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MAGNAFLUX
A Division Of Illinois Tool Works Inc.





OPERATI NG MANUAL
FOR
MAGNAFLUX
YOKE
MODEL: Y (7)




ITW INDIA LTD
Plot no. 51 to 52,207&208
Phase-2, IDA, APIIC, Pashammylaram
Medak Dist 502307.
Andhra Pradesh.
Telephone: 08455-224710
Fax: 08455 224709
Website: www.magnaflux.com





MAGNAFLUX, RegisteredU.S. patent office, a trademark of MAGNAFLUX Corporation applied to its equipment andmaterials for magnetic particle
inspection. Processes andmethods usedinmagnetic particle inspection arecovered by various U.S. Letter Patent.





2 | P age


MAGNAFLUX
A Division Of Illinois Tool Works Inc.




I NTRODUCTI ON

This manual contains the necessary information to acquaint the operator of the Y7-
Model AC/ HWDC Electromagnetic Yoke with its capabilities and operation. The purpose
of this manual is to furnish the operator with a functional knowledge of the operation
and to make understand the safety precautions which should be applied during operation
and maintenance of the equipment.

Should unusual situations arise regarding either the operation or maintenance of this
equipment, MAGNAFLUX staff is available for telephone or mail consultations. In
addition, maintenance service is available at the MAGNAFLUX Service Department.
















PERSONNELs FAILING TO COMPLETELY READ AND UNDERSTAND THESE INSTRUCTIONS
BEFORE PROCEEDING WITH THE INSTALLATION, OPERATION OR MAINTENANCE OF
THIS EQUIPMENT RUNS THE RISK OF INJURY.









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MAGNAFLUX
A Division Of Illinois Tool Works Inc.





GENERAL DESCRI PTI ON

The light weight electromagnetic yoke is the ideal tool for detection of surface or
subsurface cracks and flaws in any ferromagnetic material. No other low cost, portable
equipment offers such versatility in magnetic particle inspection.


Fast and simple to operate, it is widely used with either dry or wet method fluorescent
or non fluorescent magnetic powders, in the testing of welds, automotive or rail road
components, machine parts, steel or grey iron castings, forgings, and in plant inspection
maintenance and repair. It is supplied in a carrying case for storage and transport.



FEATURES


Choice of constant level AC or variable intensity pulsed HWDC current for surface
or sub surface flaw detection.
Solid state circuitry for infinitely variable (step less), potentiometric adjustment of
DC magnetic field.
Articulated legs to suit differing component contours. Inter pole distance
adjustable from 0 to 300 mm.
Low power consumption. Current drawn at 220 V, 1 phase supply is only 2
Amperes.
Extremely strong and intense magnetic field for superior sensitivity.
Portable and light weight.
Can be used for AC demagnetization too.
No risk of sparking or hot spots on the job.
No current flows through the component being tested.











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MAGNAFLUX
A Division Of Illinois Tool Works Inc.




PRI NCI PLE OF OPERATI ON

When the Yoke is energized by connecting to proper power supply, depressing the
Push to test switch creates an intense longitudinal magnetic field between the
legs. The resultant field can best be described as a multiplicity of invisible lines of
force extending across the gap between the legs. As the Yoke is applied to a Ferro
magnetic material, the magnetic circuit is closed and the field enters the part
making its passage between the legs and at below the surface. A crack across this
field cuts the magnetic circuit, the two sides of the crack become opposite poles
of magnet and a leakage field occurs in the air above the crack. Magnetic particles
sprinkled on the surface are attracted by this leakage field and indicate the
location of the flaw. For best results, the Yoke is positioned such that the
magnetic field created between the legs is transverse to the direction of suspected
cracks.

MAGNETI ZI NG FI ELD SELECTI ON

AC MAGNETIZATION

The induced field is surface field which only detects surface flaws. It is
particularly useful for inspecting thick and irregular sections for
surface defects. Best results are obtained with dry method.

HWDC (PULSED) MAGNETIZATION

The induced field creates the pulsating magnetic field which penetrates
the work piece and detects both surface and sub-surface flaws. The
pulsing of the field improves particle mobility & sensitivity and hence,
this mode can be used for both dry and wet method. Wet method gives
best results.




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MAGNAFLUX
A Division Of Illinois Tool Works Inc.



OPERATI NG I NSTRUCTI ONS

MAGNETIZATION

Adjust the legs to a spacing of 120 mm to 180 mm and place the yoke firmly
upon the work piece by securing best possible contact, with the suspected
defect transverse to the magnetic field between the legs. With the selector
switch in either the AC or the DC position; press the test switch to energize
the yoke and lightly dust the magnetic particles (Dry method) or flow the
magnetic particle suspension (Wet method) over the area being inspected. As
an example, when testing for longitudinal cracks in a butt weld the Yoke
would be positioned so that the legs straddle the weld. If the direction of a
possible defect is not known, two inspections should be made in such area,
turning the yoke approximately 90 degrees for second inspection. Use the
AC mode for surface flaw detection and DC for slightly sub-surface
inspection.

