magwerks difference v-2 difference v-2.pdf · pictured below are some silicon controlled rectifier...

Voice: 317.241.8011 501 Commerce Drive Sales Fax: 317.2418015 Danville, IN 46122 Engineering Fax: 317.472.2458

The Magwerks Difference

Electrical Panel

1. All components are Circuit Breaker Protected. 2. Fully PLC Controlled. 3. Closed Looped Current Control. 4. Solid State Switching. 5. Automatic Phase AC sensing where

applicable. 6. All wires in wire tracks.

From a Mobile Power Pack

From a Wet Horizontal

From a Tri-Vector MV-2996


Power Transformers: 1. Typically Twice the size of commonly used in the Industry. Magwerks pictured to the left and the Competition to the right. Both Used in the same current output rated machine 6000 amps. 2. Larger is always better in electrical components displaces more heat and carries more current 3. Silicon Orientated Grain Steel Cores. 4. Copper wire Wrapped.

5. 13.5 Volt output a little extra to overcome resistive loses

SCR Stack Comparison:

Pictured below are some Silicon Controlled Rectifier Stacks; to the left a Magwerks stack (with SCR Interface assembly) and to the right an SCR stack found in other competing manufactures machines. Everyone uses the same rated SCR’s but the heat sinks are a 1/3 the size. The smaller size heat sinks means higher temperatures, the SCR’s will be exposed to shortening their life.


Included Standard with our SCR’s stacks is the (previously mentioned) Magwerks exclusive “SCR Interface”. The SCR Interface allows a technician or operator to quickly see if the SCR is wired correctly and which SCR’s are operating. If a maintenance issue comes up this SCR interface allows a technician to quickly identify which SCR have failed. BEFORE the issue of the “Magwerks SCR Interface”, finding the failed SCR could take hours by a trained technician. Now any electrician can identify the problem saving hours of diagnostic time and money. The SCR Interface also has the added benefit of warning the technician if an SCR has been installed improperly. The Magwerks SCR Interface is STANDARD on new Magwerks machines and Re-Manufactured units. It also can be retrofitted to all models of Magwerks with little difficulty. Pictured below is Thermal Overload Safety switches. These safety switches protect your valuable investment from overheating. Depending on the machine as many as 20 thermal overloads safeties can be found. Another Magwerks Only Feature, protecting your investment.


Plug and Play Pneumatics. (if equipped) Mounted and set to the Proper Air Pressure and filled with oil. Water-Separator, Regulator, and Oiler ready to plug, with air house quick release already attached

Large Power Contactor or Circuit Breaker: depending on the model 150 Amp or 275 Amp Contactor/Circuit Breaker is used. The power contactors allow machine to be turned off & on at the operator console, standard on all Magwerks Wet Horizontal and Stationary Power Packs.


Circuit Breakers are used on the mobile power packs, to protect your investment when it is common to connect to large power source that is not fused to protect the machine. Another Magwerks only consideration for the benefit of Magwerks customers.


In 2012 Magwerks started adding more safeties to all the MPI models. Pictured on the right is a TVS Block (Transient Voltage Suppressors). The style of TVS Magwerks uses is specialized Diode that is able to react to over-voltages in 1 Pico Second (0.000,000,000,001). In the short time the unit was added to the electrical panel it has saved several customer from costly repairs from Over-Voltage that typical Surge Suppressor can stop.

Seen to the left is a Voltage Monitoring Device (VMD). The VMD was added in late 2012 to all MPI models. This safety device is protecting the machine from improper electrical connection, under-voltage, over-voltage, phase imbalances, and prolonged voltage drops. The VMD operates by continuously monitoring the incoming power, if the incoming power falls outside a pre-determined range the MPI unit shuts off. This is another device that has saved numerous customers, around the world, from costly damage caused by improper voltage input to machine and unstable electrical power from the local power companies.


Magwerks Handheld Programmer Interface

Reprogram the PLC: NO Computer necessary With this option the following items come standard 1. “Plug and Play” – just plug the handheld into the PLC communication port. That’s all! 2. Interactive touch screen allows for quick setting modifications. 3. Back-lit screen allows for machine adjustments in low-light environments. 4. Allows for easy alteration of machine data tables, and scaling factors. 5. Machine Adjustable Settings: a. Mag Shot Time b. Mag Shot Delay c. Headstock Clamp Delay (when applicable) d. Enable / Disable Dual Mag Shots e. Set 2nd Mag Shot Delay f. Automag Setting Adjustments (when applicable) g. Autobath Setting Adjustments (when applicable) h. Foot Switch Options (when applicable)

Large 6” Color Touch Screen Display, all the features available with the programmer come standard with 6” standard display with addition to: 1. Displays Current for the next Mag Shot no

more trial & error with the current knob. Turn the Current Knob and the Display informs you how much current the next shot will be (approximate).

