MT Stationary Facilities
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The test benches HELLMAG Universal 500 AC, HELLMAG Universal 700 AC and
HELLMAG Universal 1000 AC are designed for testing short-run batches and for training purposes.
- Mechanical fixing of the test item via two quick clamp devices serves for optimal electric and magnetic contact
- 2 single connectible magnetising circuits (AC current flow magnetisation / AC yoke magnetisation)
- Operation via Siemens "KTP 600" multi-colour touch panel
- Test piece current settings can be storaged
- Powerful UV LED stationary lamp
| Technical Data | HELLMAG Universal 500 AC |
HELLMAG Universal 700 AC |
HELLMAG Univeral 1000 AC |
| Art. no. | 139.900.330 | 139.900.310 | 139.900.320 |
| Clamping length AC current flow AC yoke magnetisation |
60 - 500 mm 1,200 A eff. approx. 12,000 AT |
60 - 700 mm 1,200 A eff. approx. 12,000 AT |
150 - 1,000 mm 2,000 A eff. approx. 20,000 AT |
| Tangential field strength | approx. 30 A/cm2 | approx. 30 A/cm2 | approx. 30 A/cm2 |
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Relative duty cycle |
40 % |
30 % yes yes 400 V / 50 Hz / 100 A max. 28 kVA approx. 160 x 50 x 165 cm approx. 480 kg |
40 % yes yes 400 V / 50 Hz / 125 A max. 55 kVA approx. 250 x 80 x 140 cm approx. 790 kg |
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139.900.330 HELLMAG Universal 500 AC 139.900.310 HELLMAG Universal 700 AC 139.900.320 HELLMAG Universal 1000 AC 
Test bench HELLMAG Typ Vario 2500 is suitable for e.g. testing of railway wheelset axles.
- 2 stepless adjustable magnetization cycles (AC current flow / AC coil magnetisation)
- With blackout cabin (curtains / shutter)
- Swivelling control panel
- Horizontal movable powerfull large UV LED panel lamp
- Joystick for motor control of coil transportation and rotation of test specimen
- Manually movable sleeve carriage with pneumatic clamping device
- Ring shower
- Test medium tank with pump and bypass
- Control cabinet
| Technical Data | |
| Clamping length Current flow Coil magnetization Supply voltage Control voltage Power consumption Hub of quick clamping device Test medium tank Compressed air connection Weight Automatical demagnetisation |
2,500 mm 4,200 A eff. max. 4,500 ampere-turns 400 V rotary current 24 V / 50 Hz approx. 75 kVA approx. 25 mm (two-hand operation) approx. 7 mm (foot switch) approx. 40 L 5 - 6 bar up to approx. 500 kg integrated |
139.900.xxx HELLMAG Typ Vario 2500 
Test bench ZER-O-MAT® enables comfortable and quick magnetic particle testing of the surfaces of pipes, billets, rods, hollow sections and similar test specimens.
- Max. ∅ 20 - 660 mm
- Quadratic/rectangular cross sections, irregular shaped parts and pipe-ends can be tested, too
- Application of the U-coils (ZER-O-MAT coil) which are patented and have been developed by HELLING
- Contactless magnetisation (avoidance of contact or contact burn)
- Effective magnetisation of the surface up to approx. 1.5 mm depth (Skin effect)
- Spiral transportation of the test specimen through the coil (at ED 100 %)
- No demagnetisation required
- Powerfull UV LED panel lamp Slim-Line (no warm-up time)
| Technical Data | |
| Input supply voltage Control voltage Power consumption Main supply Tangential field strength at testing surface Testable pipe dimensions Duty cycle UV illumination |
400 V / 50 Hz 230 V / 50 Hz max. 90 KVA min. 250 A ≥ 24 A/cm ∅ 20 to 660 mm up to 100 % possible UV LED panel lamp Slim Line |
000.000.000 
HELLING railway wheel testing system for detection of
- surface defects and
- near-surface defects of any orientation direction at railway wheels
by magnetic particle testing.
This facility is suitable for
- testing of assembled wheelsets
- testing during production of rolling stock wheels
- reconditioning of rolling stock wheels
This railway wheel testing system consists of a special stabil metal rack with lifting device. Contactless magnetisation of the complete surface (except the inside diameter of the wheel hub) is possible by specially developed trapezoidal coil for wheels of 700 mm - 1,200 mm diameter.
Testing is performed by fluorescent water-based magnetic particle Suspension under UV irradiation. For this purpose the trapezoidal coil is equipped with an integrated magnetic particle suspension rinsing system. The magnetic particle suspension is elevated from a 40 L tank by the integrated pump with mixing system.
| Technical Data | |
| Power supply Fuse Operating voltage Current supply |
3 x 400 V / 50/60 Hz / 11 kVA 3 x 35 A 24 V DC via copper tracks 60 x 10 mm |
| Type of coil | Trapezoidal coil with integrated magnetic particle suspension rinsing system |
| Driving motor | 0.37 kW with frequency converter and brake |
| Rotation speed | Level 1 = 1 turn/min |
| Level 2 = 2 turns/min | |
| Level 3 = 3 turns/min | |
| Magnetisiation current Magnetisation power Operation |
selectable via 6-steps switch as from level 2 > 25 A/cm control panel with operating and fault message; joystick or foot switch |
| Tank for magnetic powder suspension |
40 L tank with integrated pump and mixing system |
| Catch basins for magnetic powder suspension | stainless steel |
| Dimension Weight |
2,000 x 2,000 x 2,850 mm approx. 800 kg |
131.050.030 Railway wheel testing system 
Testing of cylindric, rectangular and irregular shaped test parts
- 2 x 230 V sockets (for connection of hand magnet)
- 2 UV lamps type ZERO 400/3 with swivel arm
- Hydraulic unit
- Collection tank with outlet valve
- Control cabinet
| Technical Data | |
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Supply voltage |
3 x 400 V / 50 Hz 230 V / 50 Hz 1.5 kVA 1,500 W approx. 3,800 µW/cm² |
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Diameter of roles |
150 mm 0 - 50 min-1 1,500 x 1,000 x 1,000 mm 590 mm approx. 300 kg |
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Test specimen: |
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| Dimensions (on roller guide) | L = 250 - 1,000 mm ∅ 100 - 650 mm |
| Weight | max. 1,000 kg |
139.900.xxx Test bench 051-100 
Contact-less inspection system for combined MPI on assembled railway wheel sets
The device is equipped with two independent high current generators for simultaneous inspection of wheels and axles.
Technical Description
- MPI wheelset testing system,
- Steel frame with 2 manually movable carriages
- Frame with base plates screwed to foundation
- Double-roller linear axis for adjusting the height of the magnetization coil
- 1 trapezoidal coil with handle and push button for magnetizing railway wheels Ø 800 to 1200 mm diameter (can be tilted forwards)
- 1 segment coil with handle and push button for magnetization of railway axles up to Ø 250 mm
- Two control cabinets containing high current transformers and control panels:
- Hellmag 7k: 400 V; 60% relative duty cycle; for trapezoidal coil
- Hellmag 15k: 400 V; 60% relative duty cycle; for segment coil
- with distance monitoring to the test piece (visual display) - optionally
- Mechanical clamping of the height adjustment
131.050.045 ROD-A-MAT railway wheel set inspection facility