In the dry method using the power blower bulb, the area between the legs of
the Yoke is dusted lightly with MAGNAFLUX POWDER and inspected closely
for flaws or other defects. Current should remain ON (Continuous method).
This process is repeated until the entire area of part is inspected.

The Continuous method should always be used for maximum sensitivity.
Always use the lowest magnetizing current necessary (in DC) to produce
distinct indications. Avoid excessively strong fields which may magnetically
saturate the test piece and cause Masking effect or Back ground which
will interfere with flaw indication.

DEMAGNETIZATION
The Y7- Yoke can usually be used to obtain a satisfactory level of
demagnetization. With the equipment in AC mode, place the part across
the poles and while the current is flowing, slowly withdraw the part from the
field to a distance of at least 60 cm before turning off the magnetizing
current.



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MAGNAFLUX
A Division Of Illinois Tool Works Inc.




TECHNI CAL SPECI FI CATI ONS


Specification



Meets requirements of ASTM E 1444 -05.


Input Supply

220 V ,50 Hz,1 Ph

Input Current

2 Amps

Distance Across Poles

0-300mm
Magnetic Field

AC-Constant level,
DC-Pulsed, Infinitely variable
Flux Density


Approx, 10,500 lines of force/ cm
2
at 100 mm pole
spacing.

Pulling Capacity

Approx, 27 Kg (60 Lbs) in DC mode at 100 mm spacing.
5 Kg (11 Lbs) in AC mode at 100 mm spacing.
Yoke Weight

3.5 Kgs Approx.


Duty Cycle

23% (3 Sec On followed by 10 Sec Off)
Controls

On/ Off Switch
AC/ DC Switch
DC Field intensity Potentiometer








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MAGNAFLUX
A Division Of Illinois Tool Works Inc.





MAI NTENANCE


A periodic visual inspection of the interior electrical components is highly
recommended. Such an inspection can preclude operational malfunctions and
components failure. Disconnect the supply before gaining access to the interior
of the magnetic yoke.

Check all the wiring for the discoloration, burnt insulation and loose
connections. Ensure the cables are free from cuts which expose the wiring.

Prevent the yoke body and its interior from wet particles and liquids. Liquid
baths or wet magnetic particles if peeped inside the body can damage the
yoke components and can affect its working efficiency.


The equipment should be cleaned with a soft brush to loosen stubborn
particles with care being exercised to avoid damaging delicate electrical
leads.

After every six months yokes should be checked for its pulling capacity. It
should lift minimum 4.5 KG at 100 mm spacing for A.C. selection and 22.5
KG at 100 mm spacing for D.C. selection.

When equipment is not in use keep it at safe place, probably in its carrying
case.











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MAGNAFLUX
A Division Of Illinois Tool Works Inc.





PRECAUTI ONS



Do not operate the Y7 yoke for longer than 3 seconds ON followed by 10
seconds OFF, i.e. 23% duty cycle.

DO NOT energize the Yoke for more than the 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 connect the Yoke to a battery for portable work.

DO NOT change the AC / DC selector switch while the unit is energized.

Ensure that there is firm contact between test piece and Yoke legs for better
indications of the defects and less noise.

DO NOT open the yoke handle and change any settings on the PCB.

DO NOT drop the Yoke from a height or subject the handle to any service
impact.

Ensure that Yoke is connected to earth through proper 3 pin plug for operator
safety.

Do not replace any parts with other than those recommended by MAGNAFLUX.

Do not smoke while performing NDT.

Do not use the supply cable to pull, lift or carry the equipment.








9 | P age


MAGNAFLUX
A Division Of Illinois Tool Works Inc.





TROUBLE SHOOTI NG




Problem


Possible Causes



a) Unit does not operate
in
AC/ DC Mode.



1) Defective push button AC Switch.
2) Open wire in power cord or plug.
3) Open coil wire.



b) Unit will not run off



1) Fused Push-to-test switch

2) J ammed Push-to-test switch.



c) Unit over heats




1) Defective circuit board
2) Shorted coil
3) Enhanced Duty Cycle



d) Unit does not operate in
AC


1) AC / DC switch contacts open

2) Open wires in PCB or wiring



e) There is no control in
DC Mode



1)Faulty level control potentiometer





Do not replace any parts with other than those recommended by Magnaflux.


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MAGNAFLUX
A Division Of Illinois Tool Works Inc.





SPARE PARTS LI ST FOR Y7-YOKE



S.NO.


PART NAME


PART NO.


1

PCB ASSEMBLY

F03033

2

PUSH TO ON SWITCH

F03093

3

AC / DC SWITCH

F03094





















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MAGNAFLUX
A Division Of Illinois Tool Works Inc.




Yoke

















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MAGNAFLUX
A Division Of Illinois Tool Works Inc.



OTHER YOKE MODELS

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MAGNAFLUX
A Division Of Illinois Tool Works Inc.



WI RI NG DI AGRAM FOR Y7-YOKE