DIO 1000 v1.1 - EN Op Manual [PDF]

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DIO 1000 Ultrasonic Flaw Detector

Operation Manual

Version 1.1 – June 2009

Version 1.1 – June 2009

Dio 1000 – Operation Manual

© STARMANS electronics, Ltd. 2009 All Rights Reserved This manual may not be copied in whole or in any portion by any means without the express written consent of STARMANS electronics, Ltd. The material in this manual is for informational purposes and is subject to change without notice. In no event will STARMANS electronics, Ltd. be liable for direct, indirect, special, incidental or consequential damages resulting from any defect in this documentation, even if advised of the possibility of such damages. Drawings and pictures in this manual contain confidential information and are supplied by STARMANS electronics, Ltd., the owner of such information. In accepting a drawing, the user agrees that it is for the user’s sole use. It will not be reproduced or distributed to others and that the drawings or the information contained herein will not be used in any manner detrimental to STARMANS electronics, Ltd.

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STATEMENT OF INSPECTION AND WARRANTY This statement covers new instruments, electro/mechanical devices, probes, transducers and supplies manufactured and sold by STARMANS electronics, Ltd. (hereinafter referred to as STARMANS) to an end user in consideration of the purchase price paid.

INSPECTION Upon receipt of the instrument, it should be examined immediately for any evidence of hidden or external damage. Damage should be promptly reported to the carrier making delivery, as the carrier is normally liable for such damage. All documentation, waybills and packing materials should be retained in order to establish claims. Please, advise STARMANS at the nearest Service Center after notifying the carrier of shipping damage so that we may assist in damage claims and supply replacement equipment, if necessary.

LIMITED WARRANTY STARMANS warrants its instruments to be free from defects in materials and workmanship for a period of 12 months from the date of shipment, under conditions of normal use and service. Batteries and other expendable items are excluded from this warranty. Specifically excluded from this warranty is equipment that becomes defective due to: a) normal wear, b) damage resulting from accident, misuse, abuse or negligence, and c) attempts to modify, repair or perform internal adjustments by parties other than authorizerd STARMANS service personnel. STARMANS reserves the right to charge on a time and material basis for repairs that are necessitated by a, b and c above. Seals may be applied in critical locations on the equipment to protect the integrity of factory calibration and QA acceptance. The “tamper-proof” design of these seals renders them fragile, so care should be taken not to break or remove these, as this will void the warranty. If any of above items should prove defective within the warranty period, STARMANS will, at its option, repair or replace them without charge, FOB the nearest STARMANS Service Center. Our policy is to accept only prepaid shipments to our authorized service centers. STARMANS makes no other warranty of any kind whatsoever and are no implied warranties of merchantability or fitness for a particular purpose. STARMANS shall not be liable for any failure of the equipment or equipment operators to discover defects in components being tested with such equipment or for any consequential damages arising from the purchase or use of the equipment. In no event shall damages for breach of warranty exceed the purchase price paid to STARMANS hereunder. STARMANS reserves the right to modify or change the specifications of its products without notice and without incurring any responsibility for modifying previously manufactured products.

CALIBRATION INTERVALS As the manufacturer, STARMANS electronics, Ltd. recommends that our electronic equipment be calibrated at the end of its one year warranty period and every 12 months thereafter.

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Contents 1. DIO 1000 Introduction ........................................................................................ 6 1.1 General Description ..................................................................................... 6 1.2 Unpacking.................................................................................................... 7 1.3 Operating Environment ................................................................................ 7 1.4 Power Requirements ................................................................................... 7 1.5 Top Panel Connectors ................................................................................. 7 2. Specifications..................................................................................................... 8 3. Control Description.......................................................................................... 10 3.1

Power Button ..................................................................................... 10

3.2

Escape Key........................................................................................ 10

3.3

Immediate Execution Keys ................................................................ 11

3.4

Display Freeze ON/OFF .................................................................... 11

3.5

Display Brightness ............................................................................. 11

3.6

Save Setup / Picture .......................................................................... 11

3.7

Load Setup / Picture .......................................................................... 11

3.8

Settings Menu (Angle Probe and Other Functions) ........................... 12

3.9

Zoom ................................................................................................. 12

