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EDDYSENSOR Operating Manual

Safety information

ESD instructions

• Ensure that the power is off and disconnected from the

equipment (pull out the plug) before opening it

• Do not use the equipment with the housing open

• Repair work must only be carried out by authorized

specialists

• Use only original spare parts and accessories

• Only trained personnel may carry out service and

maintenance

• Any modification carried out without the agreement of the

manufacturer invalidates the guarantee

Safety instructions

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Summary of Contents for EDDYSENSOR

Page 1: ...Operating manual EDDYSENSOR Doc no LAB 5329 Release 26 8 97 Release 4 ...

Page 2: ... the PRÜFTECHNIK policy of continuous product development 1997 PRÜFTECHNIK AG No copying of this informa tion in any form whatsoever may be undertaken without express written permission of PRÜFTECHNIK PRÜFTECHNIK NDT GmbH Fischerfleck 8 D 85737 Ismaning Germany Telephone 49 0 89 9 96 16 0 Telefax 49 0 89 96 79 90 eMail info pruftechnik com ...

Page 3: ...filter settings for slow applications 7 Graph of the F1 and F2 filter settings for fast applications 8 Back module 9 Connection of display device 9 Digital I O 9 Test signal suppression 9 Connection of PLC or similar 10 Example of use 10 1031 Front End Unit 11 Front module 11 Setting the gain 11 LED monitoring function 11 Functions of the Gain switch 12 Summary of the displays 12 Manual gain setti...

Page 4: ... module 22 PCB showing modification status d 22 System error from modification status e onwards 22 Encoder switch up to modification status d 22 Encoder switch from modification status e onwards 22 Encoder socket pin assignment 23 Output sockets 24 Fuses up to modification status d 25 Fuses from modification status e onwards 25 Changing a fuse 25 LAB 1110 connection box 26 Power unit 27 Function 2...

Page 5: ...et output 34 34 34 34 34 Alarm unit via a PLC 34 Alarm unit via a time lag relay 34 Alarm unit via a time lag relay using the internal current supply 34 Locating and changing fuses 35 Delay unit 35 PCB of the back module 35 Fuses up to modification status d 35 Fuses from modification status e onwards 35 Replacing the fuses 35 Power unit 36 Fuses 36 PCB of the front module 36 Replacing the fuses 36...

Page 6: ...N 50082 2 Operative restrictions Using this equipment in a residential area can lead to electro magnetic interference and therefore requires special authori zation from the national regulatory agency for post and tel ecommunications BAPT Installation site requirements Installation instructions Temperature range see Technical Data Flat level installation surface Equipment must be far enough away fr...

Page 7: ...before opening it Do not use the equipment with the housing open Repair work must only be carried out by authorized specialists Use only original spare parts and accessories Only trained personnel may carry out service and maintenance Any modification carried out without the agreement of the manufacturer invalidates the guarantee Safety instructions ...

Page 8: ...vi EDDYSENSOR Operating Manual Exchanging the plug in modules ...

Page 9: ...Unit in the left hand position and the Power Unit in the right hand position For safety reasons the back module of the Power Unit is supplied immovably as sembled in the table top housing LAB 1004 The op tional unit is the Delay Unit in the middle position The modules and their positions are shown in the diagram above EDDYSENSOR System Diagram Output signal to peripherals Input signal from test co...

Page 10: ...of the EDDYSENSOR IMPORTANT Whenever a module is removed or inserted ensure that the power is OFF and the mains plug pulled OUT Also the ESD instructions given on the separate sheet at the front of this handbook must be observed when any work is carried out on the equipment Voltage switch between 115V 230V Socket for power supply Delayed and undelayed signal outputs for the configuration with the ...

Page 11: ... level is indicated by green LEDs and above it by red LEDs Front Module Gain display Rocker switch to set the gain between 0 and 55 dBs Set the gain required for the signal on the display on the front panel of the unit to between 0 and 55 dBs using the rocker switch Set the gain high enough so that the smallest detectable defect reaches approx 60 on the bar graph display but low enough to prevent ...

Page 12: ...ed over a longer time period the filter has to be set relatively wide in order not to damp or suppress signals which occur in the acceleration phase F3 is a fixed bandwidth filter that can be switched between the two speed ranges 1 60 m min and 30 1000 m min The filters are selected by turning the hex switches on the printed circuit board of the front module see diagrams below and on next page The...

