Operating Manual

Mobile Chain Inspection Unit with Ferrotest Serial no. 15 483 01/14 482 41 Order no. 215-30460

CONTENTS

1 General safety instructions 11.1 Exposure to magnetic fields 22 Description of the unit 32.1 Designated use 32.2 Limits of the mobile chain inspection unit 32.3 Symbols displayed on the unit 42.4 Technical data 43 System components 53.1 Component overview 53.2 Component descriptions 64 Test liquid 75 Transporting the system 85.1 Transportation in the original packaging 85.2 Transporting the unpacked machine 85.3 Storing the system 96 Operating the system 96.1 Installation 96.2 Setting up the system 106.3 Filling the test liquid tank 106.4 Operating the machine 116.5 Test procedure for chains 116.6 Demagnetisation of workpieces 126.7 Troubleshooting the circulation pump 127 Maintenance 137.1 Inspection and maintenance schedule 137.2 Cleaning the machine 148 Inspection procedures 148.1 Measuring magnetic field strength 148.2 Check test liquid concentration 158.3 Checking UV intensity 169 Decommissioning and disposal 169.1 Shutting down the machine (decommissioning) 169.2 Disposing of the machine 17

- EC/EU Declaration of Conformity 17

1. GENERAL SAFETY INSTRUCTIONS

WARNING:Strong magnetic field strengths created during magnetisation may cause damage to health and have detrimental effects on electric medical implants.

Keep a safe distance during magnetisation.

WARNING - UV LAMPS OF RISK CATEGORY 2Ultraviolet radiation can cause damage to the skin and eyes.• Never look directly into the UV lamp.• Avoid skin contact. Use skin and eye protection.• Operate UV lamps only with an undamaged and correctly• mounted filter.• UV lamps should only be operated by trained personnel.

CAUTIONHeavy workpieces may injure hands.

Do not reach between workpieces and machine components when loading and unloading.

Use protective gloves.

This operation manual must be kept with the machine and be freely accessible to the operating and maintenance personnel at all times. If the machine is re-located or sold on, this manual must go with it.

IN AN EMERGENCY:The system can be switched off immediately in case of emergency:

• Deactivate the mains fuse• Unplug the mains power plug of the high current generator.• Unplug the mains power plug of the socket terminal.

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Use of the mobile chain inspection unit may lead to hazards and detrimental effects:• for the life and health of the operator or third parties,• on the machine itself,• on other equipment.

Severe injuries and damage are possible in the event of:• incorrect installation and setup,• incorrect use,• incorrect removal of covers or safety devices.

Any additions or modifications to the machine are not permitted without the writ-ten consent of the manufacturer (Magnaflux GmbH). The use of spare parts from third-party manufacturers can compromise the safety and performance of the machine; Magnaflux GmbH accepts NO liability for damage resulting from the use of spare parts and consumables not approved by us.

ALWAYS:

• read the general safety instructions - they are essential for the safe operation of the equipment.

• read and follow the instructions regarding conditions and materials, as well as all warnings and safety instructions.

• follow the sequence of operations as described.

Only persons who meet the following conditions can operate the machine:• They are familiar with the local regulations on occupational safety, accident prevention and the protection of the environment.• They have been instructed on how to operate the machine.• They have read and understood this operating manual.• They are wearing appropriate personal protective equipment (safety glasses, safety shoes, protective gloves, plus a protective helmet when transporting or performing maintenance on the machine).

Knowledge of the safety and user instructions in this manual forms a basis for safe and trouble-free operation of the machine. If you have any questions regarding the optimum use of this machine, please contact us.

1.1 EXPOSURE TO MAGNETIC FIELDS

WARNING: this machine could interfere with pacemakers and other implanted devices such as insulin pumps.

Do NOT use, or stand within 3m of, this machine if you:• have a pacemaker, insulin pump or other implanted device.• are pregnant.• under 16 years of age.