2. Displays Current Vector: Head or Coil 3. Displays Current Type: AC, Half-Wave, or

Full Wave and updates with selector switch. 4. Mag Shot Timer 5. AutoMag adjustments:

a. Adjust Clamp delay b. Adjust Mag time c. Adjust Pulse Delay

6. Automatically add time to Mag shot for low currents & customize for specific currents 7. Create Part Profiles:

a. Create names for parts to easily find them b. Up to 5 Mag shot settings per part set the Wave Form Type & automatic switch between Head or

Coil settings c. Set the Demag shot Current and Wave Form Type d. Single button access to Ketos Ring Test e. Modify the Ketos test parameters


Metering: Knowing how much current the machine is outputting is critical to know a part was magnetized. Typical Tolerance in the industry range around 5-10% compared to a Shunt Test Kit. This was not good enough for our Customers. We developed and built a new meter to hold +/- 1% with a hold feature. Continuing to see to additional needs for our customers. The meter includes a Red LED to indicate a Mag Shot was detected. This feature with Mag light on the Mag Button tells operators if the Mag pulse actually occurred. The meter holds +/- 1% in all waves forms AC, HWDC and FWDC under normal circumstances. Pumps: To keep the particle in suspension requires a pump that works day in and day out, and be maintenance free as possible. We offer Cast Iron and Stainless Steel pumps. The selection criteria for a pump is critical. Magwerks uses only 1750 rpm pumps:

1. Reducing the wear on the particle.

2. Reduces vibration. 3. Reduces noise. 4. Cuts down on heating. 5. Pumps last longer.


Accessories:

Laminated Central Conductors: Magwerks Only Need to induce a Torridal Field into a part? Magwerks offers a selection of, off-the-shelf Laminated Central Conductors and can design custom units to meet your application. Magwerks UB-400SA-V-2: 400 Watt Black Light: Offering the smallest and easiest to use 400 watt Flood black light on the market with more standard features than anyone, has now been further improved: 1. Output is 17,000-20,000 Microwatts of UV-A at 15” in a Flood Pattern, Not a spot light 2. NEW and Improved Power Supply 3. New Arm Assembly 4. New Mounting brackets

Shunt Meter Kit: Continuing on the success of the SMTS-30 Magwerks developed a new smaller SMTS-25 Shunt Test Kit. This kit has all the same power and accuracy as it larger brother in smaller package, all while being Battery Powered. No more hunting for 120 volt outlets to do calibration work on a machine. The SMTS-25 will calibrate all past and currently manufactured MPI machines on the market of any make or model.


PSAH5-SVM Exterior

1. Cabinet made from 11 and 14 gauge steel

2. Fully Enclosed design. (Designed to take a beating)

3. 6” Steel Casters 4. Controls and Contactor

Recessed for protection 5. Hinged access panels no

bolts or screws loose in the field.

6. Sealed cabinet keeps the dirt out

7. Fits through a Standard 36” door way

8. 4 Eye-Bolts for easy lifting by a crane or hoist.

9. 120 volt outlet for Black Light or other accessories.

10. Large open Box top to store cables and accessories

11. Baked on Powder Coated (not your dime store paint)

Head Stock & Tail Stock

1. Made from ¼ Inch Plate Steel not made from “cast aluminum”, Designed to take a daily beating and keeping working.

2. Baked on Powder Coated (not your dime store paint).

3. 2 ½ Inch Pneumatic Cylinder fully ball bearing supported.

4. Pre-drilled and Tapped Holes for mounting Roller Rest and Black Light Arms


Pictured Below are various sizes of Magwerks Tailstocks for Size Comparison. The Tailstocks are not fully assembled; however they are suitable for giving a size comparison.

These pictures show that Magwerks does not just bolt on larger copper plates to a standard Head & Tailstock and call them “oversized”. We approach the problem with the understanding if a larger contact surface is needed, then parts are going to be far larger, weigh significantly more, which will also require the pneumatic cylinder in the Tailstock to make good electrical connection. All Tailstocks have gear drives with ball bearing guides to eliminate the Tailstock sticking and jamming on the bed rails.