Page 13: ...s are suppressed while the defect signal itself remainsundistorted Foroptimumresultsthebandpassshouldbeaswide as possible but as narrow as necessary To give a reasonable bandwidth we recommend VLine 4 Switch setting HPH HPL VLine x 2 Switch setting LPH LPL Filter to speed relationship for filters F1 and F2 PCB Front panel Side view of the printed circuit board PCB LPH HPH HPL Low pass filter e g f...

Page 14: ...6 EDDYSENSOR Operating Manual Graph of the F1 and F2 filter settings for slow applications Speed range 0 300 m min ...

Page 15: ...7 EDDYSENSOR Operating Manual Graph of the F1 and F2 filter settings for normal applications Speed range 20 1800 m min ...

Page 16: ...8 EDDYSENSOR Operating Manual Graph of the F1 and F2 filter settings for fast applications Speed range 150 8000 m min ...

Page 17: ... signal input for end signal suppression in offline applications I O socket for the coil Connection of display device Digital I O Toconnectperipheraldevicessuchasarecorder bargraphoroscilloscope on which the signal is graphically displayed use the socket Analog Signal 0 10V RO 100 Ohm Socket for output signal Analog signal 0 10 V 2 3 4 5 1 6 The pins are allocated as follows Pin Use 1 Test signal ...

Page 18: ...fect pole 60V 100mA Connection of PLC or similar To connect equipment such as a PLC an alarm unit or a switch use the Digital I O socket with a minimum signal duration of 200 ms Test signal suppression The pins are allocated as follows Pin Use 1 Test signal suppression pole 5 30V 4 Test signal suppression pole 5 30V A voltage of 5 30 V on this socket can be used to suppress the testing for example...

Page 19: ...odule There are three LEDs which indicate Defect LED defects i e when the signal from the coil exceeds 50 of the bar graph display Coil Error LED coil defects such as a broken coil connection this signal is also available as an output continuous error Overload LED any overload conditions e g when the gain is set too high LED monitoring function The bar graph display shows the peak amplitude of the...

Page 20: ...rs to the right of each digit The default position of the Gain switch is that of the gain setting How to make the required settings is described below Set the gain required for the signal on the front panel display to between 0 and 55 dBs using the rocker switch Set the gain high enough so that the smallest detectable defect reaches approx 60 on the bar graph display but low enough to prevent nois...

Page 21: ... the acceleration phase F3 is a fixed bandwidth filter that has two optional speed ranges 1 60 m min and 30 1000 m min See the section Filter settings for F3 below No testing can be carried out while the filters are being set The filters F1 and F2 are set using the Gain switch on the front module see module diagrams on previous page By pressing the Gain switch continuously in the default Gain mode...

Page 22: ...lease to go into the high pass setting when the display shows H P Press the Gain switch for a further second and release to go into the low pass setting when the display shows L P The display then shows the current LP setting e g 1 1 and the bar of lighted red LEDs represents the scale of the LP filter setting selected see diagrams below Press either to increase the value or to decrease the LP set...

Page 23: ...low The precise setting can be determined from the filter table Ideally the filter settings should be established using a standard defect and test bench The settings should be made so that any interference signals are suppressed while the defect signal itself remains undistorted For optimum results the band pass should be as wide as possible but as narrow as necessary To give a reasonable bandwidt...

Page 24: ...6 6 00 52 00 10 2 89 1 17 148 7 7 00 60 00 12 102 20 172 8 8 00 69 00 13 7 118 23 198 9 10 00 95 00 17 1 163 28 272 10 12 00 121 00 20 5 207 34 346 11 16 00 164 00 27 4 281 46 468 12 21 00 207 00 36 355 60 592 13 28 00 276 00 48 473 80 788 14 37 00 372 00 63 4 637 106 1062 15 49 00 492 00 84 843 140 1406 16 65 00 648 00 111 1110 186 1851 17 87 00 873 00 149 1496 248 2494 18 116 00 1 158 00 198 198...