All personnel must maintain the following safety distances* from the unit during operation (that is, while the magnetisation current switched on):• People without body-implanted devices: 0.5 m / 20” • People with body-implanted devices (e.g. pacemakers): 3 m / 9’ 10”

The grey shaded zone in the diagram below shows the area of increased exposure. The operator must determine, document and identify this area, and ensure that:• only authorised and trained personnel are permitted in this areas, and• the permitted values for short-time and partial body exposure are not exceeded, or • personal protective equipment is worn to protect against exposure.

IMPORTANT: Magnetic fields an penetrate walls!

* Safety distances are determined from limit values specified in the following reg-ulations:• Accident Prevention Regulation DGUV-V15 (formerly BGV B11), June 2001• the international guidelines for limiting exposure to time-varying electric, magnetic, and electromagnetic fields (ICNIRP), 1998.

In accordance with Regulation DGUV-V15, the mobile chain inspection unit is categorised as Exposure Range 1. This range encompasses areas with restricted access, e.g. operational facilities.

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2. DESCRIPTION OF THE UNIT

2.1 DESIGNATED USEThe operational safety of this machine is only ensured if it is used as designated. The mobile chain inspection unit is exclusively intended for materials testing:• of the specified workpieces• in accordance with the magnetic particle inspection method as specified in EN ISO 9934-1, EN ISO 9934-3 and DGZfP EM0-EM5;• in stationary operation;• within the limits specified in section 2.2.

The high current generator (Ferrotest xx or Ferrotest GWH xx) must only be used with suitable magnetisation devices.

The mobile chain inspection unit must NOT be used:• in potentially explosive atmospheres• for the mechanical or thermal treatment of workpieces.• in residential and small trade environments.

Incorrect use of this machine use may lead to damage or injury and invalidates any warranty claim against Magnaflux GmbH (the manufacturer). The operator is solely responsible for the consequences of the machine being used contrary to its intended use and for actions not described in the manual. Magnaflux GmbH accepts NO responsibility for resulting loss or damages.

If you have any questions regarding the optimum use of this machine, please contact us.

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2.2 LIMITS OF THE MOBILE CHAIN INSPECTION UNIT:IMPORTANT: The limits of the machine are dependent on the connected high current generator (Ferrotest xx or Ferrotest GWH xx).

Ensure that the field strength in the workpiece is sufficient (≥ 20A/cm) for the task. Test the settings and crack detection function using an appropriate magnetic field measuring device.

Magnetising current FERROTEST 10 (coil magnetisation): infinitely variable up to AC 1000 A eff.

FERROTEST GWH 15:infinitely variable up to AC 1050 A eff.infinitely variable up to DC 950 A eff.

Duty ratio (standard) Relative: 30% ED (referring to 10 s and 50% ofeffective output)

Absolute: 3 s ON and 7 s OFF (referring to 10 sand 50% of effective output)

Type of fault Inspection of transversal cracks

WORKPIECES

Using this machine, only workpieces that conform to the following specifications can be inspected using the magnetic particle inspection method. Crack detection is severely restricted or impossible if the workpiece differs from the specification.

• Chains, unworked or machined, made of ferromagnetic materials with a magnetic conductivity μ> 100• Maximum weight: 20kg• Raw or sand-blasted surface that is free from scale, rust, oil and grease.

2.4 TECHNICAL DATA

MOBILE CHAIN INSPECTION UNIT:

ElectricalPower consumption 500 VAControl voltage 12 VAmbient conditionsOperating temperature 5 - 35 oCStorage temperature 5 - 35 oCHumidity during operation max. 90% relative humidity (non-condensing)Humidity in storage max. 90% relative humidity (non-condensing)EmissionsEMC Suitable for industrial applications in accordance

with the EMC Directive and current EMC standards.Noise Workplace related emission value at normal

operation: 75 dB (A). Measured in accordancewith DIN EN ISO 3744:2011-02

Space requirement and supply connectionsComplete installation Length: approx. 120 mm; Width: min. 2000 mmPower supply connection Connector cable, 1.5 mTest liquid systemCapacity 5 litresPump operating voltage AC 230 V / 50 HzDimensions and weights (approximate)Dimensions 850 mm wide x 510 mm deep x 900 mm tallWeight 43 kg

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 02/06/0839:2006-03 Emission resistance standard for industrial environments

2.3 SYMBOLS DISPLAYED ON THE UNIT

The CE Mark indicates conformity with the relevant EU direc-tives that apply to the product and that require a CE marking.

