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55 

9

 

MAINTENANCE 

 

9.1

 

The flaw detector maintenance includes the maintenance inspection, 

operating repair and calibration. 

9.2

 

Intervals between the maintenance inspections are set depending on 

the industrial conditions, but no less than once per  month. Connecting cable 
fixation,  condition  of  controls  and  indicators  are  checked  during  the 
maintenance inspection. 

9.3

 

The maintenance inspection includes an external examination and is 

performed by attending personnel before starting the flaw detector electronic 
unit operation. 

9.4

 

Replacement of the battery pack. 

9.4.1

 

Unscrew two screws (item 1 Figure 39). 

 

 

 

Figure 39

 

 

 

9.4.2

 

Open  the  contact  terminal  (item  1  Figure 40),  pressing  the  clip 

(item 2 Figure 40). 

 

      

 

 

Figure 40

 

 

9.4.3

 

Remove the battery pack (item 1 Figure 41).

 

 

1 

1 

2 

Summary of Contents for Eddycon C

Page 1: ...Eddy current flaw detector Eddycon C Operating manual ЕС 14327992 03 13 OM Produced by LLC ULTRACON SERVICE ...

Page 2: ... 36 3 11 RESULTS menu 36 3 12 SETTINGS menu 37 3 13 Set up of CALIBRATION menu 38 3 14 Communication with PC 41 3 14 1 Running the program 41 3 14 2 Program description 41 3 14 3 Working with the program 47 4 LABELING AND SEALING 49 5 COMPOSITION AND DELIVERY SET 50 6 SAFETY MEASURES 51 7 SETTING UP PROCEDURES 51 8 INSTRUCTIONS FOR USE 51 8 1 SINGLE COIL PROBE 51 8 2 REFLECTION DIFFERENTIAL PROBE ...

Page 3: ...full scale implementation of flaw detector technical capabilities The following graphic symbols and designations of controls plug type connections and indicators are used in the flaw detector Front panel of the Eddycon C Figure 1 Eddycon C eddy current flaw detector Front panel Automatic flaw alarm by the first and second frequencies respectively and by the mix of the 1st and 2nd frequencies as we...

Page 4: ...meter in the mode of name editing selects a digit letter changes the frequency in the mode of name editing selects a digit letter moves up through the menu in the mode of name editing selects a digit letter decreases the selected parameter in the mode of name editing selects a digit letter cancels the selection in the mode of name editing selects a digit letter pressing the key results in displayi...

Page 5: ...arameters of single coil parametric ECP with switched on Single input sets the number of rounds while operating with eddy current rotary scanner switches On Off the instrument Rear panel of the flaw detector 1 Ethernet port for connecting a communication cable to PC 2 USB port for updating the flaw detector software and recording the testing results on the external Flash Card Figure 2 Eddycon C ed...

Page 6: ...ta of receiver 4 Data of receiver Table 2 Description of connector for the instrument connection to the PC USB port Contact Signal USB type A front view 1 5 V 2 Data 3 Data 4 Common Left side panel of the flaw detector 1 LEMO jack for headphones with microphone connection 2 Charger connector 3 Switching On Off the instrument Figure 3 Eddycon C eddy current flaw detector Left side panel 1 2 3 ...

Page 7: ...tion Cont Signal EGG 0B 304 CLL front view 1 Input signal from the microphone 2 Right audio output 3 Common 4 Left audio output Table 4 Description of charger connector Cont Signal EGG 1B 304 CLL front view 1 Charging device 2 Not used 3 Charging device 4 Sync signal output ...

Page 8: ...tor for eddy current probe ECP and eddy current rotary scanner 3 Encoder Enc connector Figure 4 Eddycon C eddy current flaw detector Right side panel Table 5 Description of single parametric eddy current probe ECP connector Cont Signal Lemo ERA 00 250CLL 1 Parametric ECP 2 Common for parametric ECP 2 3 1 ...

