PCE Instruments PCE-USC 20 Operating Manual Download

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Chapter 9 Maintenance and Repair

9.1 Environmental Challenge

(1) Strictly avoid collision, heavy dust, humidity, intense magnetic field, grease dirt.

(2) Forbid cleaning housing with dissolved matters.

9.2 Battery Charge

Battery status on LED screen demonstrates the battery real-time voltage situation.

When the battery voltage is too low, namely the battery condition symbol is under

voltage status (from green into yellow), you should charge the instrument as soon

as possible.

Charging methods are as follows (it can be charged whenever power on or off).

(1) Connect the power plug of the adapter to the charge socket.

(2) Connect the power adapter to 220V/50Hz commercial power, then the charge

indicator light (green) turns on.

(3) It needs about 4.5 hours to charge the battery fully.

(4) Pluck the charge plug and it is finished.

Note:

①

input voltage of power adapter is 220V AC, output voltage is 15V

DC, the maximum charging current is 2000mA, the maximum
charging time is 6h.

②

PCE-USC 20

is equipped with the Lithium battery. Please charge

the battery in time when the under voltage symbol appears. It will
damage the battery by over discharge.

③

PCE-USC 20

can work while charging.

9.3 Battery Replacement

Renewal battery method is as following.

(1) Screw off the two fast fixed nuts located in the battery cover at the back of host

Equipment.

(2) Remove the battery cover, take out the invalid battery.

(3) Install the new battery according to the original form. (Please aim at the power

supply faucet first, and then install slowly.)

(4) Firmly press the battery with hands, turn on the power switch to check if

Summary of Contents for PCE-USC 20

Page 1: ...de US 1 Tel 561 320 9162 Fax 561 320 9176 info pce americas com www pce instruments com english www pce instruments com PCE Instruments UK Ltd Units 12 13 Southpoint Business Park Ensign way Hampshire Southampton United Kingdom SO31 4RF From outside UK 44 Tel 0 2380 98703 0 Fax 0 2380 98703 9 info pce instruments com ...

Page 2: ...f 12 4 6 Software Update and Return to Factory Default Settings 12 4 7 Important Basic Setting 13 Chapter 5 Menu Introduction 15 5 1 Normal Menus 15 5 2 Special Menus 31 Chapter 6 Function Instruction 32 6 1 Calibration Function 32 6 2 DAC Function 36 6 3 AVG Function 39 6 4 Envelope Function 40 6 5 Curve Surface Amend 40 6 6 Welding Graphic Illustration 41 6 7 Series Store Function 42 6 8 Peak Ho...

Page 3: ...r Operators 53 8 3 Technical Requirements for Detection 53 8 4 Influence Factors of the Detection Precision 54 Chapter 9 Maintenance and Repair 58 9 1 Environmental Challenge 58 9 2 Battery Charge 58 9 3 Battery Replacement 58 9 4 Trouble Elimination 59 9 5 Safety Tips 59 Appendix 61 Appendix Ⅰ User Guidelines 61 Appendix Ⅱ Range and PRF 62 Appendix Ⅲ Interfaces 62 Appendix Ⅳ Definition of Measure...

Page 4: ... as operated in in service safe inspection and life appraisal such as aerospace railway transportation boiler and pressure vessel safety check in service and life assessment 3 86 is a high tech instrument which launched by PCE Instruments Full consideration of ergonomic made for instrument s appearance its structure is strong and light easy and comfort to take as well as shockproof Scientific and ...

Page 5: ...ection Range 0 5mm 9999mm steel longitudinal wave adjustable continuously switchable steps PRF range 125mm 1KHz 125mm range 1400mm 250Hz 1400mm range 9999mm 40Hz Sampling Rate 400MHz hardware real time sampling Velocity 1000m s 15000m s adjustable continuously switchable steps Display Delay 10mm 1000mm adjustable continuously switchable steps Probe Delay 0μs 199 9μs Damping 50Ω 100Ω 200Ω 500Ω Gain...

Page 6: ...tery Language Chinese English Waterproof Level IP54 standards 2 2 Features and Functions 2 2 1 Features 1 Leading technical target abundant applied assistant function 2 Intelligible setting of keys and menu easy to operate 3 400 MHz real time hardware sampling high fidelity echo pulse 4 Broadband and amplifying circuit with low noise selectable damping excellent matching with low or high frequency...

