Download Handbook for Magnaflux Y8 Electromagnetic Yoke - Nov 11

HANDBOOK FOR
MAGNAFLUX
Y8 ELECTROMAGNETIC YOKE
PART NUMBER:
001Y024
Handbook for Magnaflux Y8 Electromagnetic Yoke
Y6/Y8 YOKE KITS
Certificate of Conformity
Y8 Yoke
Serial number:
Certified that the above item conforms to and meets the
requirements of the following:
In kit form, the Y6/Y8 Yokes are supplied
complete with black magnetic ink, white
contrast paint and a wire brush and duster, all
housed in a strong attractive carrying case.
A light source, attached to one leg of the Y6
Yoke, is activated by the magnetic field and
switches on automatically during testing. Ideal
for darker corners.
EC Directives
Specifications
Light source for Y6 Yoke – part number
002L115.
73/23/EEC
89/392/EEC
91/368/EEC
89/336/EEC (Emissions)
92/31/EEC (Emissions)
ASME V ART7
ASTM E-709
ASTM E-1444
L-10 MAGNETISING COIL
Certificate is issued under the auspices of the Equipment
Product Manager (2011):
Developed for testing shafts, spindles and
similar components.
Features:
Magnaflux (A Division of ITW Ltd),
Faraday Road, South Dorcan Industrial Estate,
Swindon, Wiltshire, SN3 5HE, UK.
Ideal for inspecting for transverse cracks
Components
are
magnetised
and
demagnetised with the same coil
110V operation
Wet or dry Magnetic Particle Inspection
(MPI) method can be used
Footswitch provides continuous control
Magnetic particle colours available:
Tel: +44 (0)1793 524566
Fax: +44 (0)1793 490459
Email: [email protected]
www.magnaflux.com
Dry method – grey, black, red
Wet method – black, red, fluorescent
USING THE Y8 YOKE
PREPARED INKS
Flash point
(°C min)
(PMCC)
Viscosity
@ 21°C
(cS)
Specific
gravity
Particle
size (µm)
Settlement
volume (%V/V)
(as supplied)
93
3.45
0.81
7 to 25
0.12
Magnaglo 410HF*
A prepared ink consisting
of Magnaglo MG410 in a
high flash kerosene of low
odour
Magnaglo 14HF*
A prepared ink consisting
of Magnaglo 14A in a
high flash kerosene of low
odour
Magnavis 7HF*
A prepared ink consisting
of Magnaflux 7C in a high
flash kerosene of low
odour
93
3.45
0.81
2 to 25
0.25
93
3.45
0.81
0.6 to 2.5
2.5
Note 1: This Yoke can be supplemented by
a magnetising coil for inspecting
mounted spindles, rear axles and
other light parts for transverse
cracks only.
Note 2: Fluorescent magnetic ink with high
intensity black light improves the
sensitivity of both the Y8 Yoke and
L10 Magnetising Coil
1.
2.
3.
*Available in both aerosol and bulk format
DRY POWDERS
Place the Yoke on the workpiece perpendicular to the direction of the cracks. Double
jointed articulated legs can be moved in two directions at each joint.
You can then adjust the spacing between the legs from about 25 to 250mm and
contour the feet to produce a good flat contact point on parts with irregular shapes.
Trigger the switch, apply the inspection medium, either wet or dry, and surface crack
indications form immediately. You can proceed rapidly in a series of steps each
finding cracks in a 150 x 150mm area.
WARNINGS
1 Grey
Maximum working temperature 315°C
3A Black
Maximum working temperature 230°C
8A Red
Maximum working temperature 175°C
Magnaflux dry powders offer a range of colour to
give good contrast on as wide a variety of
finishes as possible. In the event of contrast not
being ideal for inspection, a thin layer of
Magnaflux WCP-2 White Contrast Paint can be
applied prior to testing.
All powders are of closely controlled particle size
and shape and have desirable magnetic
properties. For best results application should be
as a cloud applied near the surface while the
current is flowing. Excess powder settling out can
be blown off.
4.
WCP-2 White Contrast Paint
Magnaflux WCP-2 is a quick-drying white
contrast paint which can be applied as a thin
coating prior to testing where enhanced contrast
is required.