Danger from electrical voltage. Work on the electrics must only be carried out by a qualified electrician.

Danger from magnetic fields. Observe the safety distances.

Danger from ultraviolet (UV) radiation. Protect skin and eyes.

People with pacemakers or other active body implants must not be present around the machine

The type plate is mounted at the right front side of the electrical cabinet. It displays important information about the machine, the power supply and the manufacturer (Magnaflux GmbH)..

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HIGH CURRENT GENERATORS:

Technical information according to DIN EN ISO 9934-3 and VDE.

Ferrotest 10 Ferrotest GWH 15Operating voltage AC 230 V / 50 Hz AC 400 V / 50HzInput (approx.) 3 kVA 8.8 kVAOpen circuit voltage 3.2 V 4.5 VControl voltage 12 V 12 VDuty cycle ED during intermittent continuous operation

Relative: 30%Absolute: 3 s ON and 7 s OFF

Dimensions (approx.) 325 mm wide x 290 mm deep x 385 mm tall

445 mm wide x 290 mm deep x 385 mm tall

Weight (approx.) 17 kg 33 kg

ELECTRIC CIRCULATION PUMP:

Mains voltage 1 x 230 V / 50 HzTest liquid delivery temperature -10° C to 110°CMax. operating pressure 10 barAmbient temperature 35 °CProtection class IP 44Electrical test in accordance with EN 60 335-2-51 TF 110

3. SYSTEM COMPONENTS

3.1 COMPONENT OVERVIEW

1. Ferrotest high current generator (see Ferrotest operating instructions)2. Power connection socket with ON/OFF switch 3. High current cable connection between high current generator and magnetis- ing coil4. Test liquid circulation pump5. Trolley frame with castors6. Castors with parking brake7. Pedal switch for test current activation8. Castors without parking brake9. Test liquid container with connections, connection joints and spray system10. Adjustment valve for the testing liquid cycle11. Magnetising coil12. Chain for testing

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Test liquid containerA collection reservoir for the test liquid, the container is connected to the circu-lation pump, the adjustment valve and the our installed spray nozzles (sprinkler system) by way of pipework. It is equipped with a sieve located at the lowest point of the container.

The test liquid container is encased with a magnetisation coil for coil magnetisation.

IMPORTANT: Fill capacity of the test liquid container is 5 litres (up to the lower edge of the cover plate). The minimum fill level is 3 litres

Magnetising coil The magnetisation coil is located on the outside of the test liquid container and is used for coil magnetisation in accordance with DIN EN ISO 9934-1.

• Circular magnetic fields around the conductors accumulate inside the coil to form a common longitudinal field.

• Transverse cracks on the workpiece are detected at an angle of approx. 30° to the coil axis

The type of magnetisation generated depends on the device type and the acces-sories installed. Please contact Magnaflux GmbH regarding the type of compo-nents you will need.

Adjustment valveRegulating valves are installed in the test equipment cycle, between the circulation pump, the test liquid container and the pipework. They regulate the flow of test liquid to the sprinkler system (spray nozzles).

IMPORTANT: the regulating valves (stop cocks) on bypass lines and/or sprinkler devices must always be open while the pump is running.

Power connection socket terminal with ON/OFF switchThe socket terminal consists of a quadruple power socket and an ON/OFF switch.

WARNING: The socket terminal is provided for the connection of a UV light and the circulation pump. The Ferrotest high current generator must NEVER be plugged into the power socket terminal.