3.10

Help ................................................................................................... 12

3.11

Lock ................................................................................................... 12

4. Menu Description ............................................................................................. 13 4.1 Basic MENU .............................................................................................. 13 4.1.1 4.1.2 4.1.3 4.1.4 4.1.5 4.1.6 4.1.7 4.1.8 4.1.9 4.1.10 4.1.11 4.1.12

GATE >--< ..................................................................................................14 GATE --< ....................................................................................................14 GATE ^ .......................................................................................................14 TR MODE ...................................................................................................14 PROBE DELAY ..........................................................................................14 DISPLAY DELAY........................................................................................14 GAIN...........................................................................................................14 STEP G ......................................................................................................14 FILTER .......................................................................................................14 VOLTAGE...................................................................................................14 VELOCITY..................................................................................................14 RANGE.......................................................................................................14

4.2.1 4.2.2 4.2.3 4.2.4 4.2.5

BANDWIDTH..............................................................................................15 TR MODE ...................................................................................................15 DETECTOR................................................................................................15 AVERAGING ..............................................................................................15 P.WIDTH ....................................................................................................15

4.2

Menu ........................................................................................... 15

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4.2.6 4.2.7 4.2.8 4.2.9 4.2.10

ATT.............................................................................................................15 DAMP .........................................................................................................15 PRF ............................................................................................................15 SPIKE/BURST............................................................................................15 P.FREQ ......................................................................................................15

4.3.1 4.3.2 4.3.3 4.3.4 4.3.5 4.3.6 4.3.7 4.3.8 4.3.9 4.3.10 4.3.11

GATE >--< ..................................................................................................16 GATE --< ....................................................................................................16 GATE ^ .......................................................................................................16 TR MODE ...................................................................................................16 PROBE DELAY ..........................................................................................16 DISPLAY DELAY........................................................................................16 GAIN...........................................................................................................16 STEP G ......................................................................................................16 DEL #xx ADD .............................................................................................16 TR.CORR/TRIGGER LINE/AUX LINE OFFSET ........................................17 DAC TYPE..................................................................................................17

4.4.1 4.4.2 4.4.3 4.4.4 4.4.5 4.4.6 4.4.7 4.4.8 4.4.9 4.4.10

GATE >--< ..................................................................................................18 GATE --< ....................................................................................................18 GATE ^ .......................................................................................................18 GATE..........................................................................................................18 GATE x .......................................................................................................18 GAIN...........................................................................................................19 STEP G ......................................................................................................19 REJECT......................................................................................................19 THICKNESS ...............................................................................................19 VELOCITY..................................................................................................19

Menu........................................................................................... 16

4.3

4.4

Menu ........................................................................................... 18

4.5

Menu ........................................................................................... 19

4.6

Menu ........................................................................................... 20 4.6.1 4.6.2 4.6.3 4.6.4 4.6.5 4.6.6 4.6.7 4.6.8

GATE >--< ..................................................................................................20 GATE --< ....................................................................................................20 AUTOCALIB ...............................................................................................21 GAIN...........................................................................................................21 ANGLE .......................................................................................................21 X-VALUE ....................................................................................................21 THICKNESS ...............................................................................................21 VELOCITY..................................................................................................21

5. Applications...................................................................................................... 22 5.1 Angle Probe Autocalibration with Test Block No.1 (EN 12223).................. 22 5.2 DAC (Distance Amplitude Correction) Curve ............................................. 24

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1. DIO 1000 Introduction 1.1 General Description The DIO 1000 has a large number of standard features, high contrast, high resolution translucent color LCD display (1024×768 pixels) and the capability to store and recall dozens instrument set-up programs, thousands A-scans, including distance amplitude correction (DAC) and a low noise receiver with selectable RF and detected displays.

Figure 1. DIO 1000 Front Panel The expanded top panel has seven connectors including two LEMOs for probes connection and five special connectors for synchronization, alarm and analog outputs, network connection (ETHERNET), USB and power connector. Notwithstanding of its of its digital signal processing, the DIO 1000 retains the high repetition rate capability and superior waveform display.

