GE SpotChecker Bedienungsanleitung

SpotChecker

Technical Reference and Operating Manual

Ident No. 49 131

Rev. 2.0

This Issue 02, 03/2009 applies to the version 1.0

Subject to change without notice.

1 Introduction 7

1.1 Safety information 8

Power supply 8

Software 8

Defects/errors and exceptional stresses 9

Further information 9

1.2 Important information on ultrasonic

testing 10

Preconditions for testing with ultrasonic

test equipment 10

Operator training 10

Technical test requirements 11

Limitations of testing 11

Ultrasonic wall thickness measurement 11

Effect of the test object’s material 12

Effect of temperature variations 12

Measurement of remaining wall thickness 12

Ultrasonic evaluation of ﬂaws 13

Flaw boundary method 13

Echo display comparison method 13

Limitations of software 14

1.3 The SpotChecker 16

Special features 16

1.4 Standard package 18

1.5 Required accessories 19

1.6 Spare parts requirements 20

2 Initial start-up and basics 25

2.1 Overview of instrument 26

Front panel 26

Back panel 27

2.2 Installing the instrument 28

2.3 Connecting a probe 29

2.4 Power supply 30

Operation using external power supply 30

Operation using batteries 31

Contents

SpotChecker Issue 02, 03/2009 3

Inserting batteries 31

Checking the battery charge level 31

Exchanging batteries 32

Charging batteries 32

2.5 Power on/Power off 33

Starting the operation 33

Closing the operation and shutting down 33

2.6 Interfaces 34

USB 34

Network 34

WLAN 34

Bluetooth 35

2.7 Trackballs and touchscreen 36

Trackballs 36

Touchscreen 36

2.8 Remote control 37

Assigning the remote control to a receiver 38

Key assignment 38

2.9 Software installation 39

Re-installation SpotChecker 39

Updates 39

Installation procedure 39

License after re-installation 40

2.10 Basic settings 41

Selecting language 41

Restricting program access 41

Activating the password protection 42

Deactivating the password protection 42

2.11 Data backup 43

Saving data to external data media 44

Uploading data from external data media 44

2.12 Online Help 45

Context-sensitive Help 45

Starting the Online Help 45

Buttons: 46

Starting the Online Help without

the software 46

Contents

4Issue 02, 03/2009 SpotChecker

Printing 47

Printing a complete chapter 47

3 Individual inspection reports 49

3.1 Ultrasonic inspection of spot

welds

within automotive industry 50

Basic principle 50

Comparison of ultrasonic inspection

with other inspection methods 51

3.2 The software SpotChecker 54

Overview 54

Application ranges 55

Structured inspection plan: 56

Evaluation with UltraCAR 57

General procedure –

linear inspection plans 58

The evaluation assistance tools 59

Evaluation Assistance I 59

Evaluation Assistance II 60

Evaluation Assistance III 61

Evaluation Assistance IV 62

A-scan and Racer view 63

Automatic A-scan freeze 65

Graphical marking of relevant echoes 66

Interface echo gate 66

Reference A-scan 67

Other inspection methods 68

3.3 Dialog probes 69

4 Care, maintenance, errors 71

4.1 Cleaning the instrument 72

4.2 Maintenance 72

4.3 Care of batteries 72

Charging batteries 73

Storage of batteries 73

4.4 Errors 73

Contents

SpotChecker Issue 02, 03/2009 5

5 Technical speciﬁcations 75

5.1 Speciﬁcation of the interfaces 76

4-pin LEMO 0S connection +15V 76

5.2 Speciﬁcations SpotChecker 77

Enclosure 77

Connections 78

Power supply 78

Ultrasound 79

Settings and evaluation 79

6 Annex 83

6.1 EC declaration of conformity 84

6.2 Manufacturer/Service addresses 86

6.3 Disposal 87

General view of the device 88

Recycling data of SpotChecker 90

7 Index 93

Contents

6Issue 02, 03/2009 SpotChecker

Introduction 1

SpotChecker Issue 02, 03/2009 7

Safety information1.1

The SpotChecker has been designed and tested ac-

cording to DIN EN 61 010 Part 1, Safety requirements

for electrical measuring, control and lab equipment,

and was technically in perfectly safe and faultless con-

dition when leaving the manufacturing works.

