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SpotChecker
Technical Reference and Operating Manual
Ident No. 49 131
Rev. 2.0

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   Summary of Contents for GE SpotChecker

  • Page 1 SpotChecker Technical Reference and Operating Manual Ident No. 49 131 Rev. 2.0...
  • Page 2 This Issue 02, 03/2009 applies to the version 1.0 Subject to change without notice.
  • Page 3: Table Of Contents

    Contents 1 Introduction Echo display comparison method Limitations of software 1.1 Safety information 1.3 The SpotChecker Power supply Special features Software Defects/errors and exceptional stresses 1.4 Standard package Further information 1.5 Required accessories 1.2 Important information on ultrasonic 1.6 Spare parts requirements...
  • Page 4 Contents Inserting batteries 2.9 Software installation Checking the battery charge level Re-installation SpotChecker Exchanging batteries Updates Charging batteries Installation procedure License after re-installation 2.5 Power on/Power off Starting the operation 2.10 Basic settings Closing the operation and shutting down Selecting language Restricting program access 2.6 Interfaces...
  • Page 5 Reference A-scan Basic principle Other inspection methods Comparison of ultrasonic inspection with other inspection methods 3.3 Dialog probes 3.2 The software SpotChecker Overview 4 Care, maintenance, errors Application ranges 4.1 Cleaning the instrument Structured inspection plan: 4.2 Maintenance Evaluation with UltraCAR 4.3 Care of batteries...
  • Page 6 5 Technical specifi cations 6 Annex 5.1 Specifi cation of the interfaces 6.1 EC declaration of conformity 4-pin LEMO 0S connection +15V 6.2 Manufacturer/Service addresses 5.2 Specifi cations SpotChecker 6.3 Disposal Enclosure General view of the device Connections Recycling data of SpotChecker...
  • Page 7: Introduction

    Introduction SpotChecker Issue 02, 03/2009...
  • Page 8: Safety Information

    Safety information Safety information Power supply The power supply for the SpotChecker is carried out The SpotChecker has been designed and tested ac- via one or two batteries or via a connected power sup- cording to DIN EN 61 010 Part 1, Safety requirements ply unit.
  • Page 9: Defects/errors And Exceptional Stresses

    Further information If you have reason to believe that a safe operation of Attention: your SpotChecker is no longer possible, you have to disconnect the instrument and secure it against unin- Observe the documentation for the other equipment tentional reconnection.
  • Page 10: Important Information On Ultrasonic Testing

    Please read the following information before using A proper training comprises for example adequate your SpotChecker. It is important that you understand knowledge of: and observe this information to avoid any operator er- ❚...
  • Page 11: Technical Test Requirements

    GE Sensing & Inspection Technologies organizes spe- cialized training courses in the fi eld of ultrasonic test- ing at regular time intervals. The scheduled dates for Ultrasonic wall thickness measurement these courses will be given to you on request.
  • Page 12: Effect Of The Test Object's Material

    The inspectors should always be informed about the time intervals. Failure to do so may lead to false thick- corresponding nominal wall thicknesses and the likely ness readings. amount of wall thickness losses. Issue 02, 03/2009 SpotChecker...
  • Page 13: Ultrasonic Evaluation Of fl Aws

    fl aws which are as far as possible governed by the be taken to select a probe which will give a suffi ciently same “distance laws” as the natural fl aws to be evalu- narrow beam at the position of the fl aw. ated. SpotChecker Issue 02, 03/2009...
  • Page 14: Limitations Of Software

    fl aw echoes appear, and the more errors occur in the evaluation result. It is therefore important to take the effect of the test object’s surfaces on the height of the echo into ac- count ( transfer correction). Issue 02, 03/2009 SpotChecker...
  • Page 15 Introduction Important information on ultrasonic testing SpotChecker Issue 02, 03/2009...
  • Page 16: The Spotchecker

    ❚ No additional computer hardware required, USB interfaces for printer, external mouse/keyboard and The SpotChecker is a compact ultrasonic instrument data communication with a computer for manual testing. The consistent use of large-scale integrated components enables to carry out essential ❚...
  • Page 17 Introduction The SpotChecker SpotChecker Issue 02, 03/2009...
  • Page 18: Standard Package

