Table 3-2 Impact of Gate State on Gate Measurement Results
Gate State Condition
MeasPt
Gate On/Off Intersection with Gate
H HdB ↘ ↓ →
Off Random * * * * * Peak
On Random √ √ √ √ √
Off Random * * * * *
On Non-intersect * * * * *
JFront
On Intersect √ √ √ √ √
Off Random * * * * *
On Non-intersect √ √ * * *
Front
On Intersect √ √ √ √ √
【Note 1】: √ means it has measurement value, while * means no measurement value.
【Note 2】: Sba has the measurement value only when two gate are valid. ↘
Chapter 4 Testing Application and Examples
4.1 Testing with A Normal Probe
General testing steps with a normal probe:
1） Set up system initial parameters (Rng, Vel, Dly, PRF, Band, Power, Damping, Thk).
2） Correct system zero and velocity. Please refer to 2.12 Auto Correction.
3） Select either of the below items:
(1) Confirm the tested bottom echo or reference sensitivity, based on which increase compensation sensitivity.
(2) Make AVG curves. Please refer to 2.15 AVG.
4） Set up the system test range and save the current system status to a blank dataset and record the dataset number.
5） In field testing, recall the test technique from the preset dataset (If necessary, adjust the scanning sensitivity) and start testing.
6） According to the echo position and amplitude shown up during testing (hitch the gate to the echo and read from the measurement data area), determine whether it is a defect echo and calculate its equivalent (If AVG curves are adopted, the flat-bottom hole equivalent to the echo amplitude can be read from the system measurement data area directly), and then process the workpiece based on the applicable standard.
4.2 Testing with An Angle Probe
General testing steps with an angle probe:
1） Setup system initial parameters (Rng, Vel, Dly, PRF, Band, Power, Damping, Thk)
2） Correct system zero and velocity (usually only the system zero can be corrected). Please refer to 2.12 Auto Correction.
3） Use a ruler to measure the probe flank（X_Value）and input it in the system.
4） Input the probe nominal Angle or KValue (If the user is demanding on measurement result, the
probe actual angle can be measured with the angle measurement function or a CSK IA test block. Please refer to 2.13 Angle Mesurement).
5） Use a standard test block (such as CSK IIIA) to make DAC curves, and set dB distance and workpiece surface compensation between the three DAC curves according to the applicable standard (such as JB/T 4730-2005, GB11345-1989). Please refer to 2.14 DAC.
6） Set up Rng for testing. Save the current system setup status and DAC curves to a blank dataset and record the dataset number.
7） In field testing, recall the test technique from the preset dataset (If necessary compensate the scanning sensitivity based on the current sensitivity) and start testing.
8） According to the echo position, amplitude shown up during testing and dB difference of DAC curves (hitch the gate to the echo and read from the measurement data area), determine whether it is a defect echo and calculate its equivalent, length and area.
4.3 Application Examples
4.3.1 Application Example of JB/T 4730-2005 Standard
Use a 2.5Z10×10K2 probe, as per JB/T 4730-2005 standard, to test the welding line of a 20mm-thick steel plate. The operating procedure is usually as follows:
1） Set up system initial parameters
Set the submenu Coor (in Config main menu) at SPath;
Set the submenu SPath (in Basic main menu) at 200mm;
Set the submenu Vel (in Basic main menu) at 3230m/s;
Set the submenu Dly (in Basic main menu) at 0mm;
Set the submenu PRF (in Config main menu) at 6;
Set the submenu Band (in Config main menu) at 1~4MHz;
Set the submenu Power (in Config main menu) at High;
Set the submenu Damping (in Config main menu) at Low;
Set the submenu Thk (in Config main menu) at 100mm
2） Measure X_Value and Zero
Press CCoorrrr to go to Corr main menu. Use the probe to scan CSK-IA test block R100. Find the peak of the echo. Hitch the gate to that echo. Adjust Zero value to bring SPath value in the measurement data area to 100. Now the distance from the incidence point to the front of probe housing is X_Value (in Config main menu). Zero is the acoustic time from the probe ceramic to the incidence point.
3） Measure Probe Angle (or KValue)
（1） Press CoCorrrr to go to Corr main menu.
（2） Select the submenu Angle_Meas. and press to go to its extended submenu.
（3） Set the extended submenu Ho_D at 30mm and Ho_Diam. at 1mm.
（4） Use the probe to be measured to scan aΦ1×6 hole at the depth of 30mm on the CSK-IIIA test block. Find the peak of the echo and hitch the gate to that echo. Select extended submenu GAStart in the submenu Angle_Meas. and press . The measurement result is displayed in the extended submenus Angle and KValue. It prompts Sure?. Press to save Angle and KValue.