MX Standard Tailstock

Magwerks Standard Tailstock

Magwerks 8” X 10” Tail Stock with Pneumatic Cylinder in both Head and Tail Stock.

Magwerks 12” X 12” Tailstock with Pneumatic Cylinders in Both Head and Tailstocks.


Wet Horizontal Tank and Frame Features:

1. Stainless Steel Tank. 2. 11 &14 gauge Steel used for all support components. 3. Sealed Cabinets. Keep the Dust, Dirt, Contaminated air out of the machine. 4. Hinged Doors for easy access to the machine internal components. 5. Large Stainless Steel Hip bar. (not made from electrical conduit ). 6. Spring hinge pins to Attached Hip Bar to the machine. It only takes 15 seconds to get into the machine

with the Hip Bar attached. 7. Maple wood Grates. One of the hardest woods on the market comes standard on our machines. If

need be can purchase plastic grates for Water Based applications 8. Operator Console:

a. Can be Rotated and Raised for easy operator use. b. Standard, machine can be turned off at the operator panel. This turns off the power to

Magnetizing Circuit which idles between 1,000 to 4,600 watts when not in operation. c. Standard on Multi-Vector machines; is an Ammeter for each Vector. No guessing the current

output on each vector d. White Light e. Ventilator Fan f. Agitation Pump

9. Forklift slots: Welded under the machine are slots for the Forklift forks to slide into. This keeps the accidentally dropping the machine when moving.

10. Standard 3 ways to operate the Mag Pulse: a. Operator Control Panel b. Hip Bar c. Foot Pedal

11. Auto-Mag feature: a. Non-Touch Screen:

i. Closes the HeadStock pneumatics, ii. Activates Auto Bath if equipped iii. activates Mag pulse, iv. Opens the head stock

b. Touch Screen equipped : steps through the above process but additional will follow the part profile settings.

c. Editable Settings: i. Clamp Delay ii. Mag Pulse Timer iii. Un-Clamp Delay iv. Auto Bath Delays (if equipped) v. Auto Bath on Times (if equipped )

12. Baked on Powder Coating (not your dime store paint). 13. 120 volt accessory outlets. 14. Needle valves to regulate the speed of both Opening and Closing of Head Stock pneumatics 15. Keyed foot pedal outlets, to keep from accidentally installing the pedal into the wrong outlet.


A Green Machine: When optionally equipped with an Auto-shutoff for the Magnetizing Circuit. User Adjustable 5 to 99 minutes of idle time. This feature can add significant savings over a year, as the power transformers consume between 1,000 watts to 4,600 watts just idling not checking parts. If not equipped with the Automatic Shut-Off, the power usage during idle time can add to a plants wasted energy. The 1,000 watt idle Mag-Circuit usage

1. If the machine idles for 24 hours the wasted power is 24 kWh 2. Assuming 4 weekends in a month machine does not operate but left on equates to 192 kWh 3. Assuming 52 weekends in a year equates to 2,496 kWh

The 4,600 watt idle Mag-Circuit usage

1. If the machine idles for 24 hours the wasted power is 110.4 kWh 2. Assuming 4 weekends in a month machine does not operate but left on equates to 883.2 kWh 3. Assuming 52 weekends in a year equates to 11,481.6 kWh

In another scenario we assume a plant runs a single 8 hour shift, 5 days week the wasted power is even greater. The 1,000 watts idle Mag-Circuit usage

1. If the machine idles for 16 hours per day the wasted power is 16 kWh 2. In one week with 16 hours idle time and 48 hours in week equates to 128 kWh 3. Assuming 52 working weeks in a year equates to 6,656 kWh

The 4600 watt idle Mag-Circuit usage

1. If the machine idles for 16 hours the wasted power is 73.6 kWh 2. In one week with 16 hours idle time and 48 hours in week equates to 588.8 kWh 3. Assuming 52 working weeks in a year equates to 30,617.6 kWh

The above numbers are calculated using 480 AC Volts at 60hz. Older equipment and even newly manufactured equipment did not / do not come with Power Contactors to turn off at the operator’s console. The only way to turn the power off is at the main disconnect. Magwerks was the first to offer the Power Contactor and has expanded on this feature to now include Auto –Shutoff for additional power savings.

magwerks difference v-2 difference v-2.pdf · pictured below are some silicon controlled rectifier...

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