In order to maintain this condition and to ensure a

safe operation, you should urgently read the following

safety information before putting the instrument into

operation. When connecting other equipment to the

SpotChecker, such as the power supply unit, follow

particularly all safety instructions that apply to these

devices.

A Attention:

The SpotChecker is an instrument for materials

testing. Any use for medical applications or other

purposes is not allowed!

The SpotChecker may only be used in industrial

environments!

Power supply

The power supply for the SpotChecker is carried out

via one or two batteries or via a connected power sup-

ply unit. The power supply unit may only be used in-

side buildings and may not be exposed to moisture or

liquids. Follow all safety instructions that are applica-

ble for the power supply unit used.

A Attention:

Never open the housing of the power supply unit. The

power supply unit does not contain any user-service-

able parts.

Software

According to the current state of the art, software is

never completely free from errors. Before using any

software-controlled test equipment, please make sure

that the required functions operate perfectly in the in-

tended combination.

Introduction Safety information

8Issue 02, 03/2009 SpotChecker

Further information

A Attention:

Observe the documentation for the other equipment

connected to the SpotChecker, such as computer or

power supply unit. The documentation contains impor-

tant safety instructions and information about permit-

ted uses.

The SpotChecker software provides extensive online

help which is always available to you when working

with the system. In this operating manual you will ﬁnd

any additional information that you might require.

If you have any questions about the use of your test

equipment, please contact your nearest representative

of GE Sensing & Inspection Technologies.

If you install additional software on the computer, GE

Sensing & Inspection Technologies will not bear any

responsibility regarding the inﬂuence this may have on

SpotChecker operation. The existing software drivers

may be overwritten in such a case.

Defects/errors and exceptional stresses

If you have reason to believe that a safe operation of

your SpotChecker is no longer possible, you have to

disconnect the instrument and secure it against unin-

tentional reconnection.

A safe operation is e.g. no longer possible

❚ if the instrument shows visible damages,

❚ if the instrument no longer operates perfectly,

❚ after prolonged storage under adverse conditions

(e.g. exceptional temperatures and/or especially

high air humidity, or corrosive environmental condi-

tions),

❚ after being subjected to heavy stresses during

transportation.

Safety information Introduction

SpotChecker Issue 02, 03/2009 9

Important information on ultra-1.2

sonic testing

Please read the following information before using

your SpotChecker. It is important that you understand

and observe this information to avoid any operator er-

rors that might lead to false test results. This could re-

sult in personal injuries or damages to property.

Preconditions for testing with ultrasonic test

equipment

In this operating manual you will ﬁnd essential infor-

mation on how to operate your test equipment. In ad-

dition, there are a number of factors that affect the

test results. A description of these factors would go

beyond the scope of an operating manual. Let us

therefore only mention the three most important re-

quirements for a safe ultrasonic inspection in this con-

nection:

❚ the operator training,

❚ the knowledge of special technical test require-

ments and limits,

❚ the choice of appropriate test equipment.

Operator training

The operation of an ultrasonic test device requires a

proper training in ultrasonic test methods.

A proper training comprises for example adequate

knowledge of:

❚ the theory of sound propagation,

❚ the effects of sound velocity in the test material,

❚ what happens to the sound wave at the interface

between two different materials,

❚ the propagation of the sound beam,

❚ the inﬂuence of sound attenuation in the test ob-

ject, and the inﬂuence of surface quality of the test

object.

Lack of such knowledge could lead to false test results

with unforeseeable consequences. You can contact

for example NDT societies or organizations in your

country (DGZfP in Germany; ASNT in the USA), or

GE Sensing & Inspection Technologies, for informa-

tion concerning existing possibilities for the training of

ultrasonic inspectors as well as on the qualiﬁcations

and certiﬁcates that can ﬁnally be obtained.

Introduction Important information on ultrasonic testing

10 Issue 02, 03/2009 SpotChecker

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