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Foerster CORCOGRAPH Ro 20 P Operating Instructions Manual

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CIRCOGRAPH
Sensor system Ro 20 P 6.460
Operating Instructions

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Summary of Contents for Foerster CORCOGRAPH Ro 20 P

  • Page 1 ® CIRCOGRAPH Sensor system Ro 20 P 6.460 Operating Instructions...
  • Page 3 FOREWORD FOREWORD These operating instructions were written to be read, understood and complied with in full by those persons responsible for operat- ing the machine. The complete operating instructions consist of the following sec- tions: Safety Description Installation Operation Maintenance Machine faults can only be avoided and fault-free operation of the machine can only be guaranteed through knowledge of the oper- ating instructions.
  • Page 4 Copyright These operating instructions contain copyrighted information. All rights reserved, INSTITUT DR. FOERSTER GmbH & Co. KG. These operating instructions are intended for assembly, operating and monitoring personnel. Copying, reproduction or translation of these operating instructions into other languages in whole or in part requires the express written approval of INSTITUT DR.

  • Page 5: Table Of Contents

    SENSOR SYSTEM Ro 20 P Table of Content page SAFETY Table of Content Dangers posed by this machine Safety information and tips Use as intended Dangers posed by accessories Emissions Danger sources Workstations Authorised operators Personal safety equipment 1.10 Safety measures at the installation location 1.11 Protective safety devices 1.12...
  • Page 6 SENSOR SYSTEM Ro 20 P Table of Content page OPERATION Dimension change Preparation Dimension change procedure Selection and installation of the protective nozzles 4.2.1 Selection of the protective nozzles Function of the protective nozzles Standard Nozzle Precision Nozzle 4.2.2 Required tools Changing nominal diameter 4.3.1 Preparation 4.3.2 Removing nozzle holder...

  • Page 7: Safety

    SENSOR SYSTEM Ro 20 P SAFETY 1.1 Dangers posed by this machine SAFETY Dangers posed by this machine The CIRCOGRAPH sensor system Ro 20 P features protective safety devices. It has been subjected to a safety test and safety acceptance test. In the event of operating errors or misuse, the machine may pose dangers and risks to §...

  • Page 8: Use As Intended

    SENSOR SYSTEM Ro 20 P 1.3 Use as intended SAFETY Use as intended The CIRCOGRAPH sensor system Ro 20 P is suitable only for non-destructive testing of round material. Diameter range 2 mm to 20 mm, continuously adjustable! Larger diameters may not be admitted into the sensor system un- der any circumstances.

  • Page 9: Danger Sources

    SENSOR SYSTEM Ro 20 P SAFETY 1.6 Danger sources Danger sources The CIRCOGRAPH sensor system Ro 20 P operates with a rotating test system and an attached roller guide system during operation. A person coming into contact with the roller guide or the rotating test system may suffer very serious injuries.

  • Page 10: Safety Measures At The Installation Location

    SENSOR SYSTEM Ro 20 P 1.10 Safety measures at the installation location SAFETY 1.10 Safety measures at the installation location The CIRCOGRAPH sensor system Ro 20 P must be installed stably on a machine foundation provided for it and must be firmly anchored to the foundation.
  • Page 11 DECLARATION of CONFORMITY Manufacturer: INSTITUT DR. FOERSTER GmbH & Co. KG Phone. +49 7121 140-0 In Laisen 70 +49 7121 140-488 72766 Reutlingen info@foerstergroup.de GERMANY www.foerstergroup.de Responsibility for documentation: Dr. Juergen Schroeder Product: CIRCOGRAPH DS Ro20 Type: 6.460.01-1001 Serial No.:...
  • Page 12 SENSOR SYSTEM Ro 20 P Notes: 6.460 - 10/2002...

  • Page 13: Description

    SENSOR SYSTEM Ro 20 P Description 2.1 Application BESCHREIBUNG Description Application Nondestructive testing of ferromagnetic, austenitic and nonferromagnetic round materials (wires, bars and tubes) for sur- ® face flaws in conjunction with the CIRCOGRAPH DS 6.430 (two ® channel with Clearance Compensation) or CIRCOGRAPH CP 6.412 (one-channel without Clearance Compensation) testing and eval- uation electronic equipment and a suitable mechanical handling...

  • Page 14: Mode Of Operation

    SENSOR SYSTEM Ro 20 P 2.2 Mode of operation Description Mode of operation The sensor system Ro 20 operates on the basis of the eddy-cur- rent principle in accordance with EN 12 . 084. Rotating systems Rotiersonde are used to detect longitudinal surface defects. Probes rotate at Sondenrotation Rotating probe Probe rotation...
  • Page 15 SENSOR SYSTEM Ro 20 P Description 2.2 Mode of operation Fig. 2/4 Test equipment configuration, CIRCOGRAPH CP (top), CIRCOGRAPH DS (bottom) 6.460 - 10/2002...