（5） After testing, verification can be performed with a Φ1×6 hole at the depth of 20mm.
4） Make DAC Curves
（1） Press DADACC to go to DAC main menu.
（2） Set the submenu DAC_Op at Record.
（3） Use the measured probe to scan a Φ1 hole at the depth of 10mm on the CSK-IIIA test block. Find the peak of the echo and hitch the gate to that echo. Adjust the echo height to around 80%. Press the confirm key and the first echo reference point is recorded and the first curve section is drawn.
（4） Repeat step (2), and record echoes of the holes from shallow to deep depth at 20mm, 30mm and 40mm. When the reference echo amplitude at a deeper depth is less than 20% of screen display amplitude, increase system sensitivity (gain value) to increase echo amplitude, so as to easily record that echo reference point.
（5） After recording the required echo reference points, a group of DAC curves are completed.
As per JB/T 4730-2005 standard, the sensitivity of DAC_L3, DAC_L2 and DAC_L1 are:
Φ1×6-9dB, Φ1×6-3dB and Φ1×6+5dB. Therefore the submenus DAC_L3, DAC_L2 and
DAC_L1 (in DAC main menu) are set at: -9dB, -3dB and+5dB. In addition, the workpiece surface compensation is normally 4dB, Comp shall be set at 4dB. Set the submenu Line_Sel at DAC_L2.
5） Set the submenu Thk (in Config main menu) as the thickness of the workpiece to be tested. In this specific example, the submenu Thk (in Config main menu) is set at 20mm. Save the current system setup status and DAC curves to a blank dataset and record the dataset number.
6） In field testing, recall the made DAC curves from the submenu Dataset (in Store main menu).
When a suspected echo appears within the DAC curve measurement range, hitch the gate to that echo. If the number displayed in the measurement data area HdB field is 5.5 (the number refers to the dB difference between the echo peak within the gate and the currently selected curve DAC_L2), the echo equivalent shall be:Φ1×6-3dB+5.5dB=Φ1×6+2.5dB, which belongs to Class 2 flaw.
4.3.2 Application Example of GB 11345-1989
Use a 2.5Z10×10K2 probe, as per Class B of GB 11345-1989 standard, to test on the welding line of a 20mm-thick steel plate. This technique is also applicable to general welding line testing. The operating procedure is usually as follows:
1） Set up system initial parameters
Set the submenu Coor (in Config main menu) at SPath;
Set the submenu SPath (in Basic main menu) at 200mm;
Set the submenu Vel (in Basic main menu) at 3230m/s;
Set the submenu Dly (in Basic main menu) at 0mm;
Set the submenu PRF (in Config main menu) at 6;
Set the submenu Band (in Config main menu) at 1~4MHz;
Set the submenu Power (in Config main menu) at High;
Set the submenu Damping (in Config main menu) at Low;
Set the submenu Thk (in Config main menu) at 100mm 2） Measure X_Value and Zero
Press CoCorrrr to go to Corr main menu. Use the probe to scan CSK-IA test block R100. Find the
peak of the echo. Hitch the gate to that echo. Adjust Zero value to bring SPath value in the measurement data area to 100. Now the distance from the incidence point to the front of probe housing is X_Value (in Config main menu). Zero is the acoustic time from the probe ceramic to the incidence point.
3） Measure Probe Angle (or KValue)
（1） Press CoCorrrr to go to Corr main menu.
（2） Select the submenu Angle_Meas. and press the confirm key to go to its extended submenu.
（3） Set the extended submenu Ho_D at 30mm and Ho_Diam at 3mm.
（4） Use the probe to be measured to scan aΦ3 hole at the depth of 30mm on the RB-3 test block. Find the peak of the echo and hitch the gate to that echo. Select the extended submenu GAStart in the submenu Angle_Meas. and press the confirm key . The measurement result is displayed in the extended submenu Angle and KValue. It prompts Sure?. Press to save Angle and KValue.
（5） After testing, verification can be performed with a Φ3 hole at the depth of 20mm.
4） Make DAC Curves
（1） Press DADACC to go to DAC main menu.
（2） Set the submenu DAC_Op at Record.
（3） Use the measured probe to scan a Φ3 hole at the depth of 10mm on the RB-3 test block.
Find the peak of the echo and hitch the gate to that echo. Adjust the echo height to around 80%. Press the confirm key and the first echo reference point is recorded and the first curve section is drawn.
（4） Repeat step (2), and record the echoes of the holes from shallow to deep depth at 20mm, 30mm and 40mm. When the reference echo amplitude at a deeper depth is less than 20%
of screen display amplitude, increase system sensitivity (gain value) to increase echo amplitude, so as to easily record that echo reference point
（5） After recording the required echo reference points, a group of DAC curves are completed.