Page 25: ...ket for the coil Connection of display device To connect peripheral devices such as a recorder bar graph or oscilloscope on which the signal is graphically displayed use the socket Analog Signal 0 10V RO 100 Ohm 2 3 4 5 1 6 Digital I O BNC socket for output signal Analog signal 0 10 V Front EDDYSENSOR from above Back FI1031BAfff The pins are allocated as follows Pin Use 1 Test signal suppression p...

Page 26: ...tion min 200 ms Internal electronic switch Application example alarm lamp Pin Use 3 Defect pole 60V 100mA switching duration min 200 ms 5 Defect pole 60V 100mA Pin 3 Pin 5 Max 60V 100mA A voltage of 5 30 V on this socket can be used to suppress the testing for example in offline applications for end signal suppression The pins are allocated as follows Pin Use 1 Test signal suppression pole 5 30V 4...

Page 27: ...ctivated after the respective adjustable distance or time delays These delays are set using the OUT1 and OUT2 switches on the printed circuit board The duration of the delayed signal is set on the WIDTH The defect channels are assigned the desired outputs via the Channel switch There is also a switch on the PCB which is used to select between ENCODER and TIME depending on whether the application r...

Page 28: ...ion Switch to select between encoder and time Prescaler Switches to set the delay Switches to set the signal duration Switch to select defect type always set to WO for this equipment Front module Upper PCB The duration of the pulses ranging from 100ms to 10s can be selected using the WIDTH switches on the right of the row together with the scaling factor 1s 0 1s given by position 1 of the Channel ...

Page 29: ... OUT1 that can be selected singly or together asrequired OUT2isalsoavailableundelayed as OUT3 to activate warning devices such as a lamp or horn The Channel switch assigns the front end unit s to activate the output It is set to WO wired OR on leaving the factory WO is always activated when a defect signal arrives For EDDYSENSOR it does not need to be changed The ON position is indicated by the po...

Page 30: ...nd adjusting the Prescaler if required see previous description The pin layout of the sockets is shown below Thereisalsoapotential freeoutputsocketofthedelayed andundelayeddefectsignalsandvoltagesforswitching FET relays The pin layout of the sockets is shown below Encoder DI 1 050BA Potential Free Output Back panel of the module showing I O Back Module Front EDDYSENSOR from above Back DI1050BA Enc...

Page 31: ... must be set to ON 3 and 4 must be set to OFF 1 is not used If no encoder is used then all must be set to OFF to the right Encoder switch up to modification status d the status is shown on the connector block of the PCB Encoder switch from modification status e onwards thestatusisshownonthecon nector block of the PCB Switch S1 showing the settings for a standard encoder Switch S1 showing the setti...

Page 32: ...m e 1 OUT1 DC 48 V max DC 48 V max 2 OUT1 630 mA max 1 25 A max 3 OUT2 DC 48 V max DC 48 V max 4 OUT2 630 mA max 1 25 A max 5 OUT3 DC 48 V max DC 48 V max 6 OUT3 630 mA max 1 25 A max 7 OUT4 not used DC 48 V max 8 OUT4 not used 1 25 A max 9 15 Volt Imax 200 mA Imax 200 mA 10 GND 11 5 Volt Imax 200 mA Imax 200 mA The current modification status of the PCB is indicated by an identifying letter on th...

Page 33: ...g fuse Always follow the ESD instructions are presented at the beginning of this handbook when changing fuses The four fuse holders The ESD instructions are presented at the beginning of this handbook They must be followed whenever work is carried out on the equipment To replace a fuse switch off the power and then a Remove the back module by loosening the four retaining screws b Pull the module c...

Page 34: ...e PLC warning device e g horn OUT4 System ready signal coil error OUT1 OUT2 OUT3 OUT4 Cable from 1050BA Power cable to mains Depending on the modification status of the 1050 module In modules with a mod status up to d each of the outputs can have a max load of 630 mA In modules with a mod status from e each of the outputs can have a max load of 1 25 A The combined total current drawn may not excee...

Page 35: ... ThePowerUnitisswitchedonbytheON OFFswitchonthefrontpanel The supply voltages of 15 15 and 5 volts are generated by a transformer on the input mains supply of 115V 230V Each of the voltage supplies has its own fuse on the lower printed circuit board of the front module as shown in the diagram below Front Module If one of the LEDs on the front panel does not light up F2 F3 or F4 or the equipmentdoe...

