NOVOTEST UD3701 Bedienungsanleitung

Operation Manual

Ultrasonic Flaw Detector

NOVOTEST UD3701

Address:

51200, Ukraine, Novomoskovsk, str. Spasskaya,5

Sales:

cell.: +38-067-593-59-77

[email protected]

http://novotest.biz/

Warranty maintenance and service support:

cell.: +38-067-593-59-77

Operation manual

Ultrasonic Flaw Detector NOVOTEST UD3701

Page 2

CONTENT

GENERAL INFORMATION...................................................................................................................5

ABBREVIATION USED .........................................................................................................................6

1 DESCRIPTION AND OPERATION OF THE DEVICE AND ITS COMPONENTS.........................7

1.1 The purpose of the device...............................................................................................................7

1.2 Technical characteristics of the device ...........................................................................................7

1.3 Standard delivery set.......................................................................................................................9

1.4 Parts.................................................................................................................................................9

1.5 Probes............................................................................................................................................11

1.5.1 Probe types.............................................................................................................................11

1.6 Design and functioning.................................................................................................................12

1.6.1 Design of the flaw detector....................................................................................................13

1.7 Device modes................................................................................................................................14

1.7.1 «FLAW DETECTOR» mode.................................................................................................14

1.7.2 «SETTINGS» mode...............................................................................................................23

1.7.3 «ARCHIVE» mode ................................................................................................................24

1.7.4 «RESULTS» mode ................................................................................................................24

1.7.5 «INFORMATION» mode......................................................................................................25

1.8 Means of measurement, tools and accessories..............................................................................25

1.9 Marking and sealing......................................................................................................................25

1.10 Packing........................................................................................................................................25

2 UNTENDED USE ...............................................................................................................................26

2.1 Maintenance limitations................................................................................................................26

2.2 Preparing the device for use..........................................................................................................26

2.2.1 Visual inspection....................................................................................................................26

2.2.2 Charging the battery...............................................................................................................26

2.2.3 Selection the probe.................................................................................................................26

2.2.4 Connecting the probe.............................................................................................................27

2.3 Preparing the object of testing ......................................................................................................29

2.4 Using the device............................................................................................................................29

2.4.1 Turning on..............................................................................................................................29

2.4.2 Device navigation ..................................................................................................................30

2.4.3 Settings...................................................................................................................................32

2.4.4 Setting the probe parameters..................................................................................................34

2.4.5 Setting the signal view...........................................................................................................36

2.4.6 Setting the device for testing..................................................................................................38

2.4.7 Automatic signalization of defects.........................................................................................42

2.4.8 «TVG» mode..........................................................................................................................43

2.4.9 «DAC» mode .........................................................................................................................46

2.4.10 «DGS» mode........................................................................................................................50

2.4.11 Additional modes.................................................................................................................51

2.4.12 Operating with device memory............................................................................................52

2.5 Calibration of flaw detector ..........................................................................................................55

2.5.1 Determination of delay in the prism of straight beam probe .................................................55

2.5.2 Determination of delay in the prism of angle beam probe.....................................................55

Operation manual

Ultrasonic Flaw Detector NOVOTEST UD3701

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2.5.3 Determination of entry angle of the probe.............................................................................56

2.5.4 Determination of probe arrow................................................................................................56

2.5.5 Determination of UT waves velocity in the tested object by straight beam probe................57

2.6 Connecting the device to PC.........................................................................................................58

2.6.1 Software installation AWP_UD3701.....................................................................................58

2.6.2 Software operation AWP_UD3701 59

3 TECHNICAL MAINTENANCE OF THE PRODUCT AND ITS COMPONENTS .........................64

3.1 Safety measures.............................................................................................................................64

3.2 Verification ...................................................................................................................................64

3.2.1 Verification and verifying instruments..................................................................................64

3.2.2 Requirements for verification officer qualification, requirements for safety and

verification conditions.....................................................................................................................65