    Introduction Standard package Standard package Product code Description Order No. SpotChecker Portable ultrasonic fl aw detector SpotChecker, 36 763 incl. Carrying case 36 764 Lithium-ion battery 10.8 V, 4.8 Ah 109 412 Power supply unit 36 777 USB cable B-A, 1 m...
  • Page 19: Required Accessories

    Introduction Required accessories Required accessories Product code Description Order No. Spot-BAT Lithium-ion batteries 10.8 V, 4.8 Ah 109 412 Spot-Chrg External battery charger 36 748 SpotChecker Issue 02, 03/2009...
  • Page 20: Spare Parts Requirements

    Introduction Spare parts requirements Spare parts requirements Product code Description Order No. Housing, upper part Housing, upper part Spotchecker 36 767 Keypad Spotchecker 36 738 Backlight inverter 109 413 Cable, backlight inverter 36 775 Trackball, left 6 p. 109 407 Cable, trackball left 6 p.
  • Page 21 Shaft, battery cover 36 805 Cover interfaces 36 769 Gasket, cover interfaces 36 771 Knurled screw, cover interfaces 36 807 Handgrip, Spotchecker 36 741 Locking disk, USM 20 34 796 Holder, handgrip Phasor XL 36 585 Washer, red (Receiver) 35 651...
  • Page 22 109 373 Heat cunductive foil, thin 36 753 Heat cunductive foil, thick 36 754 Battery, backup, CR2032 14 452 Cable battery 36 774 Cable, main-USLT 36 797 Jack RJ45/2 × USB/LAN/2 × USB pulse 109 268 Issue 02, 03/2009 SpotChecker...
  • Page 23 Introduction Spare parts requirements Product code Description Order No. PCB USLT-Spotchecker: PCB, USLT USB Spotchecker 36693 Spacer for LEMO 00 36695 Miscellaneous: Power supply/Charger (Standard) 36777 Charger (external) 36748 Battery 109412 Adaptor, Bluetooth (external, USB) 109523 Module WLAN (internal) 36823...
  • Page 24 Issue 02, 03/2009 SpotChecker...
  • Page 25: Initial Start-up And Basics

    Initial start-up and basics SpotChecker Issue 02, 03/2009...
  • Page 26: Overview Of Instrument

    Touch-sensitive screen ( touchscreen), for direct operation of the graphic interface Trackball with two keys, for direct operation of the graphic interface Function keys F1 to F6, function assignment programmable via software Key for switching on and off Issue 02, 03/2009 SpotChecker...
  • Page 27: Back Panel

    Interfaces USB, Ethernet and +15V, for connecting further instruments, network con- nection and for connecting the power supply unit Prop-up stand and handle, for transportation and inclined installation Battery compartment at the bottom, for holding one or two lithium-ion batteries SpotChecker Issue 02, 03/2009...
  • Page 28: Installing The Instrument

    Avoid quick or intense changes in temperature. If the instrument Place the SpotChecker on a stable fl at surface. has been exposed to temperature change of more The device is intended for indoor use. Select a suit- than 10 °C, you must wait two hours or three be-...
  • Page 29: Connecting A Probe

    Wrong connections lead to a mismatching which may result in considerable power losses or distortions of In addition, the dialog probes of GE Sensing & Inspec- the echo waveform. tion Technologies can also be connected, and they are automatically recognized by the USLT system.
  • Page 30: Power Supply

    When powering from mains operation, it is recom- Connect the SpotChecker to the mains socket-outlet mended to use a battery in the SpotChecker in order using the external power supply with the appropriate to prevent a system crash and data loss in the case of power cable.
  • Page 31: Operation Using Batteries

    – Insert a battery into the left-hand or into the right- hand battery compartment. Observe the accurate position of the battery: the contacts have to point back- and downwards. – Close the cover and fasten the knurled screw. SpotChecker Issue 02, 03/2009...
  • Page 32: Exchanging Batteries

    Charging lithium-ion batteries is also possible with the external battery charger recommended and delivered by GE Sensing & Inspection Technologies. You can exchange one battery during operation. – First insert a fully charged battery into an empty Note: compartment.
  • Page 33: 2.5 Power On/ Power Off

