GE Krautkramer USM 35X User manual

GE
Brand
GE
Model
Krautkramer USM 35X
Category
Measuring, testing & control
Type
User manual
Krautkramer USM 35X Issue 01, 04/2005 0-1
Contents
1 Introduction ........................................ 1-1
1.1 Safety information ..................................... 1-2
Batteries ...................................................... 1-2
Software ...................................................... 1-2
Defects/errors and exceptional stresses ..... 1-3
1.2 Important information on
ultrasonic testing ...................................... 1-3
Preconditions for testing with
ultrasonic test equipment ............................ 1-3
Operator training .......................................... 1-4
Technical test requirements ........................ 1-4
Limits of testing .......................................... 1-5
Ultrasonic wall thickness measurement ...... 1-5
Effect of the test object’s material .............. 1-5
Effect of temperature variations .................. 1-6
Measurement of remaining wall
thickness .................................................... 1-6
Ultrasonic evaluation of flaws ..................... 1-6
Flaw boundary method ................................ 1-6
Echo display comparison method ............... 1-7
1.3 The USM 35X family .................................. 1-8
The different instrument versions ................ 1-8
Special features .......................................... 1-9
1.4 How to use this manual .......................... 1-10
1.5 Layout and presentation in this
manual ..................................................... 1-11
Attention and Note symbols ...................... 1-11
Listings ..................................................... 1-11
Operating steps ......................................... 1-11
2 Standard package and
accessories ........................................ 2-1
2.1 Standard package ..................................... 2-3
2.2 Recommended accessories ..................... 2-5
Krautkramer USM 35X Issue 01, 04/2005 0-1
Contents
1 Introduction ........................................ 1-1
1.1 Safety information ..................................... 1-2
Batteries ...................................................... 1-2
Software ...................................................... 1-2
Defects/errors and exceptional stresses ..... 1-3
1.2 Important information on
ultrasonic testing ...................................... 1-3
Preconditions for testing with
ultrasonic test equipment ............................ 1-3
Operator training .......................................... 1-4
Technical test requirements ........................ 1-4
Limits of testing .......................................... 1-5
Ultrasonic wall thickness measurement ...... 1-5
Effect of the test object’s material .............. 1-5
Effect of temperature variations .................. 1-6
Measurement of remaining wall
thickness .................................................... 1-6
Ultrasonic evaluation of flaws ..................... 1-6
Flaw boundary method ................................ 1-6
Echo display comparison method ............... 1-7
1.3 The USM 35X family .................................. 1-8
The different instrument versions ................ 1-8
Special features .......................................... 1-9
1.4 How to use this manual .......................... 1-10
1.5 Layout and presentation in this
manual ..................................................... 1-11
Attention and Note symbols ...................... 1-11
Listings ..................................................... 1-11
Operating steps ......................................... 1-11
2 Standard package and
accessories ........................................ 2-1
2.1 Standard package ..................................... 2-3
2.2 Recommended accessories ..................... 2-5
0-2 Issue 01, 04/2005 Krautkramer USM 35X
Contents
3 Initial start-up ...................................... 3-1
3.1 Power supply ............................................. 3-2
Operation using the power supply unit ........ 3-2
Operation using batteries ............................ 3-3
Charging the batteries ................................. 3-5
3.2 Connecting a probe .................................. 3-7
3.3 Starting the USM 35X ................................ 3-8
Switching on ................................................ 3-8
Reset .......................................................... 3-8
Information lines in the startup screen ........ 3-8
4 Principles of operation ...................... 4-1
4.1 Operator’s controls ................................... 4-2
4.2 Screen display ........................................... 4-3
Functions on the display ............................. 4-4
Other displays ............................................. 4-5
4.3 Keys and rotary knobs .............................. 4-6
Function keys ............................................. 4-6
On/Off key .................................................. 4-6
Special keys ............................................... 4-7
Rotary knobs ............................................... 4-8
4.4 Operational concept .................................. 4-8
Setting the functions ................................... 4-9
4.5 Important basic settings ......................... 4-10
Selecting the language .............................. 4-10
Selecting units .......................................... 4-11
Setting the date ......................................... 4-12
Setting the time ......................................... 4-13
4.6 Basic settings of the display .................. 4-14
Selecting the color scheme ....................... 4-14
Setting the lighting .................................... 4-14
0-2 Issue 01, 04/2005 Krautkramer USM 35X
Contents
3 Initial start-up ...................................... 3-1
3.1 Power supply ............................................. 3-2
Operation using the power supply unit ........ 3-2
Operation using batteries ............................ 3-3
Charging the batteries ................................. 3-5
3.2 Connecting a probe .................................. 3-7
3.3 Starting the USM 35X ................................ 3-8
Switching on ................................................ 3-8
Reset .......................................................... 3-8
Information lines in the startup screen ........ 3-8
4 Principles of operation ...................... 4-1
4.1 Operator’s controls ................................... 4-2
4.2 Screen display ........................................... 4-3
Functions on the display ............................. 4-4
Other displays ............................................. 4-5
4.3 Keys and rotary knobs .............................. 4-6
Function keys ............................................. 4-6
On/Off key .................................................. 4-6
Special keys ............................................... 4-7
Rotary knobs ............................................... 4-8
4.4 Operational concept .................................. 4-8
Setting the functions ................................... 4-9
4.5 Important basic settings ......................... 4-10
Selecting the language .............................. 4-10
Selecting units .......................................... 4-11
Setting the date ......................................... 4-12
Setting the time ......................................... 4-13
4.6 Basic settings of the display .................. 4-14
Selecting the color scheme ....................... 4-14
Setting the lighting .................................... 4-14
Krautkramer USM 35X Issue 01, 04/2005 0-3
Contents
5 Operation ............................................ 5-1
