DM4E DM4 DM4 DL Operating Manual
Operating Manual for Ultrasonic Thickness Gauge Models DM4E, DM4 and DM4 DL with On-board data Logger Manual Part No. 021-002-073 REV. S Copyright 2002 Agfa NDT Inc.
THIS PAGE INTENTIONALLY BLANK
Important Notice Important Notice The following information must be read and understood by any user of a Krautkramer ultrasonic thickness gauge. Failure to follow these instructions can lead to errors in thickness measurements or other test results. Decisions based on erroneous results can, in turn, lead to property damage, personal injury or death. General Warnings Proper use of ultrasonic test equipment requires three essential elements: • Selection of the correct test equipment.
Important Notice must be developed so that couplant is used and applied in a consistent manner to minimize variations in couplant layer thickness and errors in test results. Calibration and actual thickness being measured. This effect, commonly known as “doubling,” can occur below the minimum specified range of the transducer. If the transducer being used is worn, doubling is possible at a thickness greater than the minimum of the specified range.
Table of Contents Important Notice ....................................................... 1 3.3 Selecting A File ............................................. 17 Table of Contents ...................................................... 3 Warranty / Service ..................................................... 4 3.4 Logging Readings Into Memory ..................... 18 1. Introduction ........................................................... 5 3.5 Selecting Locations ..................................
Warranty/Service Warranty Service When used in accordance with the manufacturer’s written instructions and under normal operating conditions, the Krautkramer DM4E, DM4, and DM4 DL test instruments are conditionally guaranteed to be free from defects in material and workmanship for a period of two (2) years from date of shipment. Every effort has been made to provide you with a reliable product. However, should service become necessary, Agfa NDT Inc.
1. Introduction 1.1 How To Use This Manual • Automatic probe zero for fast calibration • Automatically recognizes DIALOG Intelligent Transducers. • Automatic V-path error correction compensates for nonlinearity of dual element probes. If you are a first time user of the instrument, review Chapter 1 of this manual to become acquainted with it’s general capabilities. • Resolution of .001 in, .01 in, .1 mm, or .
1.0 Introduction The time needed for the pulse to make this round trip is divided by two and multiplied by the velocity of sound in the material under test. The result is the thickness of the material. The figure at right illustrates the pulse-echo principle of ultrasonic thickness measurement.
2. Operation 2.1 Battery Installation NOTE: When low battery indicator lights (below), replace batteries as soon as possible. Automatic shutoff occurs when batteries are too weak for reliable operation. Settings are saved and restored when turned on. When testing in remote locations, always carry spare batteries. 2-PT 2-point calibration mode. VEL Velocity display and callibration mode. MIN Minimum capture mode SPEC Special modes (DM4, DM4 DL) (Sections 2.10 through 2.13 and 2.
2.0 Operation 2.3 Keyboard Controls NOTE: SEND, C/OBST, MEM, and FILE keys are DM4 DL only. DM4 DL Data Logging and Communication Keys Activates the scrolling keys to select a file (File Select) or, if Data Logger memory is clear, setting the number of files. Setting number of files can only be performed when the entire memory is clear. Transmits data to the on board Data Logger, or to an external device via the Serial I/O port.
2.0 Operation Model DM4 Model DM4E 2.4 Getting Started 2.5 Calibration to a Known Thickness, 1-Point Read “Important Notices” at the beginning of this manual, and Chapter 6, “Application Notes,” for important information on test conditions that affect measurement results. Select a suitable probe (Section 5.2) and connect it to the probe connector on the top panel. See Section 4.3 to select a report language other than English. Press Model DM4 DL to turn on the instrument.
2.0 Operation 2.6 Calibration to a Known Thickness, 2-Point NOTE: Requires two calibration standards (or one standard with two thicknesses) of the same material, velocity, and curvature as the material under test. For best results, the thicker standard should be equal to, or slightly greater than the maximum thickness to be measured. The thickness of the thin standard should be as close as possible to the lower end of the expected measurement range.
2.0 Operation Figure 2-9 2.7 Calibration to a Known Velocity Figure 2-10 NOTE: 2-PT calibration mode must be set to OFF. If you know the velocity of sound of the material to be measured, the instrument can be calibrated to the known velocity without the use of a calibration standard. However, the calibration should always be verified by measuring a known thickness (or calibration standard) of the same material and velocity as the material to be measured.
2.0 Operation 2.8 Normal Thickness Measurement - THK Mode This procedure applies to parts with ambient surface temperatures. Refer to Section 6.2 for information on taking measurements on hot surfaces. Be sure that the instrument is on and that the appropriate calibration procedures in Section 2.5, 2.6, or 2.7 have been completed for the selected probe type and material to be measured. If using the alarm feature (DM4 and DM4 DL), make sure the correct LO and HI limits are set and the alarm is on (Sect. 2.