    Note: boots up. The green LED illuminates during operation. To switch off the SpotChecker without shutting down After start of the software the SpotChecker is ready the software or the operating system, you have to for testing operation. keep the button on the front panel depressed for at least 4 seconds.
  • Page 34: 2.6 Interfaces

    Five USB sockets and one network interface are locat- net network, e.g. for data transfer. The basic network ed behind the cover on the top side of the SpotChecker. functions are already set up, but have to be adapted and confi gurated to specifi c local-dependent condi- tions.
  • Page 35: Bluetooth

    – Plug the Bluetooth adapter in a free USB connec- tor. If the SpotChecker is switched on, the adapter is initialized and immediately ready for operation. – Shut the cover and fasten the knurled screw.
  • Page 36: Trackballs And Touchscreen

    Trackballs To select or to mark an element of the user interface, The SpotChecker features two trackballs to operate just touch the corresponding point of the screen briefl y the graphical software interface. Both trackballs work with your fi nger.
  • Page 37: Remote Control

    The wireless remote control is not included with the nal interference (e.g. welding robot in the production standard package of the SpotChecker. It is available line). Therefore, especially before storing, check to as an accessory. The remote control consists of a see whether the transmitted commands (e.g.
  • Page 38: Assigning The Remote Control To A Receiver

    – In order to establish the fi rst-time connection hold the remote control as close as possible to the de- sired SpotChecker. – Press key 1 of the remote control, hold it down and press key 8 simultaneously for approx. 2 seconds.
  • Page 39: 2.9 Software Installation

    The old program version is auto- matically deleted; the old database is maintained and The software SpotChecker is installed as well as all automatically copied into the correct directory. required drivers. Installation procedure...
  • Page 40: License After Re-installation

    Physical Address (example: 00-14-22-48-57-BB). With the fi rst-time start of the software after a re-in- – Send the detected MAC addresses to GE Sensing stallation you will be asked for a valid license. & Inspection Technologies. After this you will be given a license fi...
  • Page 41: 2.10 Basic Settings

    Attention: Without a master password, access to the system set- tings is no longer possible. If the master password is lost, please contact your nearest GE Sensing & In- spection Technologies representative. SpotChecker Issue 02, 03/2009...
  • Page 42: Activating The Password Protection

    If the password protection is acti- vated, the box is marked with a tick. – A registered name must be entered, together with a valid password, when the system is started the next time. Issue 02, 03/2009 SpotChecker...
  • Page 43: 2.11 Data Backup

    We recommend the Windows Backup tool for for the data backup. SpotChecker Issue 02, 03/2009...
  • Page 44: Saving Data To External Data Media

    Saving data to external data media Uploading data from external data media Loading data from CD or DVD requires a correspond- Attention: ing external USB drive connected to the SpotChecker. Quit working with the SpotChecker before starting with the data backup. Attention: The data backup on CD or DVD requires a corre- When uploading fi...
  • Page 45: 2.12 Online Help

    Initial start-up and basics Online Help 2.12 Online Help Starting the Online Help The Online Help for the SpotChecker consists of sev- eral chapters and individual sections just like a manu- Context-sensitive Help al. To view the required information, you have to start...
  • Page 46: Buttons

    Contents or to the next section of a sequence of Starting the Online Help without the software topics. The Online Help for the SpotChecker can be opened without activating the program itself beforehand. To do Buttons: this, you have to call the Help fi le.
  • Page 47: Printing

    Help completely if required. Proceed as follows: – Click the Contents button of the Help window. The window Help Topics appears. – Click a chapter (book symbol) or a topic (? symbol) and then the Print button. SpotChecker Issue 02, 03/2009...
  • Page 48 Issue 02, 03/2009 SpotChecker...
  • Page 49: Individual Inspection Reports

    Individual inspection reports SpotChecker Issue 02, 03/2009...
  • Page 50: Ultrasonic Inspection Of Spot Welds Within Automotive Industry

