NDT Experts ExScan1000 Manual

Ultrasonic thickness gauge

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ULTRASONIC

THICKNESS GAUGE

ExScan1000

www.okondt.com

Table of Contents

Summary of Contents for NDT Experts ExScan1000

Page 1 ULTRASONIC THICKNESS GAUGE ExScan1000 www.okondt.com...
Page 2: Table Of Contents
CONTENTS Introduction ............4 Operation ............6 The Keypad ............6 The Display ............12 The Transducer ..........18 Making Measurements ........21 Condition and Preparation of Surfaces ....24 Probe Zero............26 Calibration ............29 Scan Mode ............35 APPENDIX A Product Specifications ....
Page 3 DISCLAIMER Inherent in ultrasonic thickness measurement is the possibility that the instrument will use the second rather than the first echo from the back surface of the material being measured. This may result in a thickness reading that is TWICE what it should be.
Page 4: Introduction
INTRODUCTION The NDT Experts model ExScan1000 is a precision Ultrasonic Micrometer. Based on the same operating principles SONAR, ExScan1000 is capable of measuring the thickness of various materials with accuracy as high as ± 0.001 inches, or ± 0.01 millimeters. The principle...
Page 5 NDT Experts maintains a customer support resource in order to assist users with questions or difficulties not covered in this manual. Customer support may be reached at any of the following:...
Page 6: Operation
OPERATION The ExScan1000 interacts with the operator through the membrane keypad and the LCD display. The functions of the various keys on the keypad are detailed below, followed by an explanation of the display and its various symbols. The Keypad...
Page 7 This key is used to turn the ExScan1000 on and off. When the gauge is turned ON, it will first perform a brief display test by illuminating all of the segments in the display. After one second, the gauge will display the internal software version number.
Page 8 The PRB-0 key is used to "zero" the ExScan1000 in much the same way that a mechanical micrometer is zeroed. If the gauge is not zeroed correctly, all of the measurements that the gauge makes may be in error by some fixed value.
Page 9 The CAL key is used to enter and exit the ExScan1000's calibration mode. This mode is used to adjust the sound-velocity value that the ExScan1000 will use when calculating thickness. The gauge will either calculate the sound-velocity from a sample of the material being measured, or allow a known velocity value to be entered directly.
Page 10 The UP arrow key has two functions. When the ExScan1000 is in calibration mode, this key is used to increase numeric values on the display. An auto-repeat function is built in, so that when the key is held down, numeric values will increment at an increasing rate.
Page 11 The DOWN arrow key has two functions. When the ExScan1000 is in the CAL mode, this key is used to decrease numeric values on the display. An auto-repeat function is built in, so that when the key is held down, numeric values will decrement at an increasing rate.
Page 12: The Display
"1", and is used to display numeric values, as well as occasional simple words, to indicate the status of various settings. When ExScan1000 displaying thickness measurements, the display will hold the last value measured, until a new measurement is made.
Page 13 When the gauge is making a measurement, ten or twelve of the bars should be on. If fewer than five bars are on, the ExScan1000 is having difficulty achieving a stable measurement, and the thickness value displayed will most likely be erroneous.
Page 14 When the MM symbol is on, the ExScan1000 is displaying a thickness value in millimeters. displayed thickness exceeds 199.99 millimeters, the decimal point will shift automatically to the right, allowing values up to 1999.9 millimeters to be displayed. When the in/us symbol is...
Page 15 S symbol is illuminated on the display. The H symbol is appeared button – after pressing calibrating the sound velocity at a known thickness (1 point calibration). When the H symbol is on ExScan1000 is performing the 2 point calibration.
Page 16 When the Prb0 symbol is on, the ExScan1000 is finishing the probe zero calibration. The symbol for switching on the mode of auto display illumination. When the On symbol is on,...
Page 17 When the OFF symbol is on, the ExScan1000 is switching off the display illumination. When the Auto symbol is on, the ExScan1000 is switching on the auto mode display illumination with direct measurements. When the 1-OK symbol is on, ExScan1000...
Page 18: The Transducer
ExScan1000 uses to calculate the thickness of the material being measured. The transducer connects to the ExScan1000 via the attached cable, and two coaxial connectors. When using transducers manufactured by NDT Experts, the orientation of...
Page 19 ExScan1000. The transducer must be used correctly in order for the ExScan1000 to produce accurate, reliable measurements. Below short description transducer, followed instructions for its use.
Page 20 transducer is placed against the material being measured, it is the area directly beneath the center of the wearface that is being measured. This is a top view of a typical transducer. Press against the top with the thumb or index finger to hold the transducer in place.
Page 21: Making Measurements
(wearface down) firmly against the area to be measured. The Stability Indicator should have six or seven bars darkened, and a number should appear in the display. If the ExScan1000 has been properly "zeroed" (see page 12) and set to the...
Page 22 See page 18 for information on transducer selection. While the transducer is in contact with the material being measured, the ExScan1000 will perform four measurements every second, updating its display as it does so. When the transducer is removed from the surface, the display will hold the last measurement made.