3.2.3 Visual inspection....................................................................................................................66

3.2.4 Functionality test..................................................................................................................666

3.2.5 Determination of the modal accuracy when measuring echo-signal amplitudes from

defects .............................................................................................................................................66

3.2.6 Checking the nonlinearity of vertical scanning......................................................................67

3.2.7 Determination of reference values of conventional response, range of the control gate

and signal/noise ratio ......................................................................................................................68

3.2.8 Determination of the basic accuracy when measuring distance to the defect (thickness)

by straight beam probes ..................................................................................................................69

3.2.9 Data-report of verification .....................................................................................................70

3.3 Warranty........................................................................................................................................70

3.3.1 Basic Warranty.......................................................................................................................70

3.3.2 Extended warranty .................................................................................................................70

3.3.3 Warranty for repaired or replaced parts.................................................................................70

3.3.4 Wear parts ..............................................................................................................................70

3.3.5 Duties of the owner................................................................................................................71

3.3.6 Warranty Limitations.............................................................................................................71

3.3.7 Other cases not covered by the warranty...............................................................................72

3.3.8 Guarantees and consumer legislation.....................................................................................72

3.4 Maintenance of the device ............................................................................................................72

4 MAINTENANCE ................................................................................................................................74

5 STORAGE...........................................................................................................................................74

6 TRANSPORTATION..........................................................................................................................74

7 RESYCLING.......................................................................................................................................74

APPENDIX A.........................................................................................................................................75

Operation manual

Ultrasonic Flaw Detector NOVOTEST UD3701

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Caution!

Please read this manual carefully before using the device –Ultrasonic Flaw Detector NOVOTEST

UD3701.

This operating manual (hereinafter OM) includes general information in order to give the

operating personnel understanding of functioning and operating rules of the Ultrasonic Flaw Detector

NOVOTEST UD3701 (hereinafter referred to as the device or flaw detector). The document contains

technical characteristics, description of the design and principle of operation, as well as information

necessary for the correct use of the device. Before starting work, it is necessary to read this manual, as

the device operation must be carried out by persons who are familiar with the operation principle and

the device design.

Correct and effective use of the device requires obligatory availability:

Testing methods;

Conditions for testing, according to testing methods;

Trained, and familiar with this OM user.

The enterprise-manufacturer reserves the right to make non-critical changes, without making

worse technical characteristics of the device. These changes may not be mentioned in the text of

current document.

The standard delivery kit of the device includes the operational documentation as a part of this

OM.

The present OM applies to all modifications of the device.

Operation manual

Ultrasonic Flaw Detector NOVOTEST UD3701

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GENERAL INFORMATION

Correct and effective use of flaw detector requires obligatory availability:

Technical characteristics of flaw detector comply with requirements of test tasks;

Relevant quality-control procedures;

Well-qualified operator.

Present OM gives operator only instructions about intended use of the device. It does not give

understanding about influencing factors while testing and basic principal of ultrasonic.

Ultrasonic

Operator must be familiar with basic principal of theory about propagation of ultrasonic waves,

including understanding of sound velocity, damping, echo and reflected signal, limitations and

boarders for sound beam, etc.

Study

Operator must complete relevant training courses for correct use of flaw detector, getting clear

understanding about general principal of ultrasonic testing and practical skills for testing the particular

kind of products.

Testing

For correct ultrasonic testing operator must have quality-control procedure for this particular

product and must know special requirements for ultrasonic testing: aims of testing, choice of

appropriative testing device (method of scanning), choice of the probe, determination of known testing

conditions in materials of such kind, choice of reflector with minimal surface, cutting-off level, etc.

Evaluation of defect area

There are two main methods of evaluation of defect area.

1. By defect boarders:

If the diameter of sound beam is less than defect area, then it can be used for determination of

defect boarders. The less is beam diameter, the more accuracy in determination of defect

boarders. And vice versa, when the beam is rather wide, then determined boarders could be

quit differ from real ones.