    4. Finally, a non-existing weld produces a long echo shape of this echo sequence. sequence with small echo distances corresponding 1. In the case of a perfectly sound spot weld, the am- to the single plate thickness. plitudes of the successive echoes drop relatively Issue 02, 03/2009 SpotChecker...
  • Page 51: Comparison Of Ultrasonic Inspection With Other Inspection Methods

    fi nished component, e.g. nugget be evaluated as being “OK”. The inspection a body shell. In these cases it is nevertheless mainly result is consequently always on the safe side with SpotChecker Issue 02, 03/2009...
  • Page 52 A disadvantage of these methods is the fact that spection is nevertheless not possible for economic an inspection on the fi nished component is not pos- reasons and, in the case of destructive inspection sible. methods, also for technical reasons. As a result of Issue 02, 03/2009 SpotChecker...
  • Page 53 This rough overview of the current inspection possibili- ties already reveals the reasons for the high motiva- tion with which the well-known, unsolved problem of nondestructive inspection of spot welds using ultra- sonics has been extensively taken up again for some years now. SpotChecker Issue 02, 03/2009...
  • Page 54: The Software Spotchecker

    Overview The basic version was developed in cooperation with the automotive industry, and it is especially suitable The software SpotChecker is used for recording in- for use within the production (e.g. body shell construc- spection results from ultrasonically inspected spot tion) and for quality assurance purposes.
  • Page 55: Application Ranges

    ❚ true-to-location inspection according to the individ- SpotChecker can be used for mobile or stationary ual inspection plan spot weld inspections. It likewise supports the joint management of several inspection stations, for one or ❚...
  • Page 56: Structured Inspection Plan

    (assemblies, subassemblies, plate joints). These structured inspection plans enable a high degree of specifi cation of the inspection sequence and a split- ting-up of complete vehicles according to hierarchical levels. This means that SpotChecker meets the re- Issue 02, 03/2009 SpotChecker...
  • Page 57: Evaluation With Ultracar

    Evaluation with UltraCAR in the automobile manufacture (please see fi gure). UltraCAR is a program from GE Sensing & Inspec- Structured inspection plans can only be created tion Technologies for the statistical evaluation and by means of the Database Manager.
  • Page 58: General Procedure - Linear Inspection Plans

    General procedure – linear inspection plans An inspection plan contains all the data and settings for a standardized inspection sequence. This provides The inspection using SpotChecker generally includes a high degree of reliability, both for the inspection pro- the following steps: cess and for the inspector.
  • Page 59: The Evaluation Assistance Tools

    Up to 20 reference scans can be fi led for A-scan from the backwall echo sequence, and from each evaluation criterion for this purpose. the fl aw echoes if necessary. SpotChecker has an empirically determined table containing typical echo By using the evaluation assistance tools, SpotChecker...
  • Page 60: Evaluation Assistance Ii

    Simultaneously with the defi nition of the evaluation ranges in tabular form, SpotChecker presents the Advantage: The Evaluation Assistance II is well suited graphical display and setting of the ranges. The rang- for steel alloys.
  • Page 61: Evaluation Assistance Iii

    (“with tion. FE”) applies in this case. The indicated result is con- During the inspection process, SpotChecker com- sequently “stick weld”. pares the currently active A-scan with all A-scan char- acteristics stored in the database and carries out the Note: evaluation after this, i.e.
  • Page 62: Evaluation Assistance Iv

    Individual inspection reports The software SpotChecker The gate logic can be set for each gate: coincidence Example: (match) or anticoincidence (non-match). Defi nition of a model scan for inspection criterion OK. An overview shows the number of the sets of gates already stored for each evaluation criterion during the confi...
  • Page 63: A-scan And Racer View

    IV should in any case only be made in agree- can be individually defi ned by you. An evaluation class ment with the Service of GE Sensing & Inspection has been assigned to each thickness zone in correla- Technologies.
  • Page 64 Individual inspection reports The software SpotChecker is to observe a vertical color cursor bar indicating the A-scan view quality of the echoes. There is no additional evaluation of the A-scan. Analo- gously to the A-scan view, the evaluation in the Racer view can be carried out in fully automatic mode, in partly automatic mode, or in manual mode.
  • Page 65: Automatic A-scan Freeze

    The software SpotChecker Racer view Automatic A-scan freeze SpotChecker can automatically freeze the A-scan by means of two-dimensional gates. Up to three gates can be set up for this purpose. As soon as the echoes of the currently active A-scan are situated within these gates, the A-scan is automatically frozen.
  • Page 66: Graphical Marking Of Relevant Echoes