SPECIFICATIONS
Magnaflux, Magnaglo and Magnavis concentrates, prepared inks and dry powders meet the
requirements of ASTM E-1444 with oil suspended inks and concentrates meeting AMS specifications,
plus appropriate industrial and Government specifications, Certifications are available on request.
5.
DO NOT smoke while performing NDT
DO NOT operate the Y8 Yoke for longer than 3 seconds ON followed by 10 seconds
OFF, that is a 23% duty cycle
If the Yoke is too hot to hold in the bare hand it is a sign that the duty cycle has been
exceeded. Wait for the Yoke to cool before continuing.
DO NOT use any means to permanently operate the Yoke switch
DO NOT use the supply cable to pull, lift or carry the equipment
When the Yoke is switched OFF the magnetic attraction to the tested component will
be weakened and either the part or the Yoke could fall and cause injury
Laminar magnetic iron provides maximum efficiency with light weight. The trigger
switch is easily operated without changing hand positions.
As magnetic contact exists only between the Yoke and the test piece, the switch,
completely enclosed by a rubber gasket, is the only break in the electrical circuit. Thus
arcing on the part itself is impossible.
SAFETY DATA
RECHARGING DATA
FLAMMABILITY
Date
The Y8 Yoke is intended to be used in conjunction with appropriate chemicals as a Non
Destructive means of Testing (NDT) for defects, such as cracks, on a wide range of
manufactured components. Some chemicals may produce a flammable atmosphere at the
point of use and it is important that the testing is carried out in a well ventilated place and
that all sources of ignition are excluded.
Good quality NDT chemicals such as Magnaflux magnetic inks and powders are
formulated to minimise the risk of a flammable atmosphere when correctly used.
MAINTENANCE
Before using the Yoke, battery or battery charger:
Ensure that they are physically undamaged
Ensure the cables are free from cuts which expose the wiring
Tighten the articulated joints if they are excessively loose
If the switch area of the Yoke becomes wet with either kerosene or water it should be
disconnected from its supply until the area has dried
If the Y8 shows signs of malfunctioning or if cracks appear in the casing, the Yoke
should be removed from service immediately and examined by a qualified electrician.
Cracking is usually caused by dropping the Yoke or by twisting the articulated legs.
It is a legal requirement in many countries that the electrical safety of equipment is
checked periodically, commensurate with use, but at least once a year. The basic tests
required are to check the condition and effectiveness of the electrical insulation and the
continuity of the protective conductor (earth). These tests can be performed using as
Portable Appliance Tester (PAT) or Portable Appliance Checker (PAC).
Test lift
Remarks
Signed
HANDLING AND STORAGE OF BATTERIES
MAGNETIC FIELDS
Electric and magnetic fields (EMF’s) arise from the generation, transmission and use of
electricity. The result is that everyone today is exposed to a complex mix of EMF’s both at
home and work.
Store batteries in a cool and dry area with an impervious surface
Store batteries under a roof and protect against adverse weather conditions
Protect against physical damage and exposure to organic solvents
Do not allow metal objects to contact both terminals at the same time, as this will
cause sparking and possible injury
Never install batteries in a gas tight enclosure as gases may be generated during use
Batteries must be charged on a voltage regulated charging system and adequate
ventilation provided to avoid build up of ignitable gases
Under extreme conditions of charging equipment malfunction and/or battery failure,
high voltage and high temperature conditions may occur causing evolution of
hydrogen sulphide (H2S) gas, which is toxic. If detected by its odour of rotting eggs (at
extremely low concentrations) switch of the charging equipment, evacuate all
personnel from the area, and ventilate the area well. Seek appropriate advice before
attempting to re-starting charging.
ACCIDENTAL RELEASE MEASURES
The batteries are designed not to leak under normal conditions. If, however, electrolyte
does leak out of the battery for any reason, it should be absorbed onto dry sand, earth or
other inert material and must not be allowed to enter the drains. If possible, neutralise any
leaked electrolyte using soda ash, sodium bicarbonate, sodium carbonate or calcium
carbonate, and then wash thoroughly with water. Collect the absorbed material and place
in an inert sealed container for appropriate disposal.
Magnetic fields are created when an electric current flows. Magnetic and electric fields
then exist together. The greater the current the stronger the magnetic field.
Magnetic particle inspection involves the generation of magnetic fields to locate defects in
ferrous materials. It has been used for many years with no reported health effects.