Page 7: ... the flaw equivalent sizeΦautomatically 3 RF Displaying Function It can display the real original waveform which is convenient for the user to analyze the details of the echo and help to analyze the flaw qualitatively 4 Curve Surface Amending Function It can amend the test result of the arc surface automatically 5 Peak Holding Function Assist to record the maximum echo 6 Envelope Function Record t...

Page 8: ...ased on detecting parameters and data automatically The detection reports contain detailed detecting parameters waveform graphs and detailed echo data which can be directly printed by the connected printer or stored in the computer 13 Continuously Storing and Replaying Function It can record the dynamic waveform while detecting which makes the recorded data more detailed The menu settings are anal...

Page 9: ...fer to Figure 3 1 Figure 3 1 Overall Structure 3 1 1 Panel Keys 1 Power Key it is used to turn on off the power supply by long press for about 2s Represented by Power below 2 Gain Adjusting Keys It displays the gain value and the gain step value in the upper left corner of the Gain Adjusting Keys Main Menu Paging Keys Submenus Main Menus Main Menu Selecting Keys Submenu Selecting Keys Parameter Ad...

Page 10: ...ain Menu Paging Keys main menu page up key Press it for entering the up page of the main menu Represented by PgUp below main menu page down key Press it for entering the down page of the main menu Represented by PgDn below 4 Submenu Selecting Keys it has two functions as follows Represented by below a Select submenus first press for the submenu being selected b Switch parameter step value or subme...

Page 11: ...setting parameters or function controlling Each page of the submenus has four selections and each selection has its relative selecting key The words of the current selected submenu are yellow and the background is deep blue while the words of the un selected menu are white and the background is light blue 3 2 Interfaces The instruction of the instrument interfaces is as follows Refer to Figure 3 3...

Page 12: ...crews which are used for quickly locking and opening the battery cover i nstrument back bracket It is used for supporting the instrument in a sloping way which is available in opening and closing Figure 3 3 Interfaces 3 3 Waveform and Data Display The instruction of the waveform and data display is as follows Refer to Figure 3 4 ...

Page 13: ...se refer to appendix Ⅳ for their detailed definition 4 Gate a There are two gates which are Gate A and Gate B It is only one gate used in the common testing task and usually the default gate is Gate A b The function of the gates is to test the selected echo signal or alarm In the testing task there may appear many echo signals in the instrument screen at the same time You can move Gate A to select...

Page 14: ...se use batteries manufactured for matching instrument from factory 1 Insert battery battery compartment is in the back side of instrument use screwdriver to loosen the cover of battery compartment put battery into compartment close the battery compartment then screw down bolts 2 Battery power indicator there are five grids at lower right corner of display screen to show power supply condition if t...

Page 15: ... If the power is insufficient the instrument will power off automatically after alarming for one minute 4 Working set the instrument parameters or do the testing 5 Powering off press Power key for some time to shutdown the instrument normally the current settings are saved Note it is in the abnormal shutdown state when the power is cut off suddenly while testing the current settings may be not sav...

Page 16: ... Self checking shows irregular turn off instrument then start up again if it still can not pass the Self checking means software halted return to state of factory release and update the system to reach regular working condition 4 7 Important Basic Setting 4 7 1 Working Mode Setting Set working mode of the instrument single element or double elements Operating press PgUp or PgDn or key for PULS mai...

Page 17: ... will be displayed by percentage from total screen height meantime any wave signals lower than restraint level height will be shielded and can not be displayed For instance adjust restraint level to 20 the screen only display signals with height more than 20 0 means instrument under non restraint condition Instruction if restraint level be higher the dynamic range of instrument will be smaller the...

Page 18: ...L Material Velocity 1000 15000m s the default is 5920m s Press corresponding submenu selection key to switch between rough adjustment and fine adjustment press key to increase or key to decrease the value 1 3 D DELAY Display Delay 10 2000mm the default is 0 00mm Press corresponding submenu selection key to switch between rough adjustment and fine adjustment press key to increase or key to decrease...