Page 23 IMPORTANT Occasionally, a small film of couplant will be drawn out between the transducer and the surface as the transducer is removed. When this happens, the ExScan1000 may perform a measurement through this couplant film, resulting measurement that is larger or smaller than it should be.
Page 24: Condition And Preparation Of Surfaces
Condition and Preparation of Surfaces In any ultrasonic measurement scenario, the shape and roughness of the test surface are of paramount importance. Rough, uneven surfaces may limit the penetration of ultrasound through the material, and result in unstable, and therefore unreliable, measurements.
Page 25 act on the sound beam like frosted glass on light, the beam becomes diffused and scattered in all directions. addition posing obstacles measurement, rough surfaces contribute excessive wear of the transducer, particularly in situations where the transducer is "scrubbed" along surface.
Page 26: Probe Zero
Probe Zero Setting the Zero Point of the ExScan1000 is important for the same reason that setting the zero on a mechanical micrometer is important. If the gauge is not "zeroed" correctly, all of the measurements the gauge makes will be in error by some fixed number.
Page 27 Make sure the ExScan1000 is on. Plug transducer into ExScan1000. Make sure that the connectors are fully engaged. Check that the wearface of the transducer is clean and free of any debris. On the top of the ExScan1000, above the display, is the metal probe-disc. Apply a single droplet of ultrasonic couplant to the face of this disc.
Page 28 When performing a "probe-zero", the ExScan1000 will always use the sound-velocity value of the built-in probe-disc, even if some other velocity value has been entered for making actual measurements.
Page 29: Calibration
Calibration In order for the ExScan1000 to make accurate measurements, it must be set to the correct sound- velocity for the material being measured. Different types of material have different inherent sound- velocities. For example, the velocity of sound through...
Page 30 Make sure the ExScan1000 is on. Perform a Probe-Zero (refer to page 27). Apply couplant to the sample piece.
Page 31 ExScan1000 is now displaying the sound velocity value it has calculated based on the thickness value that was entered in step 7. Press the CAL key once more to exit the calibration mode. The ExScan1000 is now...
Page 32 Use the UP and DOWN arrow keys to adjust the displayed velocity up or down, until it matches the sound-velocity of the material to be measured. Press the CAL key once more to exit the calibration mode. The ExScan1000 is now ready to perform measurements.
Page 33 To achieve the most accurate measurements possible, it is generally advisable to always calibrate the ExScan1000 to a sample piece of known thickness. Material composition (and thus, its sound-velocity) sometimes varies from lot to lot from manufacturer manufacturer. Calibration to a sample of known thickness will...
Page 34 Apply couplant to the sample piece. Press the transducer against the sample piece, at the first/second calibration point, making sure that the transducer sits flat against the surface of the sample. The display should show some (probably incorrect) thickness value, and the Stability Indicator should have nearly all its bars Having achieved a stable reading, remove the transducer.
Page 35: Scan Mode
The ExScan1000 will now display the sound velocity value it has calculated based on the thickness values that were entered in step 7. The ExScan1000 is now ready to perform measurements. Scan Mode While the ExScan1000 excels at making...
Page 36 "scrubbed" across a surface, and any brief interruptions in the signal will be ignored. When the transducer loses contact with the surface for more than a second, the ExScan1000 will display the smallest measurement it found. When the ExScan1000 is not in calibration mode, press the UP arrow key to turn Scan Mode on and off.
Page 37: Appendix A Product Specifications
APPENDIX A Product Specifications Physical Weight: 10.58 (300 g) Size: 4.62 W x 2.34H x 1.36 D inch (117.5 W x 59.6H x 34.6D mm) Operating Temperature: -20 to 120 °F (-20 to 50 °C) Case: Extruded aluminum body / nickel plated aluminum end caps.
Page 38 Power Source Two “AA” size, 1.5 volt alkaline or 1.2 volt NiCad cells. 200 hours typical operating time on alkaline, 120 hours on NiCad. Display FSNT/POSITIVE Liquid-Crystal-Display, size 30 mm (Height) x 25 mm (Width). Measuring Range: 0.025 to 19.999 inches (0.63 to 500 millimeters) Resolution: 0.001 inch (0.01 millimeter) Accuracy:...
Page 39: Appendix B Application Notes
APPENDIX B Application Notes Measuring pipe and tubing When measuring a piece of pipe to determine the thickness of the pipe wall, orientation of the transducers is important. If the diameter of the pipe larger than approximately inches, measurements should made with transducer oriented so that the gap in the wearface...
Page 40 Perpendicular Parallel Measuring laminated materials Laminated materials are unique in that their density (and therefore sound-velocity) may vary considerably from one piece to another. Some laminated materials may even exhibit noticeable changes in sound-velocity across a single surface. The only way to reliably measure such materials is by performing a calibration procedure on a sample piece of known thickness.
Page 41 minimized. An additional important consideration when measuring laminates, is that any included air gaps or pockets will cause an early reflection of the ultrasound beam. This effect will be noticed as a sudden decrease in thickness in an otherwise regular surface. While this may impede accurate measurement of total material thickness, it does provide the user with positive indication of air gaps in the laminate.
Page 42: Appendix C Sound Velocities Of Some Common Materials
APPENDIX C Sound Velocities of some Common Materials sound velocity Material in/us Aluminum 0.250 6350 Bismuth 0.086 2184 Brass 0.173 4394 Cadmium 0.109 2769 Cast Iron 0.180 (apprx) 4572 Constantan 0.206 5232 Copper 0.184 4674 Epoxy resin 0.100 (apprx) 2540 German silver 0.187 4750...