2.0 Operation 2.12 Differential Measurement (DM4, DM4 DL) Press again to exit the gain select function. When the instrument shuts off, current setting is saved and restored when the instrument is turned on again. Differential measurement mode displays the difference between the measured thickness and a nominal value set by the user. To enter dIF mode, press or Then press until or to turn differential mode On and Off 2.
2.0 Operation 2.13 Band Pass Filter Control (DM4, DM4 DL) 2.15 Display Backlight The Band Pass Filter control of the DM4 and DM4 DL sets the band pass of the instrument receiver for the frequency of the connected probe. The default setting is HI for probes of 2 MHz to 10 MHz frequency.
2.0 Operation After briefly displaying the instrument version and display indicators, the first mode is displayed: Use or to scroll through and select the function or mode to be disabled or enabled. Figure 2-20 When the desired function or mode is displayed, press to display the current setting, On or OFF. Use or to disable (OFF) or enable (On) the displayed function or mode. again. The function or mode that has been acted Press upon will be displayed.
2.0 Operation The coupling indicator ( ) will illuminate only when two backwall The use of a DIALOG Intelligent Probe automatically selects either the standard “AUTO” or “DA3” mode. echoes are detected. In the event two backwall reflections are NOT detected: The coupling indicator ( ) will not illuminate. A row of dashes will be displayed. The red LED will flash.
3. Data Logger Operation 3.1 The DM4 DL Data Logger The DM4 DL on-board Data Logger provides a simple, reliable way to record thickness measurements. Readings are stored in one or more files by pressing the SEND key. A file is a number of Data Logger memory locations that have been grouped together for storing readings, one reading per location, and reporting measurement data. WARNING: Clearing memory permanently erases all readings stored in the DM4 DL Data Logger.
3.0 Data Logger Operation 3.4.1 Recording an OBSTRUCT Value indicates a full file, no empty locations. If a measurement cannot be made or a location is inaccessible, an “OBSTRUCT” value can be logged into the current active location. “nnn” (001 to 999) is the number of the selected file. When the desired file number is displayed, press again. The current active location number of the selected file is displayed briefly.
3.0 Data Logger Operation A row of dashes (Figure 3-5) indicates an empty location. indicates an obstructed location. A flashing plus sign indicates the reading exceeds the HI limit stored with the file. A flashing minus sign indicates a reading that is less than the LO limit. “Err” (unlikely to occur) indicates that the reading has been corrupted in memory and must be retaken. Press Press to return to measurement mode, or use or to select another file. again to return to measurement mode.
4. Serial I/O Interface 4.1 The DM4 DL Serial Interface The 7-pin Lemo #0B connector the top panel of the DM4 DL, is the Serial I/O port. It is used to transmit readings and statistical data to an external device, such as a printer or a personal computer. For simple communication with a PC, an optional DM4 DL Data Transfer Utility Program is available for use with any IBM PC, XT, or AT compatible computer with at least 256K of available memory and DOS version 3.3 or higher. Contact Agfa NDT Inc.
4.0 Serial I/O Interface Selecting Printer Driver: Before printing, the appropriate printer driver must be selected. Press If the printer is accidentally disconnected during transmission, follow the procedure in Section 4.7 to avoid losing data. When to exit or use printing is done, press until SPEC illuminates. or to select another file. Press or to select (Figure 4-2), then Printed files remain in memory after printing has been completed.
4.0 Serial I/O Interface 4.6 Importing Data Into a Spreadsheet Stored thickness data can be transferred to an IBM compatible computer and saved on disk in a format that can be imported into spreadsheet programs, such as LOTUS 1-2-3TM and Microsoft EXCELTM. NOTE: Refer to the operating manual of your speadsheet program for file import instructions. Follow procedures in Sections 4.5 and 4.2 to connect the DM4 DL to the computer and set baud rate. To enable statistics see Section 4.4.
5. Specifications 5.1 Instrument Specifications Operating Principle: Ultrasonic, pulse-echo measurement Probe Zero Adjustment: Automatic or 2-point calibration Probe Recognition: Automatic for DIALOG Intelligent Transducers V-Path Correction: Automatic, microprocessor controlled AUTO Mode Linearity: ±.002 inch (±.05 mm) when calibration point < 1 inch (25 mm); ±.003 inch (±.075 mm) when calibration point > 1 inch (25 mm) DA3 Mode Linearity: ±.004 inch (± .1 mm) Measuring Range: .020 to 20.
5.0 Specifications Power Requirements: 2 each 1.5 volt, AA alkaline cells Battery Life (Operating Time): 200 hours at 25% duty cycle, without backlight, with steel velocity and .
5.0 Specifications Nominal Frequency Contact Diameter Measurement Range (Steel) Temp. Range Model Probe Description DP-104 High Penetration 1 MHz 1.25" 31.8 mm .200" min 5.0 mm min <130°F <54°C DA301 General Purpose 5 MHz .475" 12.1 mm .0 6 0" to 8.0" 1.5 to 200 mm <130°F <54°C DA303 High Penetration 2 MHz .635" 16.2 mm .200" min 5.0 mm min <130°F <54°C DA312 Thin Materials 10 MHz .30" 7.6mm DA312B16 * Small Footprint 10 MHz .120” 3 mm KB550BTH * Boiler Tube 5 MHz .375" 9.