5.1 Overview of the functions ......................... 5-2
Function groups first operating level ........... 5-3
Function groups second operating level ...... 5-3
Function groups third operating level .......... 5-4
5.2 Setting the gain ......................................... 5-5
Defining the dB incrementation for gain ...... 5-5
5.3 Adjusting the display range
(function group BASE) .............................. 5-6
RANGE (Display range) .............................. 5-6
MTLVEL (Sound velocity) ........................... 5-7
D-DELAY (Display starting point) ................ 5-7
P-DELAY (Probe delay) ............................... 5-8
5.4 Adjusting the pulser
(function group PULS) .............................. 5-9
DAMPING (Probe matching) ....................... 5-9
POWER (Intensity) ................................... 5-10
DUAL (Pulser-receiver separation) ............ 5-10
PRF-MOD (Pulse repetition frequency) ..... 5-11
5.5 Adjusting the receiver
(function group RECV) ............................ 5-11
FINE G (Fine adjustment of gain) ............. 5-12
dBSTEP .................................................... 5-12
REJECT .................................................... 5-12
FREQU (Frequency range) ........................ 5-13
RECTIFY (Rectification) ............................ 5-13
5.6 Setting the gates
(function groups aGAT and bGAT) ......... 5-14
Tasks of the gates ..................................... 5-14
aLOGIC/bLOGIC (Evaluation logic of
the gates) .................................................. 5-15
aSTART/bSTART (Starting points of
the gates) .................................................. 5-16
aWIDTH/bWIDTH (Width of the gates) ...... 5-16
aTHRSH/bTHRSH (Response and
measurement threshold of the gates) ........ 5-16
Krautkramer USM 35X Issue 01, 04/2005 0-3
Contents
5 Operation ............................................ 5-1
5.1 Overview of the functions ......................... 5-2
Function groups first operating level ........... 5-3
Function groups second operating level ...... 5-3
Function groups third operating level .......... 5-4
5.2 Setting the gain ......................................... 5-5
Defining the dB incrementation for gain ...... 5-5
5.3 Adjusting the display range
(function group BASE) .............................. 5-6
RANGE (Display range) .............................. 5-6
MTLVEL (Sound velocity) ........................... 5-7
D-DELAY (Display starting point) ................ 5-7
P-DELAY (Probe delay) ............................... 5-8
5.4 Adjusting the pulser
(function group PULS) .............................. 5-9
DAMPING (Probe matching) ....................... 5-9
POWER (Intensity) ................................... 5-10
DUAL (Pulser-receiver separation) ............ 5-10
PRF-MOD (Pulse repetition frequency) ..... 5-11
5.5 Adjusting the receiver
(function group RECV) ............................ 5-11
FINE G (Fine adjustment of gain) ............. 5-12
dBSTEP .................................................... 5-12
REJECT .................................................... 5-12
FREQU (Frequency range) ........................ 5-13
RECTIFY (Rectification) ............................ 5-13
5.6 Setting the gates
(function groups aGAT and bGAT) ......... 5-14
Tasks of the gates ..................................... 5-14
aLOGIC/bLOGIC (Evaluation logic of
the gates) .................................................. 5-15
aSTART/bSTART (Starting points of
the gates) .................................................. 5-16
aWIDTH/bWIDTH (Width of the gates) ...... 5-16
aTHRSH/bTHRSH (Response and
measurement threshold of the gates) ........ 5-16
0-4 Issue 01, 04/2005 Krautkramer USM 35X
Contents
5.7 Calibrating the USM 35X ......................... 5-17
Calibrating the display range ..................... 5-17
Choosing the measuring point ................... 5-17
Calibration with straight- and
angle-beam probes .................................... 5-18
Calibration with dual-element (TR)
probes ....................................................... 5-21
5.8 Measuring ................................................ 5-23
General notes ............................................ 5-23
5.9 Measurement of dB difference
(function group REF) .............................. 5-25
Recording a reference echo ...................... 5-26
Deleting a reference echo ......................... 5-26
Echo comparison ...................................... 5-27
5.10 Classification of welds
(function group AWS) .............................. 5-28
Rating of welds according to AWS ............ 5-28
5.11 Calculation of flaw position
(function group TRIG) ............................. 5-31
ANGLE (Angle of incidence) ................... 5-32
X-VALUE (X-value of the probe) ................ 5-32
COLOR ..................................................... 5-33
THICKNE (Material thickness) .................. 5-33
DIAMET (Outside diameter of the test
object) ....................................................... 5-33
5.12 Data saving
(function group MEM) ............................. 5-34
Storing a data set ...................................... 5-35
Deleting a data set .................................... 5-35
Deleting all data set .................................. 5-36
Recalling a stored data set ....................... 5-36
5.13 Dataset management
(function group DATA) ............................. 5-38
TESTINF (Storing additional
information) ............................................... 5-39
PREVIEW (Dataset preview) .................... 5-41
DIR (Dataset directory) ............................. 5-42
SETTING (Function list)............................ 5-42
0-4 Issue 01, 04/2005 Krautkramer USM 35X
Contents
5.7 Calibrating the USM 35X ......................... 5-17
Calibrating the display range ..................... 5-17
Choosing the measuring point ................... 5-17
Calibration with straight- and
angle-beam probes .................................... 5-18
Calibration with dual-element (TR)
probes ....................................................... 5-21
5.8 Measuring ................................................ 5-23
General notes ............................................ 5-23
5.9 Measurement of dB difference
(function group REF) .............................. 5-25
Recording a reference echo ...................... 5-26
Deleting a reference echo ......................... 5-26
Echo comparison ...................................... 5-27
5.10 Classification of welds
(function group AWS) .............................. 5-28
Rating of welds according to AWS ............ 5-28
5.11 Calculation of flaw position
(function group TRIG) ............................. 5-31
ANGLE (Angle of incidence) ................... 5-32
X-VALUE (X-value of the probe) ................ 5-32
COLOR ..................................................... 5-33
THICKNE (Material thickness) .................. 5-33
DIAMET (Outside diameter of the test
object) ....................................................... 5-33
5.12 Data saving
(function group MEM) ............................. 5-34
Storing a data set ...................................... 5-35
Deleting a data set .................................... 5-35
Deleting all data set .................................. 5-36
Recalling a stored data set ....................... 5-36
5.13 Dataset management
(function group DATA) ............................. 5-38
TESTINF (Storing additional
information) ............................................... 5-39
PREVIEW (Dataset preview) .................... 5-41
DIR (Dataset directory) ............................. 5-42
SETTING (Function list)............................ 5-42
Krautkramer USM 35X Issue 01, 04/2005 0-5
Contents
5.14 Configuring the USM 35X for a test