  • Page 16: Construction

    SENSOR SYSTEM Ro 20 P 2.3 Construction Description Construction CIRCOGRAPH DS or DEFECTOMAT CP test electronics and the connection cables are required for a complete test system, be- sides the sensor system which scans the test material and gener- ates the eddy-current signal. Separate Leaflets: “CIRCOGRAPH DS System 6.430", Order-No.
  • Page 17 SENSOR SYSTEM Ro 20 P Description 2.3 Construction The compact CIRCOGRAPH CP test electronics is recommended in the following cases § no clearance compensation is required § a reasonably priced solution is needed In order to withstand the rough conditions of use, the Ro 20 P has been designed to be dust-protected, robust and reliable by means of complex constructional measures such as labyrinth seals and dirt deflectors.

  • Page 18: Test Heads

    SENSOR SYSTEM Ro 20 P 2.3 Construction Description 2.3.1 Test Heads The test heads are both the heart of the sensor system and its most critical components. They consist of an eddy-current probe with field, measuring and clearance windings which are installed in a precise mechanical holder and are connected by means of a highly flexible special cable with a connection plug.

  • Page 19: Rotating Head Ro 20 P

    SENSOR SYSTEM Ro 20 P Description 2.3 Construction 2.3.2 Rotating Head Ro 20 P The rotating head is the main component of the sensor system. It consists of: § rotor § transmitter § drive § housing § rotating head electronics The test direction can be selected as right or left (viewed in the throughput direction).

  • Page 20: Sensor

    The cable to the test electronics is connected using MIL plug connectors. The drive motor is connected directly using a Harting plug con- nector. Drive FOERSTER CIRCOGRAPH DS 6.430 Rotier- Vorverstärker übertrager...
  • Page 21 SENSOR SYSTEM Ro 20 P Description 2.3 Construction Indestructible 3-phase drive with a cage motor in conformance with standards. External motor control for power supply to the drive. The following versions are available: § MOC E motor control ú fixed rotational speed of 9,000 rpm at 50 Hz mains supply. ú...

  • Page 22: Diameter Adjustment

    SENSOR SYSTEM Ro 20 P 2.3 Construction Description Diameter adjustment Diameter adjustment is carried out manually with a tool. The lin- ear scale is located on the rotor. The diameter can be adjusted with an accuracy of 0.1 mm. Protective nozzles standard The protective nozzles have a dual function: They protect the test heads from damage, particularly during en- try and exit of the test material, provided that the straightness...
  • Page 23 SENSOR SYSTEM Ro 20 P Description 2.3 Construction Protective nozzles can be ordered from INSTITUT DR. FOERSTER or can be manufactured by the customer on the basis of draw- ings. Nozzle Holder Outside Nozzle Outside Nozzle Inside Nozzle Holder Inside Fig.

  • Page 24: Precision Guide

    SENSOR SYSTEM Ro 20 P 2.3 Construction Description Precision guide This option is recommended in addition to the protective nozzle function if short parts, thin bars or copper pipes are to be tested. Additional narrow-tolerance guide cores in the entry and exit ar- eas, near to the test heads, improve guidance and reduce test material vibrations during throughput.

  • Page 25: Roller Guide

    SENSOR SYSTEM Ro 20 P Description 2.3 Construction Roller guide The roller guides have two advantages: In set-up mode, a calibration piece with reference flaws can be held centrically outside the test line and the test electronics can be adjusted simply, since the rotating probes periodically scan the test flaw and display the signal quasi-statically.

  • Page 26: Technical Data

    SENSOR SYSTEM Ro 20 P 2.4 Technical data Description Technical data Ro 20 P Test material diameter range 2 to 20 mm, continuously adjustable Revolution speed MOC E motor control 9,000 rpm MOC EV motor control up to 18,000 rpm Type of test without physical contact Test heads (TH)

  • Page 27: Operating, Storage And Transport Conditions

    § temperature range -20° C to +70° C § max. relative humidity 95 %, condensation not permissible § maximum storage duration approx. 12 months (extension pos - sible after intermediate check by FOERSTER employee) 2/15 6.460 - 07/2003...

  • Page 28: Dimension Sheet

    SENSOR SYSTEM Ro 20 P 2.6 Dimension sheet Description Dimension sheet 50,0 Fig. 14 Dimension drawing 1 2/16 6.460 - 10/2002...
  • Page 29 SENSOR SYSTEM Ro 20 P Description 2.6 Dimension sheet Fig. 15 Dimension drawing 2 2/17 6.460 - 10/2002...