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1.2 Unpacking All cartons should be opened and inspected upon receipt. The cartons and contents should be inspected for any signs of damage that may have occured during shipment. If damage is noted, contact the carrier and retain the damaged shipping materials until an inspection can be performed by a representative of the carrier. With the exception of external accessories, all DIO 1000 options are installed before the unit is shipped. Check the contents of the carton or cartons against the purchase order to ensure that all accessories ordered have been received.

1.3 Operating Environment The DIO 1000 is designed as a portable instrument, an as such requires no special site preparation before operation. When operated, the instrument should be firmly supported on its tilt handle to prevent damage due to a fall. The unit should be protected as much as possible from water or chemical splashes, rapid temperature changes, or areas near large electrical equipment that may interfere with the operation of the internal circuitry.

1.4 Power Requirements The battery charger (power unit) is provided with the DIO 1000, which allows the instrument to be operated from the LiIon battery or from AC line power in the range of 100-240 Volts at a line frequency of 50 to 60 Hz.

1.5 Top Panel Connectors Seven external connectors are provided on the DIO 1000 top panel (refer to Figure 2). Djual element probe

SIngle element probe

Figure 2. DIO 1000 Top Panel Two standard LEMO connectors are used for probes connection.

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2. Specifications Pulser Type

Square wave

Pulse Amplitude

Selectable from 75 to 275 Volts in 5 V steps

Pulse Width

15 to 5000 ns

Pulser Excitation

Spike (1 pulse) or Burst (2 to 10 pulses)

Modes

SINGLE (Pulse Echo), DUAL (Dual or Through Transmit), EMAT

Receiver Bandwidth

0.5 to 30 MHz (at -3 dB)

Frequency Filters

Broadband, Narrowband, or Custom Selectable Low and High Pass Filters 1.0 MHz, 2.0 MHz, 2.25 MHz, 4.0 MHz, 5.0 MHz, 10.0 MHz

Damping

Selection values: 42, 51, 180 or 1000 Ohms

Gain Control Range

0 to 111.0 dB

Gain Control Steps

Selectable 0.1, 0.5, 1.0 and 6.0 dB

Display

RF, Halfwave+, Halfwave-, Fullwave

Time Base Pulse Repetition Rate

10 Hz to 20 kHz

Test Range

3.8 mm to 14185 mm of steel (for L-waves)

Display Delay Range

-25 mm to 12250 mm (-8.50 µs to 4124 µs)

Material Velocity

1 to 19999 m/s

Angle Beam Control

Fixed settings of 0°, 30°, 45°, 60°, 70°, 80°, or variable from 0 to 90° in 0.1° increments

Gates Four independent flaw gates controllable over entire sweep range - Floating gate, - Interface gate, - Measuring gate – relative, absolute, amplitude, time - Back-wall echo attenuator Threshold

Variable 2.1 to 97.7 % of full screen

Trigger Logic

Positive or Negative

Gate Synchronization

Initial Pulse or selected interface

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Connectors and Communication Ports Transmitter (Pulser) Receiver Analog OUT ETHERNET MULTI USB POWER General Dimensions

224×188×37 mm

Display

Color TFT 99×130 mm (1024×768 pixels)

Weight

0.74 Kg without battery + 0.54 kg battery for 8 hours operation

Operating Temperature

-10 °C to 50 °C

Storage Temperature

-40 °C to 70 °C

Power

100-240 VAC, 50 to 60 Hz, 50 VA max. for battery charging and operation

Battery

Built-in rechargeable LiIon battery pack, 3.6 V, 16 Ah

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3. Control Description Control Keys for Values Changing Status and Calculation Window

Display

Power ON/OFF

Escape Key Immediate Execution Keys

Display Freeze ON/OFF

Save Setup / Picture Display Brightness

3.1

Angle Probe Menu

Load Setup / Picture

Help

Zoom

Lock

Power Button

The POWER button toggles instrument power ON and OFF. Immediately after power is turned ON, an initialization routine is started. During the start-up routine, the instrument’s microprocessor measures and corrects circuit offsets. Also, the microprocessor verifies that all circuits are operating properly.

3.2

Escape Key

Within the Basic MENU, after this key had been depressed, the instrument may be switched OFF with or without saving the actual settings. “SAVE & EXIT & OFF” message will be displayed at the display bottom. Depress the appropriate Execution Key (YES or CANCEL). Within any other menu, Esc key will turn back into the Basic MENU.

