ENERGIZE MASTER before applying main electrical power. Startup is accomplished by powering the unit using the external power switch. Pull out ENERGIZE MASTER to operate machine. Shutdown is accomplished by pushing the ENERGIZE MASTER in and then disconnecting the unit from power using the external power switch. The ENERGIZE MASTER should be pushed in(offposition) during long periods of machine inactivity.

4-6 Normal Operation

4-7 Magnetization Procedures. The following paragraphs provide general magnetization procedures.

Warning

Dangerously high voltage potentials are present within the cabinet of this unit. To prevent electrical shock, use caution when installing, operating or performing maintenance on this equipment.

4-8 In addition to securing security of mechanical support, and observing duty cycle limitations (see table 1-1), make sure that electrical contact is not disturbed while current is flowing or the resulting arc may destroy or damage the material being inspected.