  • Page 30: Standard Components

    SENSOR SYSTEM Ro 20 P 2.7 Standard Components Description Standard Components Order-No. Designation Part-No. 1373900 ROTATING HEAD RO 20 6.460.01-1001 1638378 ROTATING HEAD RO 20, OIL AIR LUBRICATION 6.460.01-1031 1650785 TEST CABLE DS 10M, CIRCOGRAPH-DS 6.460.01-9921 1655078 TEST CABLE 10M, FOR USING WITH CP 6.460.01-9925 1638343 MOTOR CABLE 10M...

  • Page 31: Installation

    SENSOR SYSTEM Ro 20 P INSTALLATION 3.1 Setup and Connection INSTALLATION INSTALLATION Setup and Connection NOTE! The sensor system must be mounted on a horizontally shiftable lifting table in order to be able to change the di- mensions or to carry out service work outside of the test line.

  • Page 32: Electrical Connections

    SENSOR SYSTEM Ro 20 P 3.1 Setup and Connection INSTALLATION Electrical connections Connection Motor cable Connection testing cable Fig. 3/2 Rotating head, connections Remote (Option) Remote cable Motor control Power line Cooling air Motor cable 10 m 6.460.01-9931 Testing cable 10 m 6.460.01-9911 Test electronics Light barriere...

  • Page 33: Operation

    SENSOR SYSTEM Ro 20 P OPERATION 4.1 Dimension change BEDIENUNG OPERATION Dimension change The following steps must be carried out during conversion Set test head to new nominal value of protective nozzles Insert suitable protective nozzles Set roller guides to test diameter Center sensor system in the test line Preparation §...

  • Page 34: Selection And Installation Of The Protective Nozzles

    Table 4/1 Target nozzle grading for D = nominal diameter of test material DD = nominal size of protective nozzles The FOERSTER standard protective nozzle range is based on the grading recommendation above. The protective nozzles can be selected more precisely depending on the test diameter if the quality of guidance is sufficiently pre- cise.

  • Page 35: Standard Nozzle

    SENSOR SYSTEM Ro 20 P OPERATION 4.2 Selection and installation of the protective nozzles Standard Nozzle Important! Do not slide the test material in and out without nozzle - risk of major damage. Operate only with protective nozzles! Nozzle Outside Drawing No. Nozzle Inside Drawing No.
  • Page 36 SENSOR SYSTEM Ro 20 P 4.2 Selection and installation of the protective nozzles OPERATION Precision guide Important! Do not slide the test material in and out without nozzle - risk of major damage. Operate only with protective nozzles! Nozzle Outside Drawing No. Nozzle Inside Drawing No.

  • Page 37: Required Tools

    SENSOR SYSTEM Ro 20 P OPERATION 4.2 Selection and installation of the protective nozzles 4.2.2 Required tools § Hexagon screwdriver, straight a/f 5 x 200 mm T-handle 016 851 6 § Hexagon socket head wrench 5 x 100 mm 014 002 3 §...

  • Page 38: Changing Nominal Diameter

    SENSOR SYSTEM Ro 20 P 4.3 Changing nominal diameter OPERATION Changing nominal diameter 4.3.1 Preparation § select new protective nozzles according to Chapter 4.2 § switch off drive and wait for standstill § move test material out of the sensor system §...

  • Page 39: Removing Nozzle Holder

    SENSOR SYSTEM Ro 20 P OPERATION 4.3 Changing nominal diameter 4.3.2 Removing nozzle holder Adjustment side § open roller guides with hand wheel until the nozzle holder is accessible § undo fastening of outside nozzle holder § turn outside nozzle holder anti-clockwise §...

  • Page 40: Drive Side

    SENSOR SYSTEM Ro 20 P 4.3 Changing nominal diameter OPERATION Drive side § open roller guides with hand wheel until the nozzle holder is accessible § undo fastening of inside nozzle holder § turn inside nozzle holder anti-clockwise § remove inside nozzle holder Inside nozzle holder 2 hexagon sockets...

  • Page 41: Changing Nozzles

    SENSOR SYSTEM Ro 20 P OPERATION 4.3 Changing nominal diameter 4.3.3 Changing nozzles § unscrew the nozzles from the nozzle holder using two hook spanners CAUTION! If the nozzle holder is fixed in a vice, clamp on the sur- faces only! Outside nozzle holder Outside protective...