application ............................................... 5-43
TOF (Selecting the measuring point) ......... 5-44
S-DISP (Zoomed display of reading) ......... 5-46
MAGNIFY (Gate spreading) ...................... 5-48
A-Scan (Setting the A-scan) ..................... 5-48
Configuring the measurement line ............. 5-49
Setting the display .................................... 5-50
FILLED (Echo display mode) .................... 5-51
VGA .......................................................... 5-51
SCHEME .................................................. 5-51
LIGHT (LCD backlight) .............................. 5-52
SCALE (Configuring the measurement
line) ........................................................... 5-52
5.15 General configuration ............................. 5-53
DIALOG (Selecting the language) ............. 5-53
UNIT (Selecting units of measurement) .... 5-54
BAUD-R (Baud rate for transmission) ........ 5-55
PRINTER (Printer for test report) .............. 5-55
COPYMOD (Assignment of the
key) ... 5-55
TIME/DATE (Setting the time and date) .... 5-56
ANAMOD .................................................. 5-57
HORN ........................................................ 5-58
EVAMOD (Echo evaluation) ...................... 5-58
5.16 Other functions with special keys .......... 5-59
Freeze ....................................................... 5-59
Zooming the echo display ......................... 5-59
The key ............................................... 5-59
5.17 Status symbols and LEDs ...................... 5-60
Status symbols ......................................... 5-60
LEDs ......................................................... 5-60
5.18 Distance-amplitude curve
(only USM 35X DAC and USM 35S) ........ 5-61
DACMOD (Activating DAC/TCG) ............... 5-62
DACECHO (Recording reference curve) .... 5-63
T-CORR (Sensitivity correction) ................ 5-64
OFFSET (Distance of multiple DAC) ......... 5-65
Echo evaluation with DAC ......................... 5-65
Krautkramer USM 35X Issue 01, 04/2005 0-5
Contents
5.14 Configuring the USM 35X for a test
application ............................................... 5-43
TOF (Selecting the measuring point) ......... 5-44
S-DISP (Zoomed display of reading) ......... 5-46
MAGNIFY (Gate spreading) ...................... 5-48
A-Scan (Setting the A-scan) ..................... 5-48
Configuring the measurement line ............. 5-49
Setting the display .................................... 5-50
FILLED (Echo display mode) .................... 5-51
VGA .......................................................... 5-51
SCHEME .................................................. 5-51
LIGHT (LCD backlight) .............................. 5-52
SCALE (Configuring the measurement
line) ........................................................... 5-52
5.15 General configuration ............................. 5-53
DIALOG (Selecting the language) ............. 5-53
UNIT (Selecting units of measurement) .... 5-54
BAUD-R (Baud rate for transmission) ........ 5-55
PRINTER (Printer for test report) .............. 5-55
COPYMOD (Assignment of the
key) ... 5-55
TIME/DATE (Setting the time and date) .... 5-56
ANAMOD .................................................. 5-57
HORN ........................................................ 5-58
EVAMOD (Echo evaluation) ...................... 5-58
5.16 Other functions with special keys .......... 5-59
Freeze ....................................................... 5-59
Zooming the echo display ......................... 5-59
The key ............................................... 5-59
5.17 Status symbols and LEDs ...................... 5-60
Status symbols ......................................... 5-60
LEDs ......................................................... 5-60
5.18 Distance-amplitude curve
(only USM 35X DAC and USM 35S) ........ 5-61
DACMOD (Activating DAC/TCG) ............... 5-62
DACECHO (Recording reference curve) .... 5-63
T-CORR (Sensitivity correction) ................ 5-64
OFFSET (Distance of multiple DAC) ......... 5-65
Echo evaluation with DAC ......................... 5-65
0-6 Issue 01, 04/2005 Krautkramer USM 35X
Contents
5.19 Distance-amplitude curve according
to JIS Z3060-2002 (only USM 35X DAC
and USM 35S) .......................................... 5-66
DACMOD (Activating DAC according
to JIS) ....................................................... 5-67
DACECHO (Recording reference curve) .... 5-68
BOLDLI (Choice of a registration curve).... 5-70
T-CORR (Sensitivity correction) ................ 5-70
OFFSET (Distance of multiple DAC) ......... 5-70
Echo evaluation with DAC ......................... 5-71
5.20 Evaluation according to the DGS
method (only USM 35X S) ...................... 5-71
Measuring with DGS ................................. 5-71
Selecting the DGS mode .......................... 5-73
Default settings for the DGS
measurement ............................................ 5-73
Recording the reference echo and
displaying the DGS curve ......................... 5-75
Evaluation of reflectors ............................. 5-76
Transfer correction ..................................... 5-78
Sound attenuation ..................................... 5-78
Locks, error messages ............................. 5-81
Validity of the DGS method ....................... 5-81
6 Documentation .................................. 6-1
6.1 Printing data .............................................. 6-2
Preparing the printer .................................... 6-2
Preparing the USM 35X .............................. 6-2
Printing ........................................................ 6-3
6.2 Documentation with UltraDOC ................. 6-4
7 Maintenance and care ....................... 7-1
7.1 Care of the instrument .............................. 7-2
7.2 Care of the batteries .................................. 7-3
Care of the batteries.................................... 7-3
Charging the batteries ................................. 7-3
How to handle alkaline batteries.................. 7-4
7.3 Maintenance .............................................. 7-5
0-6 Issue 01, 04/2005 Krautkramer USM 35X
Contents
5.19 Distance-amplitude curve according
to JIS Z3060-2002 (only USM 35X DAC
and USM 35S) .......................................... 5-66
DACMOD (Activating DAC according
to JIS) ....................................................... 5-67
DACECHO (Recording reference curve) .... 5-68
BOLDLI (Choice of a registration curve).... 5-70
T-CORR (Sensitivity correction) ................ 5-70
OFFSET (Distance of multiple DAC) ......... 5-70
Echo evaluation with DAC ......................... 5-71
5.20 Evaluation according to the DGS
method (only USM 35X S) ...................... 5-71
Measuring with DGS ................................. 5-71
Selecting the DGS mode .......................... 5-73
Default settings for the DGS
measurement ............................................ 5-73
Recording the reference echo and
displaying the DGS curve ......................... 5-75
Evaluation of reflectors ............................. 5-76
Transfer correction ..................................... 5-78
Sound attenuation ..................................... 5-78
Locks, error messages ............................. 5-81
Validity of the DGS method ....................... 5-81
6 Documentation .................................. 6-1
6.1 Printing data .............................................. 6-2
Preparing the printer .................................... 6-2
Preparing the USM 35X .............................. 6-2
Printing ........................................................ 6-3
6.2 Documentation with UltraDOC ................. 6-4
7 Maintenance and care ....................... 7-1