Page 19: ... damping value 1 2 POWER high low the default is low Adjust transmit power chose low when higher resolution is needed while high is suitable for huge workpiece or through transmission technique Press corresponding submenu selection key or key to switch between high and low 1 3 DUAL off on the default is off off single element mode on double elements mode Press corresponding submenu selection key o...

Page 20: ...n key to switch between rough adjustment and fine adjustment press key to increase or key to decrease the value 1 3 ANGLE Refraction angle 0 85 Press corresponding submenu selection key to switch between rough adjustment and fine adjustment press key to increase or key to decrease the value Note it is invalid when the normal probe is selected 1 4 X VALUE Distance between front edge of angle probe ...

Page 21: ...he first echo press key once Move gate A to capture the second echo press key once again If successful the calibration has been done 2 1 CAL SET Select the item needs to be calibrated angle K value Press corresponding submenu selection key or key to select calibration items 2 2 HOLE DEPTH Range 0 70mm the default is 20mm Press corresponding submenu selection key to switch between rough adjustment ...

Page 22: ... set to on Press corresponding submenu selection key or key to select working mode of Gate A 1 2 a START 0 00 9999mm the default is 35 00mm when positive or negative is selected Press corresponding submenu selection key to switch between rough adjustment and fine adjustment press key to increase or key to decrease the value 1 3 a WIDTH 0 020 9999mm the default is 25 00mm when positive or negative ...

Page 23: ...mode 3 2 HIDE GENERATRIX Set the generatrix hide or not yes no the default is no Press corresponding submenu selection key or key to set 3 3 COMPENSATE Set the surface compensating value Press corresponding submenu key to select press key to increase or key to decrease the compensating value 3 4 FLAW EQUIVALENT Display the flaw equivalent value 4 1 DAC MODE amend Select the DAC MODE amend Press co...

Page 24: ...nes the default is 5 0mm Press corresponding submenu key to switch step press key to increase or key to decrease the value 2 4 PLOT Press corresponding submenu key to confirm press key to plot automatically 3 1 AVG MODE 3N PLOT Select the AVG MODE 3N PLOT Press corresponding submenu selection key or key to select AVG mode 3 2 AVG ECHO Display measurement dot number 20 at most Press corresponding s...

Page 25: ...e 1 3 SURF AMEND 10 2000mm or flat the default is flat Press corresponding submenu key to select or switch step press key to increase or key to decrease the amplitude value It is invalid when the normal probe is selected 1 4 PEAK HOLDING off on the default is off on A purple will be displayed on top of the maximum echo inside the gate if a new maximum echo appears in the gate then the will move to...

Page 26: ...e default is 100mm Input the width of groove Press corresponding submenu selection key to switch step press key to increase or key to decrease the value 1 4 REFRESH Press to generate the flaw position indication diagram Press corresponding submenu key to select press key to confirm refresh 5 1 10 STORE Menu The main menu STORE contains two pages submenus Refer to Table 5 10 Table 5 10 STORE Menu N...

Page 27: ... DELETE when there has stored settings otherwise displays SAVE Press corresponding submenu key to select SAVE or DELETE press key to carry out 2 1 DATA ID The DATA ID contains 1 30 ID test data will be stored in the selected channel Press corresponding submenu selection key to switch between CHANNEL ID and DATA ID press key to increase or key to decrease the number 2 2 REMARKS Input letters or num...

Page 28: ...elect press key to increase or key to decrease the value 1 2 START STOP Control the start stop of recording Press corresponding submenu key or key to switch between RECORDING and STOPPED 1 3 SAVE Transfer the stored data to the U disk After inserting U disk press corresponding submenu key to select press key to confirm 1 4 REPLAY Replay recorded file Press corresponding submenu key or key to switc...

Page 29: ...key or key to select working mode of Gate B 1 2 b START 0 00 9999mm the default is 14 00mm when positive or negative is selected Press corresponding submenu selection key to switch between rough adjustment and fine adjustment press key to increase or key to decrease the value 1 3 b WIDTH 0 020 9999mm the default is 10 00mm when positive or negative is selected Press corresponding submenu selection...

Page 30: ...A Press corresponding submenu key or key to switch between Gate A and off Note this function can only be used when Gate A logic is not off 1 4 ENVELOPE on off the default is off on enable envelope function off disable envelope function Press corresponding submenu key or key to switch between on and off 5 1 14 MEAS DOT Menu The main menu MEAS DOT contains one page s submenus Refer to Table 5 14 Tab...