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3.2 COMPONENT DESCRIPTIONS

High current generatorMobile high current generator of the Ferrotest series used with standard equip-ment for:• Magnetisation• Pulsed magnetisation• Demagnetisation

For more information about the high current generator, please read the operating instructions provided separately.

High current cableProvides the connection between the high current generator and the magnetising coil. It consists of:• high current connection plug (socket located on the high current generator)• tubular cable lug (for connection to magnetisation coil)

Circulation pumpDesigned specifically for use with water-based testing liquids, it pumps the testing liquid back into the test liquid container.

WARNING: the circulation pump must not run against pressure; bypass line or shower must always be open when the pump is running.

Do NOT use oil-based testing liquids. Operating this device with oil-suspended testing liquids is at the operator’s risk; the manufacturer accepts NO liability for damages.

Trolley frameSupports the test liquid container, high current generator, circulation pump and UV light. It consists of:• a rigid steel construction• castors without parking brake• castors with parking brake. Always engage before operating the device.

Pedal switchActivates the high current generator for magnetisation, pulsed magnetisation and demagnetisation.

Light source (optional)The lighting at the testing station depends on a number of parameters:• Nature of the workpiece and workpiece finish• Testing liquid• Light conditions at the workplace

Avoid dazzle from reflective surfaces of the test piece or from unsuitably mounted light sources.

If you are using test liquids without fluorescing dyes, you should have an illumina-tion intensity of at least 500 lux at the workpiece.

If you are using fluorescing test liquids:• test pieces must be assessed exclusively under UV light• a minimum UV radiation intensity of no less than 1000 μW/cm² (= 10W/m²) must be maintained ( < 20 lux)• check UV lamps regularly.

For more information, refer to the operating instructions of your chosen lamp/light source.

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4. TEST LIQUID

The test liquid for magnetic particle testing is a suspension of a magnetisable pow-der and a carrier medium like water, oil or air. The testing powder frequently has fluorescent dye added to it; accumulations of test material become much more visible under UV light.

Using the test liquidIMPORTANT: Use only water-suspendable test liquid with this system.

The test liquid must be applied evenly and in sufficient quantities to the test piece (chain). It is important to:• Ensure correct mixing ratio of test powder and carrier medium• Mix the suspension thoroughly,• Replace the suspension when it becomes contaminated.

Replacing the test liquidCheck the test liquid periodically and renew as needed. We recommend using our reference block type 1 (part number 135011) and thoroughly cleaning the test liquid container before refilling with the test liquid.

For optimised fault detection, the concentration of test liquid must exactly match the manufacturer’s specifications. Read the safety data sheet provided by manu-facturer.

5. TRANSPORTING THE SYSTEM

WARNING: Hoisted or suspended loads can cause severe Injuries and extensive material damage.• Never stand under a suspended load.• Ensure appropriate safety distance.• Transport components as close to the ground as possible.• Do not reach under a load that is being lowered.

5.1 TRANSPORTATION IN THE ORIGINAL PACKAGING• Use transportation equipment that is suitable for the load and dimensions of the system.• Wherever possible, transportation should only be carried out by personnel from the manufacturer or trained by the manufacturer.• Personnel must wear protective gloves, safety boots and a hard hat.• Cordon off transport routes in advance.• Prepare the unpacking and installation location

Procedure:

1. Determine the exact installation location.

2. Check the conditions and load bearing capacity of the floor at the proposed installation site and along the entire transport route.

3. Keep unauthorised persons away from the transport route and the installation location. Cordon the areas off if necessary.

4. Check the transport safety devices on the machine, and fit any that are missing.

5. Set the machine down on firm level ground.• Local regulations for work spaces must be observed.• Comply with the technical data provided for the system.