7.1 Care of the instrument .............................. 7-2
7.2 Care of the batteries .................................. 7-3
Care of the batteries.................................... 7-3
Charging the batteries ................................. 7-3
How to handle alkaline batteries.................. 7-4
7.3 Maintenance .............................................. 7-5
Krautkramer USM 35X Issue 01, 04/2005 0-7
Contents
7.4 Recycling ................................................... 7-6
General view of the device .......................... 7-6
Materials for separate disposal ................... 7-8
Further materials and components ........... 7-10
Recycling data of master device ............... 7-12
8 Interfaces and peripherals ................ 8-1
8.1 Interfaces ................................................... 8-2
8.2 I/O interface ............................................... 8-4
Contact assignment of the
LEMO-1-B socket ....................................... 8-5
8.3 RS 232 interface ........................................ 8-6
Contact assignment of the Sub-D socket ... 8-6
8.4 RGB interface ............................................. 8-7
8.5 Data exchange ........................................... 8-8
Connecting a printer or a PC ....................... 8-8
Activation of serial communication ............. 8-8
Printing data ................................................ 8-9
Technical Specifications
according to EN 12668-1
8.6 Remote control .......................................... 8-9
Syntax and timing ..................................... 8-11
Functions and remote control codes ......... 8-17
Other remote control codes ....................... 8-24
Control codes for the rotary knobs/
function keys ............................................ 8-26
9 Appendix ............................................ 9-1
9.1 Function directory ..................................... 9-2
9.2 EC declaration of conformity ................... 9-7
9.3 Manufacturer/Service addresses .............. 9-8
9.4 Spare parts list ........................................ 9-10
10 Changes ........................................... 10-1
11 Index ................................................. 11-1
Krautkramer USM 35X Issue 01, 04/2005 0-7
Contents
7.4 Recycling ................................................... 7-6
General view of the device .......................... 7-6
Materials for separate disposal ................... 7-8
Further materials and components ........... 7-10
Recycling data of master device ............... 7-12
8 Interfaces and peripherals ................ 8-1
8.1 Interfaces ................................................... 8-2
8.2 I/O interface ............................................... 8-4
Contact assignment of the
LEMO-1-B socket ....................................... 8-5
8.3 RS 232 interface ........................................ 8-6
Contact assignment of the Sub-D socket ... 8-6
8.4 RGB interface ............................................. 8-7
8.5 Data exchange ........................................... 8-8
Connecting a printer or a PC ....................... 8-8
Activation of serial communication ............. 8-8
Printing data ................................................ 8-9
Technical Specifications
according to EN 12668-1
8.6 Remote control .......................................... 8-9
Syntax and timing ..................................... 8-11
Functions and remote control codes ......... 8-17
Other remote control codes ....................... 8-24
Control codes for the rotary knobs/
function keys ............................................ 8-26
9 Appendix ............................................ 9-1
9.1 Function directory ..................................... 9-2
9.2 EC declaration of conformity ................... 9-7
9.3 Manufacturer/Service addresses .............. 9-8
9.4 Spare parts list ........................................ 9-10
10 Changes ........................................... 10-1
11 Index ................................................. 11-1
0-8 Issue 01, 04/2005 Krautkramer USM 35X
0-8 Issue 01, 04/2005 Krautkramer USM 35X
Krautkramer USM 35X Issue 01, 04/2005 1-1
Introduction 1
Krautkramer USM 35X Issue 01, 04/2005 1-1
Introduction 1
1-2 Issue 01, 04/2005 Krautkramer USM 35X
Introduction Safety information
1.1 Safety information
The USM 35X has been designed and tested according
to DIN EN 61 010 Part 1, 2002, Safety requirements for
electrical measuring, control and lab equipment, and
was technically in perfectly safe and faultless condition
when leaving the manufacturing works.
In order to maintain this condition and to ensure a safe
operation, you should urgently read the following safety
information before putting the instrument into operation.
A Attention:
The USM 35X is an instrument for materials testing.
Any use for medical applications or other purposes
is not allowed!
The USM 35X may only be used in industrial envi-
ronments!
The USM 35X is waterproof according to IP 66. The
USM 35X can be operated with batteries or a power
supply unit.
The power supply unit has the electrical safety class II.
Batteries
For the battery operation of the USM 35X, we recom-
mend the use of a lithium-ion battery. The operation
using alkaline batteries, NiMH or NiCad cells is likewise
possible. You should only use the products recom-
mended by us for the battery operation.
You can charge the lithium-ion battery within the instru-
ment itself or in an external battery charger. If you want
to use NiMH or NiCad cells, you have to charge them in
an external battery charger.
As soon as you connect the power supply unit to the
USM 35X, the battery power supply is interrupted. If a
lithium-ion battery is inserted, the charging process
starts automatically when you connect the instrument
to the mains supply. Please refer to chapter 3.1 on
power supply, and to chapter 7 on how to handle
batteries.
Software
According to the current state of the art, software is
never completely free from errors. Before using any
software-controlled test equipment, please make sure
1-2 Issue 01, 04/2005 Krautkramer USM 35X
Introduction Safety information
1.1 Safety information
The USM 35X has been designed and tested according
to DIN EN 61 010 Part 1, 2002, Safety requirements for
electrical measuring, control and lab equipment, and
was technically in perfectly safe and faultless condition
when leaving the manufacturing works.
In order to maintain this condition and to ensure a safe
operation, you should urgently read the following safety
information before putting the instrument into operation.
A Attention:
The USM 35X is an instrument for materials testing.
Any use for medical applications or other purposes
is not allowed!
The USM 35X may only be used in industrial envi-
ronments!
The USM 35X is waterproof according to IP 66. The
USM 35X can be operated with batteries or a power
supply unit.
The power supply unit has the electrical safety class II.
Batteries
For the battery operation of the USM 35X, we recom-
mend the use of a lithium-ion battery. The operation
using alkaline batteries, NiMH or NiCad cells is likewise
possible. You should only use the products recom-
mended by us for the battery operation.
You can charge the lithium-ion battery within the instru-
ment itself or in an external battery charger. If you want
to use NiMH or NiCad cells, you have to charge them in
an external battery charger.
As soon as you connect the power supply unit to the
USM 35X, the battery power supply is interrupted. If a
lithium-ion battery is inserted, the charging process
starts automatically when you connect the instrument
to the mains supply. Please refer to chapter 3.1 on
power supply, and to chapter 7 on how to handle
batteries.