Page 31: ...khaki background green waveform 4 black background yellow waveform 5 green background yellow waveform 6 black background red waveform Press corresponding submenu key to select then press key to choose color mode 1 3 LIGHT low middle high the default is high Press corresponding submenu key or key to switch among the three light modes Note the higher the brightness is the greater the power consumes ...

Page 32: ... alarm mode alarm off the default is off alarm sound alarm will act if it satisfies the alarm condition Press corresponding submenu key or key to switch between alarm or off 1 4 RESTRAINT Range 0 50 the default is 0 To eliminate unwanted waves such as structural noise from detected material or other clutter waves Any wave which is lower than restraint value will be eliminated else remains Press co...

Page 33: ...corresponding submenu key or key to switch between printers 1 3 DATE The format is yyyy mm dd for example 2011 08 09 means August 9 2011 Press corresponding submenu key to highlight the digit to be edited press key to increase or key to decrease the value press repeatedly to switch among year month and date Move the highlighted cursor out unit it disappears to complete data setting 1 4 TIME The fo...

Page 34: ...r save data to U disk or other storing devices by image format 3 P TEST test echo spectrum features and display It is available only in the condition of rf is selected in the submenu RECTIFY 4 COPY copy data to the U disk or other storing devices 5 Ver 1 10 software update key Note press PgUp and PgDn keys at the same time to enter the special menus After inserting the U disk with update software ...

Page 35: ...lizes automatic calibration operation automatically Calibration principle the instrument makes sound velocity and probe delay calculations through arrival time T1 and T2 of two echoes B1 and B2 with known sound path S1 and S2 Taking the CSK ⅠA test block as an example we will introduce three kinds of calibration methods as follows 6 1 1 Auto calibration of Longitude wave incident zero point and Ve...

Page 36: ...then 0 is turned to 1 in CAL submenu Figure 6 2 Move Gate A to Capture the First Bottom Echo 5 Move Gate A to capture the second bottom echo refer to Figure 6 3 Enter the CAL submenu press key to confirm echo 2 after calibration completed being displayed in the screen 1 is turned to 0 in CAL submenu then the delay calibration value will display in CAL submenu and also in P DELAY submenu Figure 6 3...

Page 37: ...eflected echo of R50 and R100 arc surface 3 Enter the CAL main menu select speed delay calibration S REF 1 50 0mm S REF 2 100 0mm Figure 6 4 Speed Delay Auto Calibration of Angle Probe 4 Move Gate A to capture the echo of R50 arc refer to Figure 6 5 Enter the CAL submenu and press key to confirm then echo1 is recorded Figure 6 5 Move Gate A to Capture the Echo of R50 arc 5 Move Gate A to capture t...

Page 38: ...obe tightly coupled on the test block Refer to Figure 6 7 Figure 6 7 Angle Auto Calibration of the Angle Probe 2 Enter the CAL main menu choose CAL SET angle k value HOLE DEPTH 30 0mm HOLE DIAM 50 0mm Adjust gain appropriately and move the probe to find the highest echo of 50 0mm hole 3 Move Gate A to capture the highest reflected echo of 50mm hole refer to Figure 6 8 Enter the CAL submenu and pre...

Page 39: ...operation steps are as follows 1 Enter the DAC menu choose DAC MODE record 2 Make the probe tightly coupled on the test block CSK ⅢA Refer to Figure 6 9 3 Put probe in position 1 aim at the first datum hole 10 0mm depth move probe to seek the highest amplitude echo 1 of 10 0mm depth hole and adjust gain to set amplitude to 80 Move Gate A to capture the echo 1 refer to Figure 6 10 select DAC ECHO a...

Page 40: ...37 Figure 6 9 the Operation Diagram of DAC Recording Figure 6 10 the First Section of DAC Curve Figure 6 11 a Completed DAC Curve Position1 Position3 Position 2 ...

Page 41: ... DAC is made on test block with highly polished surface surface compensation must be made according to surface coupling state before flaw detect input related compensate dB value in COMPENSATE submenu In DAC application mode instrument can automatically calculate flaw equivalent and display on upper side of screen as DAC dB 6 2 3 DAC Amendment Curve amend if there is inflexion point on DAC due to ...