2. By amplitude of echo-signal:

If the beam radius is more than defect area, then defect area is evaluated by the next way:

maximal echo-signal amplitude of the defect is compared to maximal amplitude of artificial

reflector in a special test block. Usually, echo-signal amplitude of the real defect is less than

amplitude of artificial reflector with the same area. This is because of not the exact

perpendicular position of the real defect to the probe beam and irregular shape of defect

surface, and it should be taken into account when testing.

Quality-testing procedures

User must know and understand quality-testing procedures, which are worked out for relevant

products.

Thickness measurement

Thickness measurement by ultrasonic –is a result of mathematical multiplication of ultrasonic

velocity in material and impulse passing time. Flaw detector allows to get the precise time value for

ultrasonic waves. The correct velocity setting depends on operator.

Sound velocity

Accuracy for thickness measurement and for defect position evaluation basically depends on the

correct setting of ultrasonic velocity in the material. Velocity depends on material physical

characteristics and its temperature.

Operation manual

Ultrasonic Flaw Detector NOVOTEST UD3701

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ABBREVIATION USED

In this OM following abbreviations and symbols are used:

DGS –distance–gain-size (defect);

DAC –distance amplitude curve;

DTC –defect control (automatic signaling of defects);

TVG –time varied gain;

LCD –liquid crystal display;

NDT –nondestructive testing;

TO –tested object;

UT probe –ultrasonic probe;

DEP –dual element probe;

SS –standard sample;

RB - Reference block;

SO-2 -Calibration Block SO-2 (GOST 14782-86);

SO-3 -Calibration Block SO-3 (GOST 14782-86);

UT –ultrasonic;

US –ultrasonic waves;

DSP –digital signal processor;

DA converter –digital-to-analog converter;

AD converter –analog-to-digital converter;

TPP –thermal power plant;

NPP –nuclear power plant.

Operation manual

Ultrasonic Flaw Detector NOVOTEST UD3701

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1 DESCRIPTION AND OPERATION OF THE DEVICE AND ITS COMPONENTS

1.1 The purpose of the device

Flaw detector is designed for product testing as for the presence of defects, including:

discontinuity and homogeneity of materials, semi-finished and finished products, welds;

measuring depth and coordinates of defect;

thickness measurement of the product;

measuring UT waves velocity in the material.

Flaw detector implements shadow, echo and mirror-shadow testing methods. Flaw detector allows

user to create, record and store in nonvolatile memory temporary implementation of pulsed ultrasonic

signals and then further data loading to PC for analysis and documentation. Integrated liquid crystal

display (LCD) provides a mapping of ultrasonic signals in the form of A-scan, as well as images of

cross sections of testing objects in the form of B-scans. Ultrasonic Flaw Detector NOVOTEST

UD3701 has extensional functions of modern professional device:

color large 7-inch touch screen display of high resolution (800*480 pixels). Also, keyboard

is available;

lightweight, portable and ergonomic impact-resistant metal housing;

high-capacity battery.

Flaw detector can be used in mechanical engineering, aerospace, metallurgy, transportation, while

installation of steel constructions and equipment on TPP or NPP.

1.2 Technical characteristics of the device

Ultrasonic Flaw Detector NOVOTEST UD3701 is a portable device made in an impact-resistant

housing, inside which a board with electronic components and accumulators is placed. The main

characteristics of the device are presented in Table 1.1. Table 1.2 shows technical characteristics of the

device.

Table 1.1 –The main characteristics of the device

Dimensions, mm

250x150х50

Display, mm

155х85

(7-inch touch screen)

Weight, not more, kg

1,4

Battery, А/h

Charger voltage, V

Operating time without charging, h

up to 20

Operating temperature range, °С

from -30 to +55

Humidity, not more, %

95 when 35 °С

Allowable range for absolute accuracy of the device when measuring depth of defects (thickness):

not more ± (0,5 + 0,01·Hx) mm, where Hx –defect depth value (thickness) in mm.