Software
According to the current state of the art, software is
never completely free from errors. Before using any
software-controlled test equipment, please make sure
Krautkramer USM 35X Issue 01, 04/2005 1-3
IntroductionSafety information
that the required functions operate perfectly in the in-
tended combination.
If you have any questions about the use of your test
equipment, please contact your nearest representative
of GE Inspection Technologies.
Defects/errors and exceptional stresses
If you have reason to believe that a safe operation of
your USM 35X is no longer possible, you have to dis-
connect the instrument and secure it against uninten-
tional reconnection. Remove the batteries if necessary.
A safe operation is e.g. no longer possible
• if the instrument shows visible damages,
• if the instrument no longer operates perfectly,
• after prolonged storage under adverse conditions
(e.g. exceptional temperatures and/or especially high
air humidity, or corrosive environmental conditions),
• after being subjected to heavy stresses during trans-
portation.
1.2 Important information on
ultrasonic testing
Please read the following information before using your
USM 35X. It is important that you understand and ob-
serve this information to avoid any operator errors that
might lead to false test results. This could result in per-
sonal injuries or damages to property.
Preconditions for testing with ultrasonic
test equipment
This operating manual contains essential information on
how to operate your test equipment. In addition, there
are a number of factors which affect the test results. A
description of these factors would go beyond the scope
of an operating manual. The following list therefore only
mentions the three most important conditions for a safe
and reliable ultrasonic inspection:
• the operator training
• the knowledge of special technical test requirements
and limits
• the choice of appropriate test equipment.
Krautkramer USM 35X Issue 01, 04/2005 1-3
IntroductionSafety information
that the required functions operate perfectly in the in-
tended combination.
If you have any questions about the use of your test
equipment, please contact your nearest representative
of GE Inspection Technologies.
Defects/errors and exceptional stresses
If you have reason to believe that a safe operation of
your USM 35X is no longer possible, you have to dis-
connect the instrument and secure it against uninten-
tional reconnection. Remove the batteries if necessary.
A safe operation is e.g. no longer possible
• if the instrument shows visible damages,
• if the instrument no longer operates perfectly,
• after prolonged storage under adverse conditions
(e.g. exceptional temperatures and/or especially high
air humidity, or corrosive environmental conditions),
• after being subjected to heavy stresses during trans-
portation.
1.2 Important information on
ultrasonic testing
Please read the following information before using your
USM 35X. It is important that you understand and ob-
serve this information to avoid any operator errors that
might lead to false test results. This could result in per-
sonal injuries or damages to property.
Preconditions for testing with ultrasonic
test equipment
This operating manual contains essential information on
how to operate your test equipment. In addition, there
are a number of factors which affect the test results. A
description of these factors would go beyond the scope
of an operating manual. The following list therefore only
mentions the three most important conditions for a safe
and reliable ultrasonic inspection:
• the operator training
• the knowledge of special technical test requirements
and limits
• the choice of appropriate test equipment.
1-4 Issue 01, 04/2005 Krautkramer USM 35X
Introduction Important information on ultrasonic testing
Operator training
The operation of an ultrasonic test device requires a
proper training in ultrasonic test methods.
A proper training comprises for example adequate
knowledge of:
• the theory of sound propagation
• the effects of sound velocity in the test material
• the behavior of the sound wave at interfaces be-
tween different materials
• the propagation of the sound beam
• the influence of sound attenuation in the test object
and the influence of surface quality of the test ob-
ject.
Lack of such knowledge could lead to false test results
with unforeseeable consequences. You can contact for
example NDT societies or organizations in your country
(DGZfP in Germany; ASNT in the USA), or also GE
Inspection Technologies, for information concerning
existing possibilities for the training of ultrasonic in-
spectors as well as on the qualifications and certifi-
cates that can finally be obtained.
Technical test requirements
Every ultrasonic test is subject to specific technical
test requirements. The most important ones are:
• the definition of the scope of inspection
• the choice of the appropriate test method
• the consideration of material properties
• the determination of limits for recording and
evaluation.
It is the task of those with overall responsibility for test-
ing to ensure that the inspector is fully informed about
these requirements. The best basis for such information
is experience with identical test objects. It is also es-
sential that the relevant test specifications be clearly
and completely understood by the inspector.
GE Inspection Technologies regularly holds specialized
training courses in the field of ultrasonic testing. The
scheduled dates for these courses will be given to you
on request.
1-4 Issue 01, 04/2005 Krautkramer USM 35X
Introduction Important information on ultrasonic testing
Operator training
The operation of an ultrasonic test device requires a
proper training in ultrasonic test methods.
A proper training comprises for example adequate
knowledge of:
• the theory of sound propagation
• the effects of sound velocity in the test material
• the behavior of the sound wave at interfaces be-
tween different materials
• the propagation of the sound beam
• the influence of sound attenuation in the test object
and the influence of surface quality of the test ob-
ject.
Lack of such knowledge could lead to false test results
with unforeseeable consequences. You can contact for
example NDT societies or organizations in your country
(DGZfP in Germany; ASNT in the USA), or also GE
Inspection Technologies, for information concerning
existing possibilities for the training of ultrasonic in-
spectors as well as on the qualifications and certifi-
cates that can finally be obtained.
Technical test requirements
Every ultrasonic test is subject to specific technical
test requirements. The most important ones are:
• the definition of the scope of inspection
• the choice of the appropriate test method
• the consideration of material properties
• the determination of limits for recording and
evaluation.
It is the task of those with overall responsibility for test-
ing to ensure that the inspector is fully informed about
these requirements. The best basis for such information
is experience with identical test objects. It is also es-
sential that the relevant test specifications be clearly
and completely understood by the inspector.
GE Inspection Technologies regularly holds specialized
training courses in the field of ultrasonic testing. The
scheduled dates for these courses will be given to you
on request.
Krautkramer USM 35X Issue 01, 04/2005 1-5
IntroductionImportant information on ultrasonic testing
Limits of testing
The information obtained from ultrasonic tests only
refers to those parts of the test object which are
covered by the sound beam of the probe used.
Any conclusions from the tested parts to be applied to
the untested parts of the test object should be made
with extreme caution.
Such conclusions are generally only possible in cases
where extensive experience and proven methods of
statistical data acquisition are available.