Page 36: ...In carrying out any work on the equipment please observe the ESD instructions given on the separate sheet at the beginning of this handbook The fuses should be checked if a front panel LED is not lit F2 F3 or F4 or if the equipment does not function F1 or F5 To do so switch off the power and then a Remove the front module by loosening the four retaining screws b Pull the module carefully out of th...

Page 37: ...YSENSOR Gain dB Gain FM 1 030F Defect Coil error Overload 100 50 0 5V 15V 15V PM 1 040F d Encoder In this example the undelayed signal is used to activate a warning device andthedelayedsignalgoestoapaintmarker 10 mdistance whichcolour marks the ends of the copper tubes for subsequent cutting These pieces are then cut out by a flying saw at a distance of 22 5 m 1030 filter settings 1031 filter sett...

Page 38: ...CODER Activating the outputs Leave the Channel switches set as they are on leaving the factory as both outputs are required Setting for non standard encoders from other manufacturers Set the gain initially to 20 using the rocker switch on the front panel to input the value This value can then be increased or decreased as required so that the smallest standard defect produces an amplitude of approx...

Page 39: ...ion of the signal is the value of 200 ms Set the delay for Output 1 on the OUT1 switches The duration of the signal is set on the OUT1 WIDTH switch TheOUT1delayfortheflyingsawatadistanceof22 5m asettingof2250 The WIDTH for OUT1 is set to 0 for the default signal duration of 1 s Settingofthedelayand duration Set the PRESCALER according to the type of encoder used in the line The PRÜFTECHNIK standar...

Page 40: ...ation min 200ms 4 Defect suppression pole 5 30V 5 Defect pole 60V 100mA 6 24 Volt available if necessary Imax 100 mA 2 3 4 5 1 6 Pin Pin assignment 1 2 5 Volt with switch 5V ON ext voltage with switch 5V OFF Imax 200 mA Only for PRÜFTECHNIK standard encoder 3 Clock 4 5 6 7 GND with switch GND ON Ext GND with switch GND OFF Encoder socket Digital signal output socket Encoder socket on DI1050BA Pin ...

Page 41: ... 1 OUT1 DC 48 V max DC 48 V max 2 OUT1 630 mA max 1 25 A max 3 OUT2 DC 48 V max DC 48 V max 4 OUT2 630 mA max 1 25 A max 5 OUT3 DC 48 V max DC 48 V max 6 OUT3 630 mA max 1 25 A max 7 OUT4 not used DC 48 V max 8 OUT4 not used 1 25 A max 9 15 Volt Imax 200 mA Imax 200 mA 10 GND 11 5 Volt Imax 200 mA Imax 200 mA OUTx OUTx Switching duration depends on settings of DM1050F ...

Page 42: ...ketisapprox 200msforeach defect This output has been configured to switch a customer PLC as shown If no PLC is available a relay can be used as shown below Some alarm lamps already have a relay built in Alarm unit via a time lag relay The internal current supply of the EDDYSENSOR pin 6 24V Imax 100mA can be used to switch a relay if no external current supply is available Alarm unit via a time lag...

Page 43: ...slot in the housing and seat it firmly f Tighten up the four retaining screws again Replacing the fuses There are four fuse holders F1 for OUT1 F2 for OUT2 F3 for OUT3 F4 is not used available The first three must contain 630 mA fast fuses If the peripheral on a specific output does not function check the corre sponding fuse The four fuse holders There are four fuse holders F1 for OUT1 F2 for OUT2...

Page 44: ...not lit F2 F3 or F4 or if the equipment does not function F1 or F5 To do so switch off the power and then a Remove the front module by loosening the four retaining screws b Pull the module carefully out of the housing c Remove the blown fuse s d Insert the new fuse s e Slide the front module into its slot in the housing and seat it firmly f Tighten up the four retaining screws again Fuse F1 for 11...

Page 45: ...lters F1 and F2 is sufficient for most normal applica tions However forcompletenessthefullF1andF2filtertables are given in the appendix These may be needed in excep tional circumstances To achieve a reasonable bandwidth we recommend VLine 4 Switch setting HPH HPL VLine x 2 Switch setting LPH LPL Select the value nearest to the speed calculated for both the low pass and high pass filters ...