Page 9: ...er Cont Description EGG 2B 316 CLL front view 1 Common 2 Positive amplifier input 3 Bridge generator output 4 Generator signal output 5 Single wire interface 6 Signal input to control the rotation speed of the rotary scanner four pulses per revolution Common 7 Rotary scanner power 8 Common of rotary scanner 9 Signal input to control the rotation speed of the rotary scanner one pulse per revolution...

Page 10: ...plication area are specified in regulatory documents for a specific type of testing products and materials 1 4 The flaw detector provides the possibility of connecting and operating ECP of the following types differential ECP differential ECP connected by the bridge circuit differential transformer ECP with center point earth differential transformer ECP single parametric ECP single transformer EC...

Page 11: ...ex plane 2 7 There is automatic LED and sound flaw alarm ALARM in the flaw detector 2 8 In processing of the testing results the flaw detector provides the following options changing of ECP signal phase the range of signal turn from 0 to 360 with a step of 0 1 1 10 filtering of ECP signal there are 5 types of filters Averaging Differential Low pass High pass Bandpass formation of a mix of two freq...

Page 12: ...12 3 DESIGN OF THE FLAW DETECTOR 3 1 Instrument appearance Instrument appearance is shown in Figure 5 Figure 5 Eddycon C eddy current flaw detector Display screen Keypad ...

Page 13: ... flaw detector consists of a casing and cover plate with the membrane keypad indicators of ALARM and overloading Mini USB port for connection to PC USB port for external flash card connection charger connector headphones and microphone b connector ECP connector c TFT display d processor and memory boards e analog board f battery ...

Page 14: ...d display areas complex plane time charts Bottom horizontal field data line Navigation menu o FREQ test frequency o PRE AMP preamplifier gain o GAIN main gain o H GAIN horizontal gain o V GAIN vertical gain o DRIVE probe drive level o PHASE phase adjustment o FILTER filter type o POSITION spot position o GRID grid o AXIS axis o ALARM short cut to ALARM Setting o SWEEP number of points in a screen ...

Page 15: ...circuit before the balancing non balance of the input circuit the current value of the input circuit expressed in from the maximum possible F sampling frequency 7 Frequency number 8 Battery life indicator 9 Temporary memory indicator of the flaw detector 10 Digital overload indicators for receiving circuit 11 digital trigger indicators of ALARM levels for the first second and mix of frequencies re...

Page 16: ... in complex plane that allows to foil defects by waveform analysis Figure 9 Figure 9 Display of signal in the complex plane XY Figure 10 Mix of two frequencies MIX The flaw detector has the mechanism of automatic flaw alarm ALARM It is provided for the creation of up to 4 frames threshold levels of alarm for each frequency and mix examples of threshold levels see Figures 14 15 16 17 These frames t...

Page 17: ...rk with Automatic measurement of the signal amplitude and phase provides a possibility to evaluate the defect size in analyzing the data The measured values of the voltage phase or amplitude are required for estimating the defect size in conformity with the selected calibration curve Such curve compares the parameters of signal amplitude or phase with the defect parameters in millimeters or percen...

Page 18: ...18 Figure 11 Circuits of PROBE connection 3 4 Menu structure Figure 12 Menu structure MENU TEST SETTINGS VIEW ARCHIVE CALIBRATION RESULTS SETTINGS ALARM ...

Page 19: ...tion Figure 13 TEST menu In this menu an operator can set change the settings of the selected frequency the values of operating frequency gain and preamplifier generator voltage initial phase of signal filter type and its parameter input type general scale and independently to axles position of complex plane center as well as set up ALARM and general flaw detector parameters Moving through the ver...

Page 20: ...tor the centering is carried out automatically Centering it is a displacement of present complex signal in user selected position on the screen of the flaw detector The algorithm is fully performed by processor module Current procedure is carried out according to digital detecting signal and necessary for signal displacement elimination caused by amplifier and digital filters Balancing should be a...