Page 42: ...tor is called distance amplitude equivalent size curve in German called AVG in English called DGS 6 3 2 AVG Making Operating Steps taking 2 5P20 normal probe CS 1 5 test block 200 2 flat bottom hole as an example 1 Set instrument and probe parameters 2 Calibrate instrument and probe 3 Make the probe tightly coupled on the CS 1 5 block move probe to seek the highest echo of flat bottom hole refer t...

Page 43: ...ade when coupling condition changes different surface condition of test block and work piece 6 4 Envelope Function 6 4 1 Summarize Envelope means profile of echo peak track when probe moves on workpiece it is given different color to distinguish from echo itself According to envelope shape users can easily find the highest echo and also make qualitative analysis of flaw properties This function ca...

Page 44: ...on Steps 1 Enter WELD GRAPH main menu 2 Select weld type X mode V mode or close welding graphic illustration function weld mode means groove mode 3 Input weld width value namely groove width 4 Input probe position namely distance from probe front edge to weld center it changes along with the probe migration Therefore input the newest probe position timely when using this function 5 Press correspon...

Page 45: ...l disappear after turning off or cut down electricity so transfer it to U disk timely 4 SAVE press this key to transfer recorded document in U disk or other storage 5 REPLAY play recorded document Note the longest time for recording is about half an hour the instrument only store one record document each record operation will overwrite previous recorded data Figure 6 15 Series Store 6 8 Peak Holdi...

Page 46: ...commonly used in forging test 6 9 2 Operation Steps 1 Move gate and capture under tested echo 2 Choose AUTO SETUP main menu press Auto Gain submenu related key instrument makes gain control automatically to adjust the highest echo amplitude within gate reaching 80 height of vertical coordinates this height can be set in parameters by operator only need to adjust submenu AGC 6 10 Rectification 6 10...

Page 47: ...preserve parameter with high frequency usage in different channel when changing flaw detect condition user can directly recall corresponding parameters this will improve working efficiency and avoid misoperation 6 11 2 Operation Steps 1 Enter CHANNEL ID submenu under STORE main menu menu interface as follows Refer to Figure 6 16 Figure 6 16 Parameter Store and Recall 2 Press key to select CHANNEL ...

Page 48: ... instrument as important content of flaw detection report The data may be directly replayed in the instrument for viewing also can be kept in computer for unified store through communication interface 6 12 2 Operation Steps 1 Enter STORE main menu select the top submenu DATA ID menu interface as follows Refer to Figure 6 17 2 Press key to select DATA ID Figure 6 17 Data Store and Replay 3 Store Se...

Page 49: ... recalled 5 Deletion Select DELETE sub menu press key then stored waveform data of current channel is deleted Note as to SAVE DELETE submenu the default is DELETE when there has data stored in DATA ID otherwise the default is SAVE ...

Page 50: ...E USC 20 Driver in installation document double click setup exe file and complete drive installation 2 Then click Data View in installation document double click setup exe file When installation is finished a logo of Data View will appear on computer desktop 3 Turn on the power of instrument connect instrument with computer connect method one end of USB communicate cable connects USB interface of ...

Page 51: ...n open the data documents in the computer or the records in the instrument Save save modified data to the original file Save as save modified data to a new file Print print the results of the data Print Preview display the effect of print Print Settings set print options Exit exit the software 2 View menu refer to Figure 7 2 Figure 7 2 View Menu Toolbar show and hide the toolbars ...

Page 52: ...nt Language menu refer to Figure 7 4 Figure 7 4 Print Language Menu Chinese set print language to Chinese English set print language to English 5 Video menu refer to Figure 7 5 Figure 7 5 Video Menu Start Start real time recording Stop Stop recording 7 3 2 Display Interface Structure It mainly contains Waveform Display Data Recall Config Result Gate A Gate B and Information Entry etc Refer to Figu...

Page 53: ...d of the gate by dragging the mouse The corresponding results are displayed in the results of Gate A and B 2 Data Recall Select the DATA ID No to be recalled click data replay to display the data in the DATA ID on corresponding position of the software 3 Config It displays configuration values corresponding to current data ID 4 Gate A It displays start point width and threshold of Gate A 5 Gate B ...