Allowable range for absolute accuracy of the device when measuring coordinates of defects:

± (0,5 + 0,01·X) mm, where X –defect coordinate value in mm.

Allowable range for absolute accuracy of the device when measuring amplitudes ratio:

± 0,5 dB per every 10 dB.

Operation manual

Ultrasonic Flaw Detector NOVOTEST UD3701

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Table 1.2 –Technical characteristics of the device

Scan, µs:

–minimum

–maximum

0 –14

0 –1000

Delay, µs

0 –1000

Maximum thickness of tested object, mm

Up to 6000 (echo-signal) for steel

Velocity range, m/s

1000 - 9999

Delay in the prism, µs

0 –100

Damping, Оhm

Input impedance

50 Оhm / 600 Оhm

Amplitude of the probe pulse, V

200 (U1); 150 (U2); 100 (U3)

Repetition frequency of the probe pulse, Hz

Automatically controlled

from 10 to 100

Analog amplifier, MHz

wideband 0,4 –20

(-6 dB)

Gain control range, dB

126

The range of variation of temporal sensitivity adjustment

TVG, dB

Up to 70 (12 dB/µs)

Quantity of control points for TVG

Quantity of control points for DAC

Automatic signaling of defects (DTC –defect control)

dual-gates

Setting range of DTC gates, µs

from 0 to 1000

Limits setting of DTC gates, % display height

from 0 to 100

Signal detection

Positive or negative half-wave,

wave, radiofrequency signal (in the

whole scanning range)

Device body protection.

Level of the device body protection from penetration of solids and water is IР 65, according to

required standard.

MTBF

Mean time between failures (MTBF) of the device without taking into account the reliability

factor of the probes is not less than 6000 h.

Service time

The total average service life of the device is not less than 10 years.

The criteria of decommissioning of the device - economic inexpediency of restoring the operable state

of the components of the instrument by repairing.

Operation manual

Ultrasonic Flaw Detector NOVOTEST UD3701

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1.3 Standard delivery set

Electronic unit.........................................................................................................................1 pc.

UT probes:

Straight beam probe ........................................................................................................ 1 pc.

Angle beam probe........................................................................................................... 1 pc.

*Type and quantity of probes could be changed or added according to the customer order.

Charger....................................................................................................................................1 pc.

Cable for PC............................................................................................................................1 pc.

Case.........................................................................................................................................1 pc.

Operation manual....................................................................................................................1 pc.

* At the request of the customer, the delivery set can be expanded with additional equipment or

parts. The exact information about the delivery set is indicated in the passport of the device.

In Figure 1.1 UT probes of different kinds are illustrated:

Figure 1.1 –UT probes

1.4 Parts

The device consists of an electronic unit and connected probes. User can control the device by

keypad or touch screen display. Signals, measurement results, device modes and other information is

indicated on color touch screen display.

UT probes are connected to the device through coaxial cables. Detachable connections (ports) are

located on the upper end panel of the housing. The device is power supplied by internal recharging

battery or charger. Charger is connected via USB port on the right side of the device housing and is

included to the standard delivery set. Also, USB port is used for PC connection. Parts of the flaw

detector are shown in Figure 1.2., and control keys are described in the Table 1.3.

Operation manual

Ultrasonic Flaw Detector NOVOTEST UD3701

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1–port for single element probe and piezo-element output (transmitter); 2 –port for piezo-element

input (receiver); 3 –colored 7-inch touch screen display; 4 –indicator of Аgate; 5 –indicator of B

gate; 6 –keyboard; 7 –USB port; 8 –battery indicator.

Figure 1.2 –Ultrasonic Flaw Detector NONOTEST UD3701

Table 1.3 –Control keys

–power on/of

–touch screen on/of

–save measurements/settings

–«freezing» of the screen

–changing the parameter discreteness

–opening the parameters group «Gates»

–main display menu

–opening the parameters window

–Select/open/close key for parameters group

–Selection keys

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