Page 21: ...s the overall gain simultaneously for X and Y coordinates 4 H GAIN horizontal gain for amplifying the probe voltage varied in the range from 0 to 30 dB with a step of 0 1 1 10 dB 5 V GAIN dB vertical gain for amplifying the probe voltage varied in the range from 0 to 30 dB with a step of 0 1 1 10 dB This item is often used to set up single coil probe for visual increase of angle between lift off s...

Page 22: ...nd held probes It is important that the low pass filter is not too low because defect signals are not displayed anymore if you move the probe across the crack at a speed that is too high with regards to the filter frequency If for example you move the probe very slowly across the crack then the dot slowly tracks the full defect signal at a low pass frequency of 10 Hz If one the other hand you move...

Page 23: ...lectronic noise by the so called fuzzy signal image instead of a steady dot This happens frequently if you carry out inspections with low frequencies or high gain The filter frequency does not depend on the alternating frequency of the current that flows through the coils but on how frequently the test signals change If for example you move a probe across a crack the frequency depends on how fast ...

Page 24: ...es of frames frames are switched off circle frame type threshold frame type sector frame type cutoff frame type 13 SWEEP number of samplings displayed on time charts see Figure 8 pos 4 256 512 1024 2048 4096 8192 16384 32768 measurements 14 PROBE Connector type Refl Bridge Single 15 RPM rounds per minute for the eddy current rotary scanner Selected from the standard range 600 840 1020 1200 1500 18...

Page 25: ...e frame To set up circle type frame operator should select Type in special item of settings ALARM see Figure 14 Figure 14 Setup of Type of threshold level R parameter variation allows change the inner radius of threshold level Height parameter variation is carried out in the range from 0 to 32768 with a step of 1 10 100 1000 10000 see Figure 14 Setup of Threshold type frame To set up threshold typ...

Page 26: ... should select Type in special item of settings ALARM see Figure 16 Figure 16 Setup of Type of threshold level R parameter variation allows change the inner radius of threshold level Height parameter variation is carried out in the range from 0 to 32768 with a step of 1 10 100 1000 10000 see Figure 16 W parameter variation allows change the width of threshold level Radius parameter variation is ca...

Page 27: ...s parameter can be activated Setup of Trapezium type frame To set up trapezium type frame operator should select Type in special item of settings ALARM see Figure 17 Figure 17 Threshold level setup Type X1 parameter variation allows changing the angle position of threshold level in X1 direction X1 parameter variation is carried out in the range from 32768 to 0 with a step of 1 10 100 1000 10000 se...

Page 28: ...sing key 2 3 If the recommendations specified in paras 2 1 2 2 didn t resolve the overload then it is necessary to reduce the probe drive and repeat paras 2 1 2 2 Lightning of the right overload indicator pos 10 Figure 8 indicates the general overload of the input of the receiving circuit General overload may include overload by the input of the receiving circuit exceeding the maximum allowed sign...

Page 29: ...ed to as the standard depth of penetration This depends primarily on the operating frequency and the conductivity of the metal It is generally considered that materials of thickness greater than 3 standard depths of penetration can be measured without any correction factors being required For example at 60 kHz this figure the effective depth of penetration is around 0 05 1 25 mm in Aluminium Alloy...

Page 30: ...ONDUCTIVITY Figure 18 CONDUCTIVITY Test Mode To press to enter the TEST menu In the menu TEST under the position Current set to choose by buttons the appropriate setting for the measurement at a specified frequency and to press the button to activate the settings CP13 60 kHz CP13 480 kHz Figure 19 Choosing and activating settings CP13 60 KHZ After settings activation make calibration at standard s...

Page 31: ...etting up samples the more accurate is the measurement Before beginning the calibration at the positions of Cond 1 the lower conductivity value and Cond 2 higher conductivity value there must be set the values of the conductivity of the samples which will be calibrated using the buttons To set up the coatings thickness measurement there must be used the 20 mil 0 5 mm film thickness Gap value is 20...