As per Class B of GB 11345-1989 standard, the sensitivity of DAC_L3, DAC_L2 and DAC_L1 are: Φ3-16dB, Φ3-10dB, Φ3-4dB. Therefore the submenus DAC_L3, DAC_L2 and DAC_L1 are set at: -16dB, -10dB and -4dB. In addition, the workpiece surface
compensation is normally 4dB, Comp shall be set at 4dB. Set the submenu Line_Sel at DAC_L2.
5） Set the submenu Thk (in Config main menu) as the thickness of the workpiece to be tested. In this specific example, the submenu Thk (in Config main menu) is set at 20mm. Save the current system setup status and DAC curves to a blank dataset and record the dataset number.
6） In field testing, recall the made DAC curves from submenu Dataset (in Store main menu). When a suspected echo appears within the DAC curve measurement range, hitch the gate to that echo.
If the number displayed in the measurement data area HdB field is 5.5 (the number refers to the dB difference between the echo peak within the gate and the currently selected curve DAC_L2), the echo equivalent shall be: Φ3-10dB+5.5dB=Φ3-4.5dB, which belongs to Class 2 flaw.
Chapter 5 Peripheral Devices, Ports and Accessories
5.1 Probe Ports
When testing with the system, use the BNC cable configured with the system or a cable of the same type to connect with a proper probe. All the probe models manufactured by SIUI are suitable for the digital ultrasonic flaw detector CTS-9006/CTS-9009.
For testing with one probe, either BNC probe connector socket (in internal parallel connection) can be used. While for testing with a dual (TR) probe (one ceramic for transmitting, and the other for receiving) or two probes (one for transmitting, and one for receiving), please be noted that you should connect the transmit probe to the lower socket (a T is marked on the system housing), and the receive probe to the upper socket (with an R mark). The wrong connection may result in abnormality such as echo waveform disorder.
5.2 USB Port
5.2.1 Connecting to a USB Disk
Operation:
1） Connect a USB disk to the system USB port directly.
2） After 10 seconds, the system prompts USB disk connected, indicating the system can identify the USB disk properly.
【Note】: If the system cannot identify the USB disk, please refer to Appendix A Common Failures and troubleshooting.
5.2.2 Removing a USB Disk
Unplug the USB disk form the system USB port directly.
5.2.3 Connecting to a USB Printer
Operation:
1） Connect a USB printer to the system USB port directly.
2） After 3 seconds, the system prompts USB printer connected, indicating the system can identify the USB printer connection.
5.2.4 Removing a USB Printer
Unplug the USB printer form the system USB port directly.
5.2.5 Printing with a USB Printer
Operation:
1） Connect a USB printer, please refer to 5.2.3 Connecting to a USB Printer;
2） In Config main menu, Select the submenu F1 and set it at Print.
3） When the submenu F1 is set at Print, press F1F1 to print.
【Note 】 : If the system cannot print, please refer to Appendix A Common Failures and troubleshooting.
5.3 Battery
5.3.1 Battery Installation and Removal
Please follow the below operation procedure to install the battery (DC-92):
1） Align the contact plate at the bottom of the battery with the port at the lower part of the system and insert the battery (see #1 in Fig.5-1).
2） After inserting the battery, push the battery in place and turn the screw rightwards to fix it (see #2 in Fig.5-1).
Please follow the below operation procedure to remove the battery:
1） Loosen the screw leftwards to take out the screw (see #1 in Fig.5-2).
2） Take out the battery upwards (see #2 in Fig.5-2).
Fig. 5-1 Battery Installation Fig. 5-2 Battery Removal
5.3.2 Charging the Battery
Operation:
1） Insert the charger/adaptor (CD-92) plug into the AC socket (AC 100V~240V).
2） Insert the DC Out plug of the charger/adaptor in the battery (DC-92) charge in socket. The indicator on the adaptor will be on (in red) and start recharging.
3） When the charger/adaptor indicator turns green, it means the recharge is finished. Usually it takes 6 hours for one full recharge.
4） Disconnect the charger/adaptor from AC power supply and the battery.
【Note】: When the battery is recharged, it is normal if the charger/adaptor indicator flashes between red and green in a short time.
5.3.3 Using the Battery
The battery capacity indicator is located on the right of the measurement data area. The higher the indicator is, the higher capacity will be. When there is 20% capacity left, it means that the battery
power is running out, and you should recharge or replace the battery in time. A new DC-92 battery, if fully charged, may work continuously over 7 hours.
【Note】: When the battery power is very low, to avoid battery over-discharge, the system will be turned off automatically.