The sound beam can be completely reflected from
boundary surfaces within the test object so that flaws
and reflection points lying deeper remain undetected. It
is therefore important to make sure that all areas to be
tested in the test object are covered by the sound beam.
Ultrasonic wall thickness measurement
All ultrasonic wall thickness measurements are based
on a time-of-flight measurement. Accurate measure-
ment results require a constant sound velocity in the
test object. In test objects made of steel, even with
varying alloying constituents, this condition is mostly
fulfilled. The variation in sound velocity is so slight that
it is only of importance for high-precision measure-
ments. In other materials, e.g. nonferrous metals or
plastics, the sound velocity variations may be even
larger and thus affect the measuring accuracy.
Effect of the test object’s material
If the test object’s material is not homogeneous, the
sound may propagate at different sound velocities in
different parts of the test objects. An average sound
velocity should then be taken into account for the range
calibration. This is achieved by means of a reference
block whose sound velocity corresponds to the average
sound velocity of the test object.
If substantial sound velocity variations are to be ex-
pected, then the instrument calibration should be read-
justed to the actual sound velocity values at shorter
time intervals. Failure to do so may lead to false thick-
ness readings.
Krautkramer USM 35X Issue 01, 04/2005 1-5
IntroductionImportant information on ultrasonic testing
Limits of testing
The information obtained from ultrasonic tests only
refers to those parts of the test object which are
covered by the sound beam of the probe used.
Any conclusions from the tested parts to be applied to
the untested parts of the test object should be made
with extreme caution.
Such conclusions are generally only possible in cases
where extensive experience and proven methods of
statistical data acquisition are available.
The sound beam can be completely reflected from
boundary surfaces within the test object so that flaws
and reflection points lying deeper remain undetected. It
is therefore important to make sure that all areas to be
tested in the test object are covered by the sound beam.
Ultrasonic wall thickness measurement
All ultrasonic wall thickness measurements are based
on a time-of-flight measurement. Accurate measure-
ment results require a constant sound velocity in the
test object. In test objects made of steel, even with
varying alloying constituents, this condition is mostly
fulfilled. The variation in sound velocity is so slight that
it is only of importance for high-precision measure-
ments. In other materials, e.g. nonferrous metals or
plastics, the sound velocity variations may be even
larger and thus affect the measuring accuracy.
Effect of the test object’s material
If the test object’s material is not homogeneous, the
sound may propagate at different sound velocities in
different parts of the test objects. An average sound
velocity should then be taken into account for the range
calibration. This is achieved by means of a reference
block whose sound velocity corresponds to the average
sound velocity of the test object.
If substantial sound velocity variations are to be ex-
pected, then the instrument calibration should be read-
justed to the actual sound velocity values at shorter
time intervals. Failure to do so may lead to false thick-
ness readings.
1-6 Issue 01, 04/2005 Krautkramer USM 35X
Introduction Important information on ultrasonic testing
Effect of temperature variations
The sound velocity within the test object also varies as
a function of the material’s temperature. This can cause
appreciable errors in measurements if the instrument
has been calibrated on a cold reference block and is
then used on a warm or hot test object. Such measure-
ment errors can be avoided either by warming the refer-
ence block to the same temperature before calibrating,
or by using a correction factor obtained from tables.
Measurement of remaining wall thickness
The measurement of the remaining wall thickness on
plant components, e.g. pipes, tanks and reaction ves-
sels of all types which are corroded or eroded from the
inside, requires a perfectly suitable gauge and special
care in handling the probe.
The inspectors should always be informed about the
corresponding nominal wall thicknesses and the likely
amount of wall thickness losses.
Ultrasonic evaluation of flaws
In present-day test practice, there are basically two
different methods of flaw evaluation:
If the diameter of the sound beam is smaller than the
extent of the flaw, then the beam can be used to ex-
plore the boundaries of the flaw and thus determine its
area.
If, however, the diameter of the sound beam is larger
than the size of the flaw, the maximum echo response
from the flaw must be compared with the maximum
echo response from an artificial flaw provided for com-
parison purposes.
Flaw boundary method
The smaller the diameter of the probe’s sound beam,
the more accurately the boundaries (and therefore the
flaw area) can be determined by the flaw boundary
method. If, however, the sound beam is relatively
broad, the flaw area determined can substantially differ
from the actual flaw area. Care should therefore be
taken to select a probe which will give a sufficiently
narrow beam at the position of the flaw.
1-6 Issue 01, 04/2005 Krautkramer USM 35X
Introduction Important information on ultrasonic testing
Effect of temperature variations
The sound velocity within the test object also varies as
a function of the material’s temperature. This can cause
appreciable errors in measurements if the instrument
has been calibrated on a cold reference block and is
then used on a warm or hot test object. Such measure-
ment errors can be avoided either by warming the refer-
ence block to the same temperature before calibrating,
or by using a correction factor obtained from tables.
Measurement of remaining wall thickness
The measurement of the remaining wall thickness on
plant components, e.g. pipes, tanks and reaction ves-
sels of all types which are corroded or eroded from the
inside, requires a perfectly suitable gauge and special
care in handling the probe.
The inspectors should always be informed about the
corresponding nominal wall thicknesses and the likely
amount of wall thickness losses.
Ultrasonic evaluation of flaws
In present-day test practice, there are basically two
different methods of flaw evaluation:
If the diameter of the sound beam is smaller than the
extent of the flaw, then the beam can be used to ex-
plore the boundaries of the flaw and thus determine its
area.
If, however, the diameter of the sound beam is larger
than the size of the flaw, the maximum echo response
from the flaw must be compared with the maximum
echo response from an artificial flaw provided for com-
parison purposes.
Flaw boundary method
The smaller the diameter of the probe’s sound beam,
the more accurately the boundaries (and therefore the
flaw area) can be determined by the flaw boundary
method. If, however, the sound beam is relatively
broad, the flaw area determined can substantially differ
from the actual flaw area. Care should therefore be
taken to select a probe which will give a sufficiently
narrow beam at the position of the flaw.
Krautkramer USM 35X Issue 01, 04/2005 1-7
IntroductionImportant information on ultrasonic testing
Echo display comparison method
The echo from a small, natural flaw is usually smaller
than the echo from an artificial comparison flaw, e.g.
circular disc flaw of the same size. This is due, for in-
stance, to the roughness of the surface of a natural
flaw, or to the fact that the beam does not impinge on it
at right angles.