Page 32: ... sample and press Figure 22 Entering the gap value for setting on the Cond 1 sample Measuring Conductivity and Coating Thickness with the Eddycon C Guidelines for successful operation For accurate measurement of conductivity the surface coating thickness should be 0 5 mm 0 020 inches The surface to be measured should be flat or of the same curvature as the calibration standards Where curved surfac...

Page 33: ... mode test mode Can be Conductivity Expert and Simple Conductivity mode is intended for conductivity and thickness measuring In Simple mode a part of operating settings is not displayed Max smp frequency measurement frequency for the TEST mode Samplings frequency in Hz sampling frequency of ECP per 1 second from 1 kHz to 10 kHz If the value of the selected frequency from a fixed number of measurem...

Page 34: ...pulses per 1 mm generated by encoder from 10 to 10000 pulses mm with a step of 1 10 100 1000 pulses mm N meas mm number of measurements per 1 mm Input active connector for ECP 1 Single for single coil ECP 2 Refl for other ECP Date selection of current date year month date Time selection of current time hours minutes seconds 3 9 VIEW When entering VIEW menu an operator is offered to view and analyz...

Page 35: ... points in a strip chart When moving the cursor in the strip chart the complex plane display is updated with the signal which is located within the cursor width The values of amplitude in volts phase in degrees and defect depth in millimeters or percent are displayed in the information line Note The flaw detector has a feature which allows the quick signal noise ratio measurement In order to measu...

Page 36: ... The given menu allows storing and loading of the testing results In selecting Results menu the flaw detector displays the window with a list of results Figure 21 The list of results contains catalogs folders and files The catalogs are displayed in the top part of the list and are marked with the folders icon the files in the bottom part and are numbered The catalogs in their turn can comprise sub...

Page 37: ...e current result and delete the selected result Figure 27 Operations with the testing results When loading the saved testing results the setups which were used while the testing are set in the instrument and the automatic transition move to VIEW menu is carried out When saving the results and anywhere where it is necessary to enter the text information function keys delete the previous character b...

Page 38: ...egistration certificate the required ECP exciting voltage gain scale and take the calibration block 2353 08 Ra 1 25 In the TEST menu place the ECP on the flaw free section before an artificial flaw with the depth of 0 1 mm5 and press key balancing Pass all defects having chosen such scanning speed to have all signals from defects of regular shape i e max symmetric relative to the peak signal on ti...

Page 39: ...he defect depth Amplitude Phase 2 Select the units of defect measurement mm 3 Calibration block selection 4 Position of the measuring cursor on the time chart 5 Width of the measuring cursor on the time chart 6 The type of the measuring cursor see item 3 7 Figure 30 CALIBRATION menu Note After plotting the calibration curve there is no point in changing the units of defects measurements 4 5 6 1 2 ...

Page 40: ...e help of keys move to the CURVE POINTS 1 and by and keys set the depth of the first defect of the calibration curve i e 0 1 mm see Figure 31 Then it is essential to perform similar operations for all other defects by setting corresponding depth Figure 31 Plotting of the calibration curve Each newly added point of the calibration curve is assigned with a number 1 2 3 and so on The max number of th...

Page 41: ... form a report 3 14 1 Running the program To run the program it is required to copy the files to the PC hard disk drive from the disk that is included to the flaw detector delivery set run the file Eddycon _C exe 3 14 2 Program description The operating window of Eddycon C program includes the following areas Figure 32 1 main menu 2 tab panel 3 time diagrams area 4 signal display area active area ...

Page 42: ... program directory of Eddycon C This file can be located in the flaw detector memory or also be stored on hard disk drive of PC if previously copied to the hard disk drive 3 14 3 2 Double click of the mouse left button opens the file Loading subitem allows to view the files of all testing results saved in the flaw detector memory and to copy them to the hard disk drive of PC 3 14 3 2 When selectin...

Page 43: ...guage of program interface Figure 35 Selecting the interface language window Note Reload the program to change the interface language Select Exit subitem to finish the Eddycon C program When selecting Report item of the main menu there appears a window for filling in the report form of the testing carried out Figure 36 ...