6. Application 6.1 General Notes The DM4 is easy to use and will produce reliable, consistent measurements when used correctly and with an understanding of factors that may affect measurement reliability. This section explains some of the more common considerations. 6.1.1 Flaws If, during testing, the DM4 suddenly reads a value which is much thinner than the apparent thickness of the part, it may be reading the distance to a flaw in the test piece, rather than the distance to the backwall. See Section 1.
6.0 Application Notes A 100% duty cycle can be employed when taking measurements below 400°F (204°C). No cooling of the probe is required. If taking thickness readings at temperatures above 400°F, cool the probe in air as follows: • 15 seconds for temperatures from 400°F to 550°F • 30 to 120 seconds for temperatures from 550°F to 1,000°F Thickness measurements made at high temperatures must be corrected for the effect of temperature on the material sound velocity.
7. Worldwide Service Centers Agfa NDT GmbH Robert-Bosch-Strasse 3 D-50354 Huerth (Efferen) Cologne, Germany Phone: (49) 2233-6010 Fax: (49) 2233-601402 E-Mail: hotline@AgfaNDT.de Krautkramer UK Ltd Millburn Hill Road University of Warwick Science Park Coventry, England CV4 7HS United Kingdom Phone: (44) 0845 601 5771 Fax: (44) 0845 130 5775 E-Mail: ndtsales.gb.ng@Agfa.co.uk Agfa NDT SA 68, Chemin des Ormeaux F-69760 LIMONEST France Phone: (33) 47-217-9220 Fax: (33) 47-847-5698 E-mail: ndt@France.Agfa.
Appendix A: Displays, Quick Reference Initial display, DM4E Section 2.4 2-point calibration Couple to thick standard. Section 2.6 Initial display, DM4 Section 2.4 Receiver Gain Control (DM4, DM4 DL) Section 2.10 Initial display, DM4 DL Section 2.4 Automatic Gain; Automatic Backlight Sections 2.10, 2.15 Fatal memory failure! Call for service High Gain; High Band Pass Filter (DM4, DM4 DL) Sections 2.10, 2.13 Memory Failure. Press MODE key to reset instrument operating software.
Appendix A: Displays, Quick Reference Reading exceeds HI Alarm limit (DM4, DM4 DL) Section 2.11 File no. nnn active Section 3.3 (DM4 DL) Reading less than LO Alarm limit (DM4, DM4 DL) Section 2.11 File no. 1 full Section 3.3 (DM4 DL) Differential measurement mode (DM4, DM4 DL) Section 2.12 Location no. 5 active SEND confirmed Section 3.4 (DM4 DL) Differential reading exceeds nominal by amount shown. (DM4, DM4 DL) Section 2.12 Differential reading less than nominal amount shown.
Appendix A: Displays, Quick Reference Clear file no. 1 Section 3.8 (DM4 DL) Japanese report language selected Section 4.3 (DM4 DL Baud rate selection Section 4.2 (DM4 DL) Report selection Section 4.4 (DM4 DL) English report language selected Section 4.3 (DM4 DL) Header for report Section 4.4 (DM4 DL) German report language selected Section 4.3 (DM4 DL Statistics for report Section 4.4 (DM4 DL French report language selected Section 4.3 (DM4 DL Epson FX 850 printer setting Section 4.
Appendix A: Displays, Quick Reference Sending file no. 5 Transmission in process Section 4.4, 4.5 (DM4 DL) File SEND aborted Section 4.4, 4.5 (DM4 DL) Spreadsheet formatted report Section 4.6 (DM4 DL) Non-compatible probe for Dual Multi measurement mode Section 2.
Appendix B: Locations Per File Based on Number of Files #Of Files ** 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 #Of Loc Per File 999 999 999 999 999 899 770 673 598 537 488 447 412 383 357 334 314 297 281 266 254 242 231 221 212 204 196 189 182 176 170 165 160 155 150 146 142 138 134 131 128 125 122 119 116 113 111 108 106 104 102 100 98 96 Total Readings All Files 999 1998 2997 3996 4995 5394
Appendix C: Operational Software Reset WARNING! Using this procedure completely resets the instruments to its factory default settings for all measurement and data logging parameters. All readings stored in the on-board data logger will be permanently erased. To prevent loss of data, transfer all files to a computer or printer. This procedure resets all instrument parameters to their original factory default settings.
Index Page A Alarm ............................................................................ 12 Alarm Limits ................................................................. 11 Automatic shut-off .......................................................... 7 B Backlight ....................................................................... 14 Battery Installation .......................................................... 7 Baud Rate .....................................................................