  • Page 42: Adjusting Probe Clearance

    SENSOR SYSTEM Ro 20 P 4.3 Changing nominal diameter OPERATION 4.3.4 Adjusting probe clearance The test heads are adjusted to the nominal diameter (clear open- ing) of the protective nozzles. The adjustment scale is calibrated in such a matter that a safety distance of 0.2 mm is maintained between the protective nozzle and test head when adjusting to the nominal diameter over the entire adjustment range.
  • Page 43 SENSOR SYSTEM Ro 20 P OPERATION 4.3 Changing nominal diameter § Open rotor cover To do this, pull ball handle and swivel out locking plate Opening, rotor lock- ing device Cover lock Cover Fig. 4/11 Adjustment side, rotor cover and rotor locking device 4/11 6.460 - 10/2002...
  • Page 44 SENSOR SYSTEM Ro 20 P 4.3 Changing nominal diameter OPERATION § Insert wrench 154 215 0 in the graduated disc (with pointer) § Insert 5 mm socket spanner into the opening of the rotor lock- ing device and fix rotor in position 5 mm socket spanner Wrench...

  • Page 45: Adjusting Roller Guide

    SENSOR SYSTEM Ro 20 P OPERATION 4.4 Rotational speed preselection 4.3.5 Adjusting roller guide § open roller guide in accordance with material diameter § insert test material § adjust roller guide so that the rollers just touch the test mate- rial NOTE! The test piece must run centrically through the sensor...

  • Page 46: Switching On Motor

    SENSOR SYSTEM Ro 20 P 4.5 Switching on motor OPERATION Switching on motor NOTE! Check the diameter and height settings of the sensor system before switching on. The operating elements used to switch on the rotating head drive are located on the motor control. The motor control is installed in a separate housing.

  • Page 47: Maintenance

    SENSOR SYSTEM Ro 20 P Maintenance 5.1 Maintenance schedule WARTUNG Maintenance Maintenance schedule WARNING: Do not touch or tamper with the sensor system, with the rotating unit operating! Risk of serious injury! Always switch off the drive and wait for the machine to stop before performing work of any kind! Deceleration times: without braking...

  • Page 48: Cleaning

    5.2 Cleaning Maintenance Cleaning WARNING! Do not use cold cleaner! Isopropyl alcohol or denatured ethyl alcohol are recom- mended as cleaning agents. § make sure the areas around the rotating parts are clean! § remove abrasion and dirt with an industrial vacuum cleaner. Clean rotating disc and test heads with alcohol.

  • Page 49: Removing Test Heads

    SENSOR SYSTEM Ro 20 P Maintenance 5.3 Removing test heads Removing test heads NOTE! Make sure the plug contacts are clean! § swivel cover outwards § set test heads to maximum diameter § remove lid on front side ú undo four M6 x 10 DIN 912 hexagon socket screws ú...
  • Page 50 SENSOR SYSTEM Ro 20 P 5.3 Removing test heads Maintenance § remove graduated ring and spiral disc ú undo four M6 x 16 DIN 912 hexagon socket screws ú remove graduated ring, if necessary press off with two M8 screws ú...
  • Page 51 SENSOR SYSTEM Ro 20 P Maintenance 5.3 Removing test heads § remove ring ú undo four M6 x 16 DIN 912 hexagon socket screws ú press off ring with two M6 screws M6 x 16 Fig. 5/4 Removing ring 6.460 - 10/2002...
  • Page 52 SENSOR SYSTEM Ro 20 P 5.3 Removing test heads Maintenance § take out test heads ú undo the plug connection of the test head cable using pliers ú push the test head outwards in a radial direction and remove § clean test heads (grease lightly if necessary) Fig.

  • Page 53: Installing Test Heads

    SENSOR SYSTEM Ro 20 P Maintenance 5.3 Removing test heads 5.3.1 Installing test heads CAUTION! Use test heads in pairs with the same specifications. The type number is found on the upper side of the test heads. § clean all parts, especially the contact surfaces §...

  • Page 54: List Of Parts Subject To Wear

    SENSOR SYSTEM Ro 20 P 5.4 List of parts subject to wear Maintenance List of parts subject to wear Item-Nr Designation Order-Nor. Quantity installed Quantity recommended Part-No. on stock Rotierkopf 137 276 9 6.460.01 Riemen 017 936 1 Poly-V 280; J4 Firma Flender Spezialunterlegring 017 927 2 Nylite Siegel D = 6...
  • Page 55 Institut Dr. Foerster GmbH & Co. KG Division TS In Laisen 70 D-72766 Reutlingen Postfach 15 64 D-72705 Reutlingen Germany Telefon: +49 (0) 7121 140-270 Fax: +49 (0) 7121 140-459 e-mail: ts@foerstergroup.de Internet: www.foerstergroup.de 6.460 UA06/EN Order no.: 1638360 Edition:...

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