Page 44: ...Disable setting To print out the testing protocol press Print button in the upper part of a testing protocol window To save the testing protocol in a pdf format press button To exit the review mode of a testing protocol it is required to press button 3 14 2 2 Tab panel Tab panel includes three tabs Each tab corresponds to the selected frequency or to the mix of frequencies MIX Frequency 1 Frequenc...

Page 45: ...range from 256 to 32768 Type of measurement allows to select the required type of cursor measurement from the following list Peak Peak the measurement is made between two points situated at the max distance from each other in cursor width Vrt M vertical maximum the measurement is made between two points situated at the max distance from each other in cursor width in vertical projection Cnt Pk cent...

Page 46: ...rsor by holding the left mouse button down Signal angle allows to change the signal phase selects the step for signal phase change from 0 to 90 changing the signal phase with counterclockwise rotation considering the selected step changing the signal phase with clockwise rotation considering the selected step restoring the initial signal phase Scale HV simultaneous horizontal and vertical scaling ...

Page 47: ...ing cable that is included to the flaw detector delivery set Switch on the flaw detector by pressing the power On Off button and hold it pressed until a short beep sound is emitted Wait until the flaw detector is recognized on PC as a removable media when the flaw detector is recognized as a removable media it is displayed on PC screen 3 14 3 2 Saving the testing results from the flaw detector mem...

Page 48: ... testing results measurements of the signal parameters as well as to make the report protocol followed by its printing out Note Viewing a list of data on the testing results from the flaw detector memory does not store this data automatically in PC memory 3 14 3 4 Printing out results of testing To print out the testing results it is required Select Report item in the main menu Fill in the report ...

Page 49: ... designation of the flaw detector year and quarter of manufacture serial number designation of specifications TU pattern approval mark Labeling is performed in English 4 2 Labeling is made on the flaw detector casing by polygraphic technique 4 3 Pattern approval mark is made on the flaw detector electronic unit by at least two seals made on screws of casing cover ...

Page 50: ... WLD100K3 43DA0 1 pc Eddy current probe WLD100K5A 5 2 35DA0 1 pc Eddy current probe WLD100K5A 5 2 43DA0 1 pc Eddy current probe WLD100K5A 5 2 35DAT0 1 pc Eddy current probe WLD100K5A 5 2 43DAT0 1 pc Charger Mascot Type 2542 1 pc Reference standart RS 2353 1 3N Fe with gaps 4 0 5 mm 2 pcs Bag 1 pc Case 1 pc Tansport case 1 pc Operating manual for Eddycon C 1 copy Quick start guide 1 copy Operation ...

Page 51: ...USE 8 1 SINGLE COIL PROBE 8 1 1 Connect the ECP to the flaw detector using a connecting cable 8 1 2 Select parameter PROBE Single type in the TEST menu 8 1 3 Set the ECP frequency in a range specified in the registration certificate for the ECP 8 1 4 Set the ECP drive not more than 2 V 8 1 5 Press key to select the capacitor 8 1 6 Place the ECP to the flaw free area of a calibration block 8 1 7 Pr...

Page 52: ... 1 Connect the ECP to the flaw detector using a connecting cable 8 2 2 Select parameter PROBE Reflection or Bridge type in the TEST menu 8 2 3 Set the ECP frequency in a range specified in the registration certificate for the ECP 8 2 4 Set the ECP drive not more then recommended in a registration certificate for the ECP 8 2 5 Place the ECP to the flaw free area of a calibration block 8 2 6 Press k...

Page 53: ...n a registration certificate for the ECP 8 3 6 At ROT PRESENT position set up On In displayed menu choose the type of the rotary scanner and press key 8 3 7 At RРМ position firstly set the min rounds 600 8 3 8 Press the switched on button on the case of the rotary scanner The ECP should be in the air 8 3 9 To set the scanner rounds properly press key and wait for the end of the procedure 8 3 10 Pr...