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3.3

Dio 1000 – Operation Manual

Immediate Execution Keys

These keys provide execution of the menu item displayed just above them.

3.4

Display Freeze ON/OFF

The actual waveform may be “frozen” by depressing this key (the red indicator *FROZEN* is displayed in the Status Window). Then the complete display content may be saved to the memory. Depress this key again to “defrost” the screen. Depressing this key for time longer than 1 sec switches the instrument to peak freezing mode – maximum (peak) echo amplitudes will be “collected” in this mode (the red indicator *PEAKS* is displayed in the Status Window). Next short depressing of this key allows to freeze and save actual picture (the red indicator *FROZEN PEAKS* is displayed in the Status Window).

3.5

Display Brightness

The intensity of display illumination may be adjusted as follows: - short depressing – brightness UP; - long depressing – brightness DOWN. Default display brightness value is 50 %. This setting is not saved in the last status.

3.6

Save Setup / Picture

The complete settings of the instrument may be saved to the memory position (SET_01 to SET_08, SET_09 is factory default) chosen by the appropriate Execution Key. If the Waveform Freeze key had been depressed, then the complete display content may be saved as a picture (.png format) to the memory group (PIC_01 to PIC_09) chosen by the appropriate Execution Key.

3.7

Load Setup / Picture

The complete settings of the instrument may be loaded from the memory position (SET_01 to SET_09) chosen by the appropriate Execution Key. If the Waveform Freeze key had been depressed (PIC_x has green background), then previously saved pictures may be displayed on the screen. In order to display previous/next picture, depress “” key. The other options are: RECALL – recall settings which were actual during saving the picture; DELETE – delete actually displayed picture; Pxx->USB – send the actually chosen group of pictures (PIC_01 to PIC_09) to the USB port.

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3.8

Dio 1000 – Operation Manual

Settings Menu (Angle Probe and Other Functions)

This key provides the access to the settings menu for angle probe and other specific settings.

3.9

Zoom

This key provides zoomed display of the gate area. Next depressing of this key will return to the initial range.

3.10

Help

This key activates the help mode.

3.11

Lock

After the instrument power ON or Transmitter Mode change, the pulser is OFF, in order to prevent accidental probe damage with buil-in preamplifier. Make sure that the probe is connected properly, then enable the pulser by short depressing of the Lock key. Long depressing (longer than 3 sec) the Lock key will lock/unlock the instrument – see picture. Instrument settings cannot be changed in the “locked” condition. Only context items, which don’t affect operation, in the bottom row are active (MENU, UNITS, VOLUME, GRID, FILL, LANG). Some functions are available also: Freeze, Setup choice and its loading (SET_xx), Picture Save (PIC_xx, in frozen condition), listing of saved records.

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4. Menu Description Note: The active menu item is always highlighted with green background of the menu item text.

4.1 Basic MENU Basic MENU items may be switched OFF/ON by depressing the “MENU” button – see figure below: Important Basic MENU items remain active even with menu switched OFF – Time Base, GATE positioning and switching between gates, GAIN. The menu item appears after first depressing, without value change; second depressing changes its value; item will disappear after ě sec. Functions of Immediate Execution Keys (yellow buttons just below the screen) are as follows: Switches ON/OFF the HW_SET menu. Switches ON/OFF the DAC menu. Switches a memory group for saving/loading set-ups (SET_01 to SET_09). Switches ON/OFF the GATES menu. Switches ON/OFF the B-SCAN mode. Switches ON/OFF the main menu items (next to the control keys). Switches ON/OFF the AUTOCALIBRATION mode. Switches the waveform display. Green background means activated mode: FW – full wave rectified; *FW – full wave rectified with envelope (red *ENV* indicator is displayed just below the time base scale); RF – radio-frequency (alternating)` *RF – radio-frequency with envelope (red *ENV* indicator is displayed just below the time base scale). Note: If DETECTOR in HW_SET menu is set to NEG HW (POS HW), then HW- (HW+) is displayed instead of FW.

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4.1.1

Dio 1000 – Operation Manual

GATE >--