If this fact is not taken into account when evaluating
natural flaws, there is a danger of underestimating their
magnitude.
In the case of very jagged or fissured flaws, e.g. shrink
holes in castings, it may be that the sound scattering
occurring at the boundary surface of the flaw is so
strong that no echo at all is produced. In such cases, a
different evaluation method should be chosen, e.g. use
of the backwall echo attenuation in the evaluation.
The distance sensitivity of the flaw echo plays an im-
portant part when testing large components. Attention
should be paid here to choosing artificial comparison
flaws which are as far as possible governed by the
same ”distance laws” as the natural flaws to be evalu-
ated.
The ultrasonic wave is attenuated in any material. This
sound attenuation is very low, e.g. in parts made of
fine-grained steel, likewise in many small parts made of
other materials. However, if the sound wave travels
larger distances through the material, a high cumulative
sound attenuation can result even with small attenua-
tion coefficients. There is then a danger that echoes
from natural flaws appear too small. For this reason, an
estimate must always be made of the effects of attenu-
ation on the evaluation result and taken into account if
applicable.
If the test object has a rough surface, part of the inci-
dent sound energy will be scattered at its surface and
is not available for the test. The larger this initial scat-
tering, the smaller the flaw echoes appear, and the
more errors occur in the evaluation result.
It is therefore important to take the effect of the test
object’s surfaces on the height of the echo into account
(transfer correction).
Krautkramer USM 35X Issue 01, 04/2005 1-7
IntroductionImportant information on ultrasonic testing
Echo display comparison method
The echo from a small, natural flaw is usually smaller
than the echo from an artificial comparison flaw, e.g.
circular disc flaw of the same size. This is due, for in-
stance, to the roughness of the surface of a natural
flaw, or to the fact that the beam does not impinge on it
at right angles.
If this fact is not taken into account when evaluating
natural flaws, there is a danger of underestimating their
magnitude.
In the case of very jagged or fissured flaws, e.g. shrink
holes in castings, it may be that the sound scattering
occurring at the boundary surface of the flaw is so
strong that no echo at all is produced. In such cases, a
different evaluation method should be chosen, e.g. use
of the backwall echo attenuation in the evaluation.
The distance sensitivity of the flaw echo plays an im-
portant part when testing large components. Attention
should be paid here to choosing artificial comparison
flaws which are as far as possible governed by the
same ”distance laws” as the natural flaws to be evalu-
ated.
The ultrasonic wave is attenuated in any material. This
sound attenuation is very low, e.g. in parts made of
fine-grained steel, likewise in many small parts made of
other materials. However, if the sound wave travels
larger distances through the material, a high cumulative
sound attenuation can result even with small attenua-
tion coefficients. There is then a danger that echoes
from natural flaws appear too small. For this reason, an
estimate must always be made of the effects of attenu-
ation on the evaluation result and taken into account if
applicable.
If the test object has a rough surface, part of the inci-
dent sound energy will be scattered at its surface and
is not available for the test. The larger this initial scat-
tering, the smaller the flaw echoes appear, and the
more errors occur in the evaluation result.
It is therefore important to take the effect of the test
object’s surfaces on the height of the echo into account
(transfer correction).
1-8 Issue 01, 04/2005 Krautkramer USM 35X
Introduction The USM 35X family
1.3 The USM 35X family
The USM 35X is a lightweight and compact ultrasonic
flaw detector especially suitable for
• locating and evaluating material defects,
• measuring wall thicknesses,
• saving and documenting test results.
With its frequency range from 0.5 to 20 MHz and a
maximum calibration range of 10 m (steel), the USM 35X
is designed for use on large workpieces and in high-
resolution measurements.
The different instrument versions
The USM 35X is available in several versions which are
desgined for different applications:
• USM 35X
Standard version for universal ultrasonic test applica-
tions.
• USM 35X DAC
The multiple DAC curves and time-corrected gain
enable a field-oriented echo amplitude evaluation
according to almost all international test specifica-
tions.
• USM 35X S
DGS evaluation mode in addition to multiple DAC
curves and TCG.
DGS curves are stored for all narrow-band single-
element probes; amplitude evaluation is carried out
either in dB above DAC curve or equivalent reflector
size (ERS).
• Data Logger option
This option is available for all USM 35X versions and
is used for the recording and documentation of thick-
ness readings.
1-8 Issue 01, 04/2005 Krautkramer USM 35X
Introduction The USM 35X family
1.3 The USM 35X family
The USM 35X is a lightweight and compact ultrasonic
flaw detector especially suitable for
• locating and evaluating material defects,
• measuring wall thicknesses,
• saving and documenting test results.
With its frequency range from 0.5 to 20 MHz and a
maximum calibration range of 10 m (steel), the USM 35X
is designed for use on large workpieces and in high-
resolution measurements.
The different instrument versions
The USM 35X is available in several versions which are
desgined for different applications:
• USM 35X
Standard version for universal ultrasonic test applica-
tions.
• USM 35X DAC
The multiple DAC curves and time-corrected gain
enable a field-oriented echo amplitude evaluation
according to almost all international test specifica-
tions.
• USM 35X S
DGS evaluation mode in addition to multiple DAC
curves and TCG.
DGS curves are stored for all narrow-band single-
element probes; amplitude evaluation is carried out
either in dB above DAC curve or equivalent reflector
size (ERS).
• Data Logger option
This option is available for all USM 35X versions and
is used for the recording and documentation of thick-
ness readings.