Page 54: ...ting The filter is set by trial and error 8 3 19 During the ECP rotation in a hole perform the ALARM setup Visually set the ALARM relative to the signal from a defect After the ALARM was properly set up the light alarm will be triggered on the flaw detector keypad at detecting the defect digital indicators on the display and sound alarm if it has not been turned off in SETTINGS menu ...

Page 55: ...ndition of controls and indicators are checked during the maintenance inspection 9 3 The maintenance inspection includes an external examination and is performed by attending personnel before starting the flaw detector electronic unit operation 9 4 Replacement of the battery pack 9 4 1 Unscrew two screws item 1 Figure 39 Figure 39 9 4 2 Open the contact terminal item 1 Figure 40 pressing the clip ...

Page 56: ...Charge the storage battery When the instrument is switched On the inscription Storage battery needs charging is displayed The storage battery is discharged Charge the storage battery ATTENTION THE FLAW DETECTOR MUST BE SWITCHED OFF WHEN NON TYPICAL IMAGES APPEAR ON THE FLAW DETECTOR SCREEN AND SOFTWARE PROGRAMS BUZZ IF REPEATED SWITCHING ON OF THE FLAW DETECTOR NOT EARLIER THAN IN 3 MINUTES DOES N...

Page 57: ...ct of precipitations with a possibility of transshipping from one type of transport to the other Air shipments are allowed only in the pressurized modules Arrangement and fixation of boxes in transport vehicles should prevent them from displacement shocks or impacts 11 3 Storing the flaw detector in one room with acids reagents paints and other chemicals and materials the vapors of which may have ...

Page 58: ...tor with serial number _________ meets the requirements of specification ЕС 14327992 03 13 RE and is considered to be suitable for operation Person responsible for acceptance _______________ _________________________ S P Date of manufacture ________________20____ ...

Page 59: ...rate 2 3 10 А 4 After accelerated charging the trickle charge mode is activated 5 Electric supply of charging device AC mains voltage from 100 to 240 V and frequency of 47 63 Hz Current consumption at full load up to 0 9 A 6 Cable length of charging device no more than 2 0 m Lemo EGG 1B 304 CLL Front view 1 Charging device 2 3 Charging device 4 Sync signal output Figure A 1 Soldering pattern of ch...

Page 60: ...nd austenitic steels 2 SS650K06DA0 Ø 6 500 1500 Ø 13 35 3 SS400K07DA0 Ø 7 300 600 Ø 13 35 4 SS300K08DA0 Ø 8 200 400 Ø 13 35 5 SS340K09DA0 Ø 9 250 400 Ø 13 35 Surface and subsurface cracks pores corrosive defects in aluminum alloys ferromagnetic and austenitic steels and etc 6 SS170K13DA0 Ø 13 100 250 Ø 13 35 7 SS50K15DA0 Ø 15 50 150 Ø 15 50 8 SS10K33DA0 Ø 33 1 100 Ø 33 50 9 SU450K3А6х8A0 Ø 6 8 900...

Page 61: ...d austenitic steels and etc 15 SU300K08DA0 Ø 8 100 450 Ø 35 150 16 SU350K6x0 5DA1 6 0 5 350 600 Ø 12 61 Testing for the presence of surface cracks in a metric thread with a step of 2 mm made on products of ferromagnetic material Used with the SKV MR 01 scanner 17 SU350K6x0 5DA2 6 0 5 350 600 Ø 12 61 Testing for the presence of cracks in a metric thread with a step of 4 mm made on products of ferro...

Page 62: ...ic thread with a step of 5 08 mm made on products of ferromagnetic material Used with the SKV MR 05 scanner 21 RO1 7M5A9DFD0 Ø 9 1500 2500 Ø 9 55 Detection of surface defects in parts holes made of aluminum alloys ferromagnetic and austenitic steels 22 SU30К16DD0 Ø 16 30 200 Ø 50 55 Special purpose probe for detection of surface cracks in fencing epees made of austenitic steels probes in a protect...

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