Page 54: ...ter input click OK button to confirm then the information will be saved to the file if you close the window before confirming it will not be saved 7 Unit Select the unit or change the display unit 8 SCALE Select the display mode of the baseline 7 4 Test Report This instrument provides four kinds of information for test reports as follows 1 Through PRINT menu Special menu copy screen graphics and m...

Page 55: ...en view them via online software 3 In SAVE submenu main menu SERIES STORE transfer dynamic echo recordings to U disk and then view them via online software 4 After the connection between matched USB cable and PC detection information on the software interface can be part of test report ...

Page 56: ...ut the method of flaw detection Normal training includes following contents 1 ultrasonic propagation principles 2 influence to test materials sound velocity 3 sound wave characteristic of different materials interface 4 influence from sound attenuation and surface condition to tested materials Lack of these knowledge may cause unforeseeable and wrong flaw detect results please contact related NDT ...

Page 57: ...equired for accurate measurement results Tested materials made by steel even various kinds of alloy components changes of sound velocity are very little and it will not influence test precision but for high quality measuring In other materials e g nonmetal or plastic changes of sound velocity may be very large so influence measuring precision 8 3 3 Surplus Wall Thickness Measurement For surplus wa...

Page 58: ...value is obtained by calculating the velocity of the referenced test blocks with equivalent velocity to that of the workpiece 8 4 2 Temperature Influence Material sound velocity will change along with material temperature If the instrument is calibrated in a relative low environment temperature but applied in a relative high environment temperature in this situation the test result will deviate fr...

Page 59: ... obtain the concentrated acoustic beam as narrow as possible in the flaw area 2 Echo Comparison Method A natural flaw reflection echo is usually lower than that of an artificial flaw e g similar size disc flaw This situation is caused by rough surface of natural flaw or an unfavorable angle coming out when sound beam transmits onto flaw If it is not considered in the natural flaw evaluation there ...

Page 60: ...ery small This may lead to danger of underestimating natural flaw size so estimate the influence of attenuation in evaluation and take it under consideration when necessary If surface of tested objects is rough a part of incident sound energy will be lost due to beam scattering on object surface this affects detection When scattering gets stronger reflection echo gets lower leading to bigger error...

Page 61: ...icator light green turns on 3 It needs about 4 5 hours to charge the battery fully 4 Pluck the charge plug and it is finished Note input voltage of power adapter is 220V AC output voltage is 15V DC the maximum charging current is 2000mA the maximum charging time is 6h PCE USC 20 is equipped with the Lithium battery Please charge the battery in time when the under voltage symbol appears It will dam...

Page 62: ...ecurity standards its application must satisfy external environment condition it is also required for operators to have corresponding technical background to guarantee safe operation Before application please read following safety tips Note this instrument is a nondestructive inspection instrument applying to materials inspection forbidden to use as medical instrument It is only limited to laborat...

Page 63: ...er supply take battery out if necessary send it to assigned service place for maintenance 1 Instrument has obvious mechanical damage for example serious extrusion or collision in transportation 2 Instrument keyboard or screen display abnormal 3 Storage in high temperature high moisture or corrosive environment for long time ...

Page 64: ...pend on maintenance card user reserve union or purchase invoice copy to contact subsidiary company maintenance station in each area for maintenance within the warranty period can t bring forth maintenance card or purchase invoice copy We will calculate the warranty period in accordance with factory warranty for a period of one year 3 Beyond warranty period failure of our product service stations a...

Page 65: ...aces PCE USC 20 is equipped with three USB interfaces including A and B type and can realize the function of communicate with host PC and control serial printer printing flaw detect report The definition of interfaces is as follows Interface definition Pin NO Instruction Input Output Type 1 USB Output USB 2 ALARM Output TTL ...

Page 66: ...hat is actual value of range Da Depth from the test piece surface the probe contacted side to the reflector represented by the first echo in Gate A Db Depth from the test piece surface the probe contacted side to the reflector represented by the first echo in Gate B Pa Projection distance from the probe s front edge to the reflector represented by the first echo in Gate A Pb Projection distance fr...

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