Page 46: ...38 EDDYSENSOR Operating Manual ...

Page 47: ...and nonferrous Annealing lines Detection of holes in the weld seam in order to shut off cooling water to prevent water from entering the inside of the tube Tube forming processes Detection of the weld seam to place the tube in the posi tion required for bending Transverse weld detection Detection of butt welds joining tubes and bands End to end testing Detection of the start of a new test piece Ma...

Page 48: ... 317 634 44 19 32 63 1 6 460 199 331 662 46 20 33 66 1 7 480 207 346 691 48 21 35 69 1 8 500 216 360 720 50 22 36 72 1 9 520 225 374 749 52 22 37 75 1 A 540 233 389 778 54 23 39 78 1 B 560 242 403 806 56 24 40 81 1 C 580 251 418 835 58 25 42 83 1 D 600 259 432 864 60 26 43 86 1 E 620 268 446 893 62 27 45 89 1 F 640 277 461 922 64 28 46 92 2 0 660 285 475 950 66 28 48 95 2 1 680 294 490 979 68 29 4...

Page 49: ...3 1360 588 979 1958 136 59 98 196 4 4 1380 596 993 1987 138 60 99 199 4 5 1400 605 1008 2016 140 60 101 202 4 6 1420 613 1022 2045 142 61 102 204 4 7 1440 622 1037 2074 144 62 104 207 4 8 1460 631 1051 2102 146 63 105 210 4 9 1480 639 1065 2131 148 64 107 213 4 A 1500 648 1080 2160 150 65 108 216 4 B 1520 657 1094 2189 152 66 110 219 4 C 1540 665 1109 2218 154 66 111 222 4 D 1560 674 1123 2246 156...

Page 50: ...0 1011 1685 3370 234 101 169 337 7 5 2360 1020 1699 3398 236 102 170 340 7 6 2380 1028 1713 3427 238 103 172 343 7 7 2400 1037 1728 3456 240 104 173 345 7 8 2420 1046 1742 3485 242 104 174 348 7 9 2440 1054 1757 3514 244 105 176 351 7 A 2460 1063 1771 3542 246 106 177 354 7 B 2480 1071 1785 3571 248 107 179 357 7 C 2500 1080 1800 3600 250 108 180 360 7 D 2520 1089 1814 3629 252 109 182 363 7 E 254...

Page 51: ... 142 238 475 A 5 3320 1434 2390 4781 332 143 239 478 A 6 3340 1443 2405 4810 334 144 241 481 A 7 3360 1452 2419 4839 336 145 242 484 A 8 3380 1460 2433 4867 338 146 244 487 A 9 3400 1469 2448 4896 340 147 245 489 A A 3420 1478 2462 4925 342 148 246 492 A B 3440 1486 2477 4954 344 148 248 495 A C 3460 1495 2491 4983 346 149 249 498 A D 3480 1503 2505 5011 348 150 251 501 A E 3500 1512 2520 5040 350...

Page 52: ... 185 308 616 D 6 4300 1858 3096 6192 430 186 310 619 D 7 4320 1866 3110 6221 432 186 311 622 D 8 4340 1875 3124 6250 434 187 313 625 D 9 4360 1884 3139 6279 436 188 314 628 D A 4380 1892 3153 6307 438 189 316 630 D B 4400 1901 3168 6336 440 190 317 633 D C 4420 1910 3182 6365 442 191 319 636 D D 4440 1918 3196 6394 444 192 320 639 D E 4460 1927 3211 6423 446 193 321 642 D F 4480 1936 3225 6451 448...

Page 53: ...0 2126 3542 7085 492 212 355 708 F 6 4940 2134 3556 7114 494 213 356 711 F 7 4960 2143 3571 7143 496 214 357 714 F 8 4980 2152 3585 7171 498 215 359 717 F 9 5000 2160 3600 7200 500 216 360 720 F A 5020 2169 3614 7229 502 217 362 723 F B 5040 2177 3628 7258 504 218 363 725 F C 5060 2186 3643 7287 506 218 365 728 F D 5080 2195 3657 7315 508 219 366 731 F E 5100 2203 3672 7344 510 220 368 734 F F 512...

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