6. Insert the forks of a suitable forklift into the transport pallet at the marked positions.

7. Move the forklift forward until the fork extends approx. 20 cm past the edge of the pallet.

8. Carefully lift the machine off the ground.

9. Transport the machine as close to the ground as possible to the unpacking location.

10. Lower the machine slowly to the ground. Do not reach under the machine while lowering.

Unpacking the machine:

1. Where applicable, cut open and remove the protective wrapping.

2. Open the wooden crate with a crowbar.

3. The system components are bolted to the pallet and secured with straps. Unscrew the fastening bolts and carefully loosen the straps.

4. Use a forklift or crane to lift small parts and accessories off the pallet.

5.2 TRANSPORTING THE UNPACKED MACHINE

1. The system has been designed for mobility and can be moved to its operating location on its own wheels.

2. If the system has already been commissioned, it must be decommissioned before transport.

3. Remove the Ferrotest high current generator, empty the test liquid container and secure the cables and hoses for transport.

4. Determine the exact installation location.

5. If the machine is being transported by car, it must be sufficiently secured against possible flying parts. Use the eyelets provided for proper fastening. Check transport locks on the system and add locks as needed. Engage the parking brakes on the castors

6. Check the conditions and load bearing capacity of the floor at the proposed installation site and along the entire transport route.

7. Transport and set the machine down on firm level ground.• Local regulations for work spaces must be observed.• Comply with the technical data provided for the system.

8. Once the system is in position, engage the parking brakes on the castors.

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5.3 STORING THE SYSTEMShort-/ medium-term storage:Short- or medium-term storage (up to 6 months) of the system can be effected with-out the need for any special measures, provided the ambient conditions detailed in the technical specifications are complied with.

• Decommission the system• Disconnect the power supply• Drain all auxiliary material, e.g. lubricants and testing liquid• Clean the system

Long-term storage:If the system is to be stored long-term, specific measures for corrosion prevention will be necessary. These measures will depend on the ambient storage conditions. Please contact the manufacturer if you have any questions.

• Decommission the system• Disconnect the power supply• Drain all auxiliary material, e.g. lubricants and testing liquid• Clean the system thoroughly and apply corrosion protection as needed• Cover the machine or use shrink wrap

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6. OPERATING THE SYSTEM

6.1 INSTALLATIONOnce the system has been transported to its intended installation location, secure the castors with the parking brake. The system should only be placed on smooth level ground; irregularities in the ground cause the machine to tilt, which may affect the flow of the test liquid.

Mobile chain testing device with parking brake.

[2] Push down the parking brake on the castors; the brake is now activated

[3] Push up the parking brake on the castors; the brake is now released

This system is equipped with a high current generator from the product series FERROTEST. It is important to read the operating manual for this unit as well.

1. Connect the high current generator (1) to a separate mains power source. The high current generator (1) must NEVER be plugged into the power socket terminal (2)!

2. Connect the pedal switch (7) to the high current generator and secure with brackets (four-pole plug connection).

3. Connect the high current generator (1) and the magnetisation coil (11) with two high current cables. Plug the high current plug connectors of the high current generator and the pipe cable lugs of the high current cable (3) into the magnet- tisation coil.

4. Connect the circulation pump (4) to the power socket terminal (2).

5. Connect optional accessory, e.g. UV lamp, to the power socket terminal (2).

6.2 SETTING UP THE SYSTEMInitial commissioning of the system must only be performed by specially trained personnel. Follow the instructions in this manual and the safety regulations for the machine and third-party components.

Before switching on:1. Remove unauthorised persons from the machine.2. Visually inspect the entire machine.3. Check the power supply.4. Check the fill level of the testing liquid

6.3 FILLING THE TEST LIQUID TANK

WARNINGSpilt test liquid could cause accidents. Wipe up any liquid spills immediately.

Hygiene is of critical importance when handling test liquids. Ingredients in the test material may cause skin irritation or lead to other health risks. Always follow the instructions in the manufacturer’s Safety Data sheet when handling test materials.

The test liquid container must be filled with a suitable test liquid before operation. Full compliance with the manufacturer’s instructions for the mixing ratio and the relevant Safety Data Sheet is mandatory.

IMPORTANT: Only use water-suspendable test liquid with this system!