5.3.4 Battery Maintenance
The capacity and the service life of the rechargeable battery depend on whether the battery is used properly. Please recharge the battery DC-92 with the configured charger/adaptor (CD-92). On how to recharge the battery, please refer to 5.3.2 Charging the Battery.
In the following cases, the battery shall be charged:
1） Before using the battery for the first time;
2） If the battery is stored for or over 3 months;
3） After frequent discharge.
Cautions on using the battery:
1) When the system is being operated with an adaptor or the battery is being recharged, please connect with stable and reliable mains power supply (AC 100V~240V, 50Hz~60Hz);
2) The system battery （DC-92）can only be recharged with the charger （CD-92）and the method specified in this Operation Manual.
3) Please recharge the system battery in a cool and ventilated room, otherwise, the battery charging effect might be affected.
4) When the system is not in use for a long time, the battery should be recharged and discharged at least once every three months.
5) During storage or transportation, the battery shall be stored with half capacity, i.e. its voltage shall be 7.2V~7.7V, so as to avoid any gas generated or gas inflation.
6) When system battery comes to the end of its service life, in order to avoid environmental pollution, do not discard, break or crush the battery at will. Please dispose it properly according to applicable laws and regulations or national standards.
7) It is prohibited to throw the battery into fire, so as to avoid explosion or producing toxic
chemicals.
8) Do not charge the battery near fire source or in extremely hot environment.
9) It is prohibited to make electric conductor contact battery pole plate, so as to avoid short circuit.
10) Keep the battery from moisture and never throw it into water.
11) Do not store the battery in the temperature higher than 60 or lower than ℃ -20 ;℃
12) Do not use the battery if it is in peculiar smelling, heats, distortion, changed color or any other abnormity.
5.4 Charger/Adaptor
The system configured charger/adaptor (CD-92) can serve as the system adaptor and the system battery charger.
Cautions on using the charger/adaptor:
1) Do not use the adaptor (charger) on a plug-loosen socket.
2) Do remember that the total load of the adaptor (charger) plugged into the socket shall not exceed its rated load.
5.5 Bag
Please refer to Fig. 5-3 and Fig. 5-4 for how to use the system bag.
Fig. 5-3 Fig. 5-4
Chapter 6 Training, System Maintenance and Service
6.1 Training
To ensure a safe and proper operation, the operator shall receive appropriate training on ultrasound testing, and read this operation instruction before operating this system. The lack of relevant knowledge on ultrasound testing may lead to unpredictable wrong testing results. Therefore, to acquire information on ultrasonic testing training and qualification, please contact relevant NDT societies, organizations or SIUI.
6.2 System Maintenance
Please use the factory configured accessories and options, such as the BNC probe cable and the communication cable. Incompatible cables may result in system internal circuit failure or external connector damage. DO NOT drop any liquid into the system.
The system housing, glass panel and other parts can be cleaned with a piece of cloth soaked with a little water or neutral household cleanser.
【Note】: DO NOT use any solvent to clean the system. The plastic parts may be damaged or
become fragile if being cleaned with solvent.
6.3 Service
The system adopts the latest technologies and is made of high quality components. The process inspection, the in-process testing and the quality management system are all certified by ISO9001, ensuring that the system performance is optimized.
SIUI provide 2 years’ warranty for the system main unit. In case any failure is found in the system, please shut off the system and take out the battery. Contact SIUI service department whenever it is necessary to repair or recalibrate the system. The warranty does not cover any unauthorized repair or disassembly.
Under the following situations, the safe operation of the system is not ensured:
1） The system is obviously damaged (with abnormal display or internal sound).
2） The system is stored in adverse environment for a long time (e.g. abnormal temperature or high humidity, or erosive condition).
3） Severe fall-down or pressure during transportation.
【Note】: Before transportation, the system shall be packed to meet the requirements of shockproof, waterproof and humidity-proof, in order to avoid system damage due to rain, snow, mechanical collision or strong shock.
Appendix A Common Failures and Troubleshooting
A.1 The system cannot power on
a） If the power supply is from the battery:
1） Try to replace the battery with full capacity if the capacity is low;
2） Change the power supply to the charger/adaptor.
b） If the power supply is from the charger/adaptor:
1） Check if the system is connected to the charger/ adaptor plug, or if the plug come loose;
2） Check if the charger/ adaptor indicator is on (if on, which means it works properly);
3） If the battery is not used on the system, try to use the system with a fully charged battery.
c） If the failure still exists after trying the solutions above, please contact the distributor or SIUI.
A.2 The system cannot power off
a） Long press the power key for 8 seconds to force the system shutdown;
b） If force shutdown fails, unplug the charger/ adaptor or remove the battery to cut off power supply. Reboot the system to see whether it is in normal operation. If not, try to contact the distributor or SIUI for repair as soon as possible.