Krautkramer USM 35X Issue 01, 04/2005 1-9
IntroductionThe USM 35X family
Special features
• low weight (2.2 kg including lithium-ion battery) and
compact size
• waterproof instrument case with protection class
IP 66
• long operating time (> 12 hours) by means of lithium-
ion battery with internal and external charging possi-
bility
• handy – equipped with a non-slip, ratcheting prop-up
stand, also used as handle
• rotary knobs for direct adjustment of gain as well as
for changing the currently selected function
• two independant gates for accurate wall thickness
measurements from the workpiece surface up to the
first echo, or between two backwall echoes, including
measurement on coated workpieces with a resolution
of 0.01 mm (up to 100 mm), referred to steel
• magnify gate: spreading of the gate range over the
entire screen width
• 5.7", 1/4 VGA-TFT color display to display the digi-
tized signals (320 × 240 pixels, 115 × 86 mm )
• VGA interface for the connection of an external
monitor
• color display of gates for an easier distinction
• easily recognizable reflection geometry when using
angle-beam probes by the variation of A-scan or
background color at every deflection point
• data memory: 800 data sets, including alphanumeric
description, documentation possibility via a printer
• increased calibration range: up to 9999 mm (steel),
depending on the frequency range
• semiautomatic two point calibration
• pulse repetition frequency variable in ten steps
to avoid phantom echoes when testing large
workpieces
• choice of frequency range for the connected probe
• signal display mode: full-wave rectification, positive
half-wave or negative halv-wave and radio frequency
• display of 4 readings plus 1 reading zoomed in the
A-scan, user-configurable
Krautkramer USM 35X Issue 01, 04/2005 1-9
IntroductionThe USM 35X family
Special features
• low weight (2.2 kg including lithium-ion battery) and
compact size
• waterproof instrument case with protection class
IP 66
• long operating time (> 12 hours) by means of lithium-
ion battery with internal and external charging possi-
bility
• handy – equipped with a non-slip, ratcheting prop-up
stand, also used as handle
• rotary knobs for direct adjustment of gain as well as
for changing the currently selected function
• two independant gates for accurate wall thickness
measurements from the workpiece surface up to the
first echo, or between two backwall echoes, including
measurement on coated workpieces with a resolution
of 0.01 mm (up to 100 mm), referred to steel
• magnify gate: spreading of the gate range over the
entire screen width
• 5.7", 1/4 VGA-TFT color display to display the digi-
tized signals (320 × 240 pixels, 115 × 86 mm )
• VGA interface for the connection of an external
monitor
• color display of gates for an easier distinction
• easily recognizable reflection geometry when using
angle-beam probes by the variation of A-scan or
background color at every deflection point
• data memory: 800 data sets, including alphanumeric
description, documentation possibility via a printer
• increased calibration range: up to 9999 mm (steel),
depending on the frequency range
• semiautomatic two point calibration
• pulse repetition frequency variable in ten steps
to avoid phantom echoes when testing large
workpieces
• choice of frequency range for the connected probe
• signal display mode: full-wave rectification, positive
half-wave or negative halv-wave and radio frequency
• display of 4 readings plus 1 reading zoomed in the
A-scan, user-configurable
1-10 Issue 01, 04/2005 Krautkramer USM 35X
Introduction How to use this manual
1.4 How to use this manual
The present operating manual applies to all instrument
versions of the USM 35X. Differences in the functions
or setting values are always marked.
Before operating the USM 35X for the first time, it is
absolutely necessary that you read the chapters 1, 3
and 4 of this manual. They will inform you about the
necessary preparations of the instrument, give you a
description of all keys and screen displays, and explain
the operating principle.
In doing this, you will avoid any errors or failures of the
instrument and be able to use the full range of instru-
ment functions.
You will find the latest changes to this operating manual
in chapter 10
Changes
. It describes corrections that
have become necessary at short notice and have not
yet been included in the general manual. If no correc-
tions have become necessary, this chapter is empty.
The specifications/Technical Specifications according
to EN 12668-1 for the USM 35X family can be found in
the attachment at the end of this operating manual.
The Data Logger option, which can be applied to all
USM 35X versions, is described in a chapter of its own
– at the end of the operating manual. All functions refer-
ring to the Data Logger and the tolerance monitor are
described here. At the same time, the standard operat-
ing manual applies to all other functions.
1-10 Issue 01, 04/2005 Krautkramer USM 35X
Introduction How to use this manual
1.4 How to use this manual
The present operating manual applies to all instrument
versions of the USM 35X. Differences in the functions
or setting values are always marked.
Before operating the USM 35X for the first time, it is
absolutely necessary that you read the chapters 1, 3
and 4 of this manual. They will inform you about the
necessary preparations of the instrument, give you a
description of all keys and screen displays, and explain
the operating principle.
In doing this, you will avoid any errors or failures of the
instrument and be able to use the full range of instru-
ment functions.
You will find the latest changes to this operating manual
in chapter 10
Changes
. It describes corrections that
have become necessary at short notice and have not
yet been included in the general manual. If no correc-
tions have become necessary, this chapter is empty.
The specifications/Technical Specifications according
to EN 12668-1 for the USM 35X family can be found in
the attachment at the end of this operating manual.
The Data Logger option, which can be applied to all
USM 35X versions, is described in a chapter of its own
– at the end of the operating manual. All functions refer-
ring to the Data Logger and the tolerance monitor are
described here. At the same time, the standard operat-
ing manual applies to all other functions.
Krautkramer USM 35X Issue 01, 04/2005 1-11
IntroductionLayout and presentation in this manual
1.5 Layout and presentation in
this manual
To make it easier for you to use this manual, all operat-
ing steps, notes, etc., are always presented in the
same way. This will help you find individual pieces of
information quickly.
Attention and Note symbols
A Attention:
The Attention symbol indicates peculiarities and spe-
cial aspects in the operation which could affect the
accuracy of the results.
H Note:
Note contains e.g. references to other chapters or spe-
cial recommendations for a function.
Listings
Listings are presented in the following form:
• Variant A
• Variant B
• ...
Operating steps
Operating steps appear as shown in the following ex-
ample:
– Loosen the two screws at the bottom.
– Remove the cover.
– ...
Krautkramer USM 35X Issue 01, 04/2005 1-11
IntroductionLayout and presentation in this manual
1.5 Layout and presentation in
this manual
To make it easier for you to use this manual, all operat-
ing steps, notes, etc., are always presented in the
same way. This will help you find individual pieces of
information quickly.
Attention and Note symbols
A Attention:
The Attention symbol indicates peculiarities and spe-
cial aspects in the operation which could affect the
accuracy of the results.
H Note:
Note contains e.g. references to other chapters or spe-
cial recommendations for a function.
Listings
Listings are presented in the following form:
• Variant A
• Variant B
• ...
Operating steps
Operating steps appear as shown in the following ex-
ample:
– Loosen the two screws at the bottom.
– Remove the cover.
– ...
1-12 Issue 01, 04/2005 Krautkramer USM 35X
1-12 Issue 01, 04/2005 Krautkramer USM 35X
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GE Krautkramer USM 35X User manual

GE
Brand
GE
Model
Krautkramer USM 35X
Category
Measuring, testing & control
Type
User manual
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