Before first use: 1. Ensure the machine is switched off.

2. Fill the container with fresh test liquid. Do not overfill the container; it has a capacity of 5 litres. Take note of the system’s centre of gravity.

• Minimum fill level: 3 litres• Maximum fill level: to the lower edge of the cover plate

3. Switch the machine on.

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Subsequent re-fills:1. Switch off the machine.

2. Drain the test liquid container and dispose of the used test liquid in accordance with local regulations. Pay special attention to environmental compatibility, health risks, disposal guidelines and applicable legislation.

3. Clean the machine.

4. Fill the container with fresh test liquid. Do not overfill the container; it has a capacity of 5 litres. Take note of the system’s centre of gravity.

• Minimum fill level: 3 litres• Maximum fill level: to the lower edge of the cover plate

5. Switch the machine on.

IMPORTANT: Once the test liquid container has been filled, check the concentra-tion and reaction capability of the test liquid before conducting a trial run.

• The correct concentration of test liquid is critical to reliable detection of faults. • The lifecycle of test liquids is dependent on the inspection brief and the condi- tion of the workpieces.• Check test liquids at regular intervals and replace as needed.

For more information, read the chapter on maintenance.

6.4 OPERATING THE MACHINEThe machine must be operated by one person. Normal operation is from the front of the machine.

6.5 TEST PROCEDURE FOR CHAIN1. Insert the chain into the test liquid container.

2. Turn on the circulation pump and the high current generator. The flushing system attached to the test liquid container will start up. IMPORTANT: the test liquid must be evenly applied evenly to the chain in sufficient quantity.

3. Press the pedal switch to turn on the inspection current (the magnetisation).

4. The chain will be lifted through the centre of the high current coil, which will magnetise it. IMPORTANT: Check whether sufficient magnetisation (>20 A/cm) has been reached; repeat the process for the next partial range.

5. Pause the magnetisation after a chain length of approx. 300 - 500 mm and carry out a visual inspection of the magnetised chain section. Test liquid will accumulate on any cracks present in the chain.

6. Repeat the procedure for subsequent chain sections.

NOTE: For the inspection of high-remanence steels, the test object can be pulled through the centre of the coil slowly in a single step, using a FERROTEST GWH 15 (connection to the half-wave direct current (HWDC)). This procedure must be approved by the test supervisor on the basis of a trial run.

WARNINGDanger of skin irritation from testing liquids. The sprinkler system creates a spray mist.Wear/use appropriate personal protective equipment (PPE).Comply with the warning notices in the Safety Data Sheet.

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6.6 DEMAGNETISATION OF WORKPIECESAfter testing using the magnetic particle inspection method, some residual mag-netism will remain in the workpiece. Eliminating this magnetism residue will avoid negative effects during later processing or when using the workpieces.

When magnetising with alternating current (AC), demagnetisation must also be car-ried out using AC. For this purpose, the electronic current control unit continuously controls the magnetising current towards zero along an e-function.

For demagnetisation:• there must be a field of alternating polarity and• the field strength must continuously decrease towards zero.

Course of the magnetising current during demagnetisation

In demagnetisation with a coil, the continuous decrease in field strength in the workpiece is achieved by moving the workpiece out of the AC field.

IMPORTANT: read the operating manual for the Ferrotest high current generator.

6.7 TROUBLESHOOTING CIRCULATION PUMP

Fault Cause SolutionPump fails to start Supply failure Check fuses and possible

loose electrical connectionsPump blocked due to furred bearings

Switch to maximum speed for a short period or see below.

Impurities in the pump Dismantle and clean the pump

Noise in the system Pump flow setting is too high

Change to a lower speed

Air in the system Vent the systemNoise in the pump Inlet pressure too low Increase the inlet pressure

Pump fails to startIf the spray quantity is insufficient, without being able to improve the level control on the pump, the pump shaft may be stuck or blocked. To rectify:

1. Disconnect the device from the mains and secure it.

2. Open the inspection nut.

3. Using a screwdriver in a rotating move- ment, free the shaft axis (groove) from the blockage. Shaft axis must turn smoothly.