Although and extremely useful and effective Non Destructive Testing (NDT) method, there
are growing concerns that exposure to EMF’s could have detrimental health effects.
There is very little conclusive information on the effects of exposure to intense fields.
However, research by various authorities has shown that under certain circumstances
acute exposure to intense fields of around 60 mT can result in headaches and alterations
in visual response.
The National Radiological Protection Board (NRPB) has developed guidelines to protect
people from these potential effects. No health risks have been established for weak fields.
Typical magnetic field strengths for domestic appliances
Vacuum cleaners – 2-20 microtesla @ 30 cm from the appliance
Electric drills – 2-20 microtesla @ 30 cm from the appliance
Typical magnetic field strengths for some Magnaflux MPI equipment
MAG 50 coil – 1.3 millitesla @ 30 cm
MAG 50 head/tailstock – 1.5 millitesla @ 45 cm
Y6 Yoke < 1 millitesla @ 15 cm
Units of measurement for Magnetic Field Strength – tesla (T)
1 tesla = 1,000 millitesla (mT); 1 millitesla = 1,000 microtesla (µT)
MAGNETIC FIELD RISK
Persons susceptible to strong magnetic fields, including those with pacemakers, are
advised not to use or approach this equipment without seeking professional advice.
TECHNICAL SPECIFICATION
BATTERY HEALTH AND SAFETY
YOKE AND BATTERY
WARNING:
DC Voltage
6
Supply Current (A) in air
Weight (Kg) – lifted at 140 mm pole
spacing
BATTERY CHARGER
1.5
22.5
The gases given off when charging are explosive.
No smoking or naked flames
Ensure that cables and electrical equipment are handled in such a way to avoid
sparks
Before fitting or removing the batteries, make sure that all equipment connected to it is
switched off to avoid accidental sparking
Never short circuit the battery terminals as the resulting sparks and arcs can injure
personnel and are a fire hazard
Do not charge batteries above above +50°C, or disc harge or store above +60°C
When charging, connect the battery to the charger before switching the charger on.
Reverse the process at the end of charging.
When charging indoors, ensure there is adequate ventilation
WARNING:
Input: 230 volts 50/60Hz
Output: 6.85/7.25 volts DC @ 2 amps
Treat sulphuric acid with respect. It is a highly corrosive liquid and will cause severe injury
if splashed on the skin or in the eyes, or if taken internally. It rapidly destroys most
clothing. Sulphuric acid is scheduled as a poison in Part 2 of the Poisons List.
CERTIFIED TEST LIFT WEIGHTS
Always:
Available for both AC and DC.
AC Test Weight (4.5 Kg) – part number 026T018B
DC Test Weight (18 Kg) – part number 026T018A
Wear acid-resistant clothing, goggles, PVC gloves and rubber boots
Have a copious supply of water available
Keep an eyewash bottle ready, containing 1% of saline solution
BATTERY CHARGER
PARTS LIST
OPERATION
Description
Y8 Yoke cable 3 core
First stage – constant current mode
Visual indication – RED LED ON, GREEN LED OFF
Second stage – constant voltage mode
Visual indication – AS ABOVE
Part Number
001C065
Y8 cable bush
014B027
Cable cover
17771A3
Leg/foot assembly
075C004
Third stage – float charge mode. The battery will be maintained 100% charged.
Visual indication – GREEN LED ON, RED LED OFF
Switch kit
005K026
LED PROTOCOL
Y8 plug (PLG 1)
016P085
Battery charger plug (PLG 2)
016P085
Battery charger (BC 1)
039B002
Battery socket (SKT 1)
015S135
Battery (BAT 1)
003B014
Fuse (FS 1)
001F115
Charger status
Bulk charge mode
Float charge mode (charge complete)
Battery reversal detected
High temperature detected
Short circuit
Open circuit
LED Status
Red – static ON
Green – static ON
Red – flashing
Red + Green flashing simultaneously
Red + Green flashing alternatively
Red + Green static simultaneously
Note: On power up the system will enter a ‘soft start’ mode. This facility checks for
possible faults, for example, reverse battery connection etc, before operating maximum
charge current.
Battery pouch
520797
WARNING
DO NOT REPLACE ANY PARTS
RECOMMENDED BY MAGNAFLUX.
WITH
OTHER
THAN
THOSE