    The software SpotChecker Graphical marking of relevant echoes Interface echo gate During the inspection by means of SpotChecker, and Special probes are used for the spot weld inspection during the confi guration of the Evaluation Assistances, whose delay block consists of a lens fi lled with water.
  • Page 67: Reference A-scan

    Individual inspection reports The software SpotChecker version. An automatic evaluation of the A-scan by one Reference A-scan of the Evaluation Assistances is carried out after the A reference A-scan stored in the database can be conversion. used in connection with the Evaluation Assistances.
  • Page 68: Other Inspection Methods

    The reference A-scan can be scaled and in that way adapted to the individual test environment. Other inspection methods Besides the ultrasonic inspections, SpotChecker can also be used for the documentation of other shop methods (e.g. chipping test using chisel, button test, or micrograph).
  • Page 69: Dialog Probes

    The use of dialog probes is fully supported by The probe monitoring feature included in SpotChecker SpotChecker. This helps to avoid any errors in the de- simplifi es every probe change to be carried out by us- scription and selection of probes.
  • Page 70 Issue 02, 03/2009 SpotChecker...
  • Page 71: Care, Maintenance, Errors

    Care, maintenance, errors SpotChecker Issue 02, 03/2009...
  • Page 72: Cleaning The Instrument

    Cleaning the instrument Cleaning the instrument 4.2 Maintenance The care of the SpotChecker is limited to the regular Check the pins of the connectors at regular intervals. outside cleaning. Use a moist cloth to clean the hous- The pins must not be damaged.
  • Page 73: Charging Batteries

    Attention: battery charger. Pay attention to the instructions for Do not open the housing of the SpotChecker. The unit use included with the battery charger. does not contain any user-serviceable parts. If you are...
  • Page 74 Issue 02, 03/2009 SpotChecker...
  • Page 75: Technical Specifi Cations

    Technical specifi cations SpotChecker Issue 02, 03/2009...
  • Page 76: Specifi Cation Of The Interfaces

    Specifi cation of the interfaces Specifi cation of the interfaces 4-pin LEMO 0S connection +15V Top view of the interface Pin assignment and signals Pin Signal Function Level Direction 1 GND_EXT ground 3 +15V_EXT_IN power +15 V ±5 % input Issue 02, 03/2009 SpotChecker...
  • Page 77: 5.2 Specifi Cations Spotchecker

    Technical specifi cations Specifi cations SpotChecker 5.2 Specifi cations SpotChecker Note: The availability of particular technical features is dependent on the installed software. Enclosure Storage temperature –20 ... +60 °C Operating temperature 0 ... +45 °C Dimensions (W × H × D) 225 ×...
  • Page 78: Connections

    Technical specifi cations Specifi cations SpotChecker Connections Probes 2 × LEMO 00 Triax Power supply unit 1 × LEMO 0S, 4-pin socket Network 1 × RJ45 4 × USB type A socket, 1 × USB type B socket Power supply...
  • Page 79: Ultrasound

    Technical specifi cations Specifi cations SpotChecker Ultrasound Pulser type Spike pulse Pulse repetition frequency (PRF) max. 1,000 Hz, 3 settings (depending on the calibration range), continuous setting approx. 8 ... 1,000 Hz., no continuous pulse sequence Voltage max. 400 V...
  • Page 80 Technical specifi cations Specifi cations SpotChecker Rectifi cation full-wave, positive half-wave, negative half-wave, RF display (up to 150 mm/5.9" steel) Suppression 0 ... 90 % linear DAC/TCG DAC with up to 16 curve points (reference refl ectors), dynamic range 37 dB, maximum slope 6 dB/μs;...
  • Page 81 Technical specifi cations Specifi cations SpotChecker A-scan digitization 1,024 × 1,024 pixels Display freeze static A-scan freeze, dynamic A-scan freeze (peak value, echo dynamics + real- time signal), average freeze via 2 to 32 ultrasonic pulse cycles Echo comparison simultaneous display of the currently active signal and a stored A-scan...
  • Page 82 Issue 02, 03/2009 SpotChecker...
  • Page 83: Annex