4. Close the inspection nut.

5. Connect the device to the mains and put it into operation.

6. Never let the pump run dry!

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Spray pattern stage IIn the filled state, let the pump run until the pump circuit is completely vented. Spray pattern is then uniform.

Spray pattern stage II

Spray pattern stage III

7. MAINTENANCE

DANGERHigh voltages can lead to fatal electric shocks and burns.

Components can still carry dangerous electric current for several minutes after disconnection from the mains.

Work on the electrical installation must be performed:• by a qualified electrician only, and• in accordance with the standards applicable at the location,

7.1 INSPECTION AND MAINTENANCE SCHEDULE

Interval: 8 hours

Test liquid container:• Check indication capability of the test liquid• Clean the test liquid tank• Replace the testing liquid• Remove and clean spray nozzles as needed• Check and clean the testing liquid sieve as needed

Interval: 40 hours• Clean the entire machine using a mild industrial detergent - no solvents, acids or bases.• Perform visual check of the machine.• Check the magnetisation• Check the intensity of your UV light• Perform visual check of your UV filter screen. Replace defective filters.

Interval: weekly• Clean all components using a mild industrial detergent - no solvents, acids or alkaline solutions.• Rinse test liquid sieve with water.

Interval: 6 monthsClean the contact points (current transitions) between Dinse plug, high current cable and magnetising coil.

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Materials required:• Contact grease Tungrease VC563 (Magnaflux item no. 71100-118653)• Medium/fine grade steel wool

1. Switch off machine2. Disconnect the high current cables.3. Clean the contact points.4. Apply a thin coat of contact lubricant to the contact points..5. Restore the connections.

Contact faceHigh current connection

7.2 CLEANING THE MACHINEClean the machine:• only when switched off.• using either used test liquid, and/or water and a hose with low pressure nozzle; never using compressed air or solvents.• always before you change the test liquid.

1. Remove all test pieces.2. Remove Ferrotest high current generator.3. Rinse out the interior of the machine with a hand shower or hose.4. When cleaning with water from an outside source, the water will run into the test liquid container - make sure it does not overflow. Take note of the machine’s centre of gravity.5. Use a cloth to rub off stubborn dirt. Do not use any metallic tools.6. Drain and clean the test liquid tank.7. Fill with fresh test liquid.

Always comply with any warning notices in the manufacturer’s Safety Data Sheet regarding proper disposal of the testing liquid.

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8. INSPECTION PROCEDURES

8.1 MEASURING MAGNETIC FIELD STRENGTHThe intensity and direction of the magnetic field are important parameters in magnetic particle inspection. Always check the magnetisation when setting up the coil to test a new workpiece.

The FSM-2 (pictured below) is to measure tangential magnetic field strength. The field strength is displayed on the FSM-2 in A/cm both as effective (RMS) and, after switch-over, as peak value.

Operating the FSM-2:

1. Magnetise your test workpiece.

2. Place the FSM-2’s measuring probe on the test piece.

3. Read magnetic field strength in A/cm on display.

For more information about the FSM-2, see its Product Data Sheet and operating manual.

8.2 CHECKING TEST LIQUID CONCENTRATIONThe detection of faults in workpieces becomes less reliable as the quality of the test liquid diminishes. The lifespan of test liquids depends on the testing environ-ment and the condition of the workpieces.

It is important to regularly check the indicating ability of your test liquid, particularly after prolonged work interruptions and after replacing the test liquid.

For optimised fault detection on workpieces, the test liquid concentration must exactly match manufacturer specifications.

Using a centrifuge tube:

1. Fill the centrifuge tube with freshly mixed test liquid.2. Wait for 30 minutes.3. Check the settled magnetic particles against the graduation marks on the centrifuge tube.

NOTE: in systems where the magnetic particle suspension is kept in pumping cycles, do not test the quality of the suspension with the ASTM bulb. Dirt particles in the testing media can affect the indicated result.

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Using an AS 5282 test ring:

1. Spray test ring evenly with test liquid.2. Hold the ring by its edge and inspect under a UV light.3. Compare indications with the illustrations in the manual (examples below).

Test liquid OK Test liquid spent; time to replace

8.3 CHECKING UV INTENSITYThe detectability of defects can be significantly increased by using fluorescent magnetic test liquid and a UV light.

The light intensity of the UV lamp plays an important role. The light intensity should be approx. 1000 μW/cm², although this can vary depending on individual test conditions and ambient light.

Light intensity can decrease noticeably as the lamp is used so it is important to regularly check the intensity of your UV lamps and replace them as needed.

Using the J221 UV intensity meter:

1. Switch on UV lamp.2. Wait for the lamp to reach maximum light intensity.3. Place the sensor of the UV meter under the lamp.4. Read the intensity value on the meter display.

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9. DECOMMISSIONING AND DISPOSALDANGERHigh voltages may lead to fatal electric shocks and burns.

The power socket inside the control cabinet remains live even when the main switch is shut off.

Work on the electrical installation must be performed:• in accordance with the standards applicable at the location, • by a qualified electrician only.

9.1 SHUTTING DOWN THE MACHINETemporary shut-down:1. Drain the test liquid container and dispose of the used test liquid in accordance with local regulations2. Switch off the machine.3. Shut off the compressed air supply to the machine.4. Secure the machine against being switched on.5. Clean the machine. Final shut-down:1. Switch off the machine and unplug from the mains.2. Roll up the supply cable and secure it to the system. 3. Shut off the compressed air supply to the machine and disconnect the supply line.4. Drain the test liquid container and dispose of the used test liquid in accordance with local regulations

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9.2 DISPOSING OF THE MACHINEBefore disposal, check that all power supplies to the machine are disconnected.

Observe the applicable local guidelines for disposal of the machine. Batteries, paints, varnish, chemical substances (such as solvents, cleaning agents, etc.), adhesives, fluorescent tubes, UV lamps, used oil and oil filters must be disposed of as special waste as they constitute a risk to health and the environment

Procedure:1. Decommission (shut down) the machine.2. Dismantle the machine from the upper assemblies downwards.3. Separate out the different materials:

• metals• plastics• composites• electronic components• other materials - test liquid, lubricant, etc.

4. Dispose of all materials properly according to locally applicable regulations.

If you have any questions, contact Magnaflux GmbH.

EC/EU DECLARATION OF CONFORMITYFOR MAGNAFLUX STANDARD EQUIPMENT

We hereby declare that this equipment complies with the follow-ing EU Directives. The device has been tested and approved. Any modification made to the device without our written consent will invalidate this declaration.

Applicable EC/EU Directives: EC Machinery Directive, version 2006/42/EC Annex II AElectromagnetic Compatibility (EMC) Directive 2014/108/EU

Equipment model: Mobile Chain Inspection System with Ferrotest

Machine number: _________________________

Applied harmonised 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 applicable standards and specifications: VDE 0100-410:2007, VDE 0113-1:2014 BGV B11, ICNIRP

Authorised person for documentation: Mr. Georg Koch, Quality Management Officer

Address: Magnaflux GmbH, Bahnhofstr. 94-98, D-73457 Essingen, Germany

Person responsible: Signature:Sales/Design ManagerMr. Silvio Georgi

Date: 01/01/2018

Bahnhofstr 94-98, 73457 Essingen, Deutschland Telephone: +49 (0) 7365 81-0 Fax: +49 (0) 7365 81-449 Email: sales.de@magnaflux.com Web: eu.magnaflux.com/de

Faraday Road, South Dorcan Industrial Estate, Swindon, SN3 5HE, UKTelephone: + 44 (0)1793 524566 Fax: +44 (0)1793 490459 Email: sales.eu@magnaflux.com Web: eu.magnaflux.com