    Annex SpotChecker Issue 02, 03/2009...
  • Page 84: Ec Declaration Of Conformity

    The accordance with the requirements of the directive Robert-Bosch-Str. 3 2004/108/EC is proved by compliance of following stan- USLT USB 036752 50354 Hürth dards: GERMANY SpotChecker 036763 • EN 61000-6-2:2005 • EN 55011:2007 + A2:2007 Group 2, Class A Name: Dipl. Ing. Johannes Büchler Remark: Position: „Group 2 contains all ISM equipment in which radio-fre-...
  • Page 85: 6.2 Manufacturer/ Service Addresses

    Should you detect an error on your product, inform Phone +49 (0) 22 33 - 601 111 your local GE Sensing & Inspection Technologies ser- +49 (0) 22 33 - 601 402 vice indicating the error and describing it. If there is anything special that you would like to know France about the use, handling, operation and specifi...
  • Page 86 Annex Manufacturer/Service addresses Great Britain GE Inspection Technologies Limited 892 Charter Avenue Canley Coventry CV4 8AF GREAT BRITAIN Phone +44 845 - 130 3925 +44 845 - 130 5775 GE Inspection Technologies, LP 50 Industrial Park Road Lewistown, PA 17044...
  • Page 87: Disposal

    Annex Disposal 6.3 Disposal Visit http://www.geinspectiontechnologies.com/en/aboutus/ GE Inspection Technologies is an active participant in ehs/index.html Europe’s Waste Electrical and Electronic Equipment for take-back instructions and more information about (WEEE) take-back initiative, directive 2002/96. this initiative. The equipment you purchased required the extrac- tion and use of natural resources for its production.
  • Page 88: General View Of The Device

    Annex Disposal General view of the device In the following you fi nd an instrument overview as well as guidelines and notes for recycling and waste disposal of the components. Issue 02, 03/2009 SpotChecker...
  • Page 89 Upper & lower housing with press fi tted brass sockets Li Ion battery The battery is located in the battery case in the bottom. To open the case use the milled screws. 2 × printed boards inside of the instrument SpotChecker Issue 02, 03/2009...
  • Page 90: Recycling Data Of Spotchecker

    Annex Disposal Recycling data of SpotChecker Recycling/materials code Weight approx. (kg) Important information Materials/components, that have to be treated and disposed separately LCD display 0.35 The fl uorescent tubes of the LCD display contain small amounts of mercury (Hg) Lithium Ion battery 0.30...
  • Page 91 Materials/components that are in general advantageous Stainless steel 0.15 Carry handle Aluminium 0.05 Battery interfase cover Aluminium 0.20 Heat sink Composite Key pad 0.35 Consisting of: Foil/aluminium/glass/spring steel Mounting parts, cable 0.35 Total weight including battery SpotChecker Issue 02, 03/2009...
  • Page 92 Annex Disposal Issue 02, 03/2009 SpotChecker...
  • Page 93: Index

    Index SpotChecker Issue 02, 03/2009...
  • Page 94 Boundaries of the fl aw 13 Dust 28 Care 72 Environmental conditions 9 Changes in temperature 28 Errors 9, 73 Cleaning 72 Evaluation 13, 79 Clearance 28 Connecting a receiver probe 29 Connecting a transmitter probe 29 Connections 78 Issue 02, 03/2009 SpotChecker...
  • Page 95 Help window 45 Network 27, 34 Instrument setting 43 Interfaces 34 Online help 9, 45 Operating temperature 77 Knowledge 10 Operation 33 Operator 10 Overview of instrument 26 Language 41 LEMO 0S connection 76 License 40 SpotChecker Issue 02, 03/2009...
  • Page 96 Index Sound attenuation 14 Spare parts requirements 20 Pin assignment 76 Specifi cation interfaces 76 Pins 72 Specifi cations SpotChecker 77 Power off 33 SpotChecker 16, 54 Power on 33 Standard package 18 Power supply 8, 78 Storage 9 Power supply unit 8, 27, 30, 72...
  • Page 97 Index Transmitter connection 29 Transmitter remote control 37 Ultrasonic inspection 10 Ultrasound 79 Update 39 USB 27, 34 Use 8, 9 Wall thickness measurement 11 WLAN 34 SpotChecker Issue 02, 03/2009...
  • Page 98 Issue 02, 03/2009 SpotChecker...

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