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Foerster CIRCOGRAPH DS Operating Instructions Manual

Sensor system ro 65
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CIRCOGRAPH
DS
Sensor system Ro 65
6.452
Operating Instructions
Original Instructions

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Summary of Contents for Foerster CIRCOGRAPH DS

  • Page 1 ® CIRCOGRAPH Sensor system Ro 65 6.452 Operating Instructions Original Instructions...
  • Page 3 Introduction These Operating Instructions are intended to be read, understood and observed in all points by the persons responsible for operating the equipment. The complete Operating Instructions consist of the following sections: Safety Functional description Installation Operation Maintenance Knowledge of the Operating Instructions is essential for avoiding equipment faults and for ensuring trouble-free operation.
  • Page 4 Copyright © Copyright 2011 INSTITUT DR. FOERSTER GmbH & Co. KG INSTITUT DR. FOERSTER GmbH & Co. KG remains the sole owner of all rights pertaining to all the information contained in these documents. The documents are intended only for the purpose of operating and maintaining the units supplied.

  • Page 5: Table Of Contents

    Table of Contents SAFETY ........................1 Dangers posed by this machine ..................1 Safety information and tips....................1 Use as intended ......................2 Dangers posed by accessories ..................2 Emissions ........................2 Danger sources ....................... 3 Workstations........................3 Authorised operators ....................... 3 Personal safety equipment....................
  • Page 6 Table of Contents INSTALLATION......................25 Setup and Connection....................25 OPERATION......................27 Dimension change ......................27 Selection and installation of the protective nozzles............28 4.2.1 Selection of the protective nozzles ..............28 4.2.2 Required tools ....................29 Adjusting nominal diameter ................... 30 4.3.1 Preparation ......................
  • Page 7 Table of Contents Maintenance of the roller guides ................... 51 Lubrication ......................51 5.5.1 5.5.2 Replacing the track rollers ................. 52 5.5.3 Removing the roller guide levers ............... 53 Checking and changing the V-ribbed belt ..............54 List of parts subject to wear................... 58 6.452...
  • Page 8 Table of Contents Notes: 6.452...

  • Page 9: Safety

    SAFETY 1.1 Dangers posed by this machine 1 SAFETY 1.1 Dangers posed by this machine The sensor system features protective safety devices. It has been sub- jected to a safety test and safety acceptance test. In the event of operat- ing errors or misuse, the machine may pose dangers and risks to the life and limb of the operator, the machine and other operator’s valuables and...

  • Page 10: Use As Intended

    1.3 Use as intended SAFETY 1.3 Use as intended The sensor system is suitable only for non-destructive testing of round material. Diameter range: see 2.4 Technical Data Smaller diameters and larger diameters may not be admitted into the sensor system under any circumstances. Material with a cross-section which is anything other than round may not be admitted into the sensor system under any circumstances.

  • Page 11: Danger Sources

    SAFETY 1.6 Danger sources 1.6 Danger sources The sensor system 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. Switch off the drives before you put your hands into or touch the sensor system.

  • Page 12: Personal Safety Equipment

    1.9 Personal safety equipment SAFETY 1.9 Personal safety equipment You are to wear ear plugs, if the A-weighted equivalent sound pressure level at the workstations of the sensor system is greater than 85 dB(A). Sound pressure level for this equipment: see 2.4 Technical Data. 1.10 Safety measures at the installation location The sensor system must be installed stably on a machine foundation pro- vided for it and must be firmly anchored to the foundation.

  • Page 13: Declaration Of Conformity

    SAFETY 1.13 Declaration of Conformity 1.13 Declaration of Conformity 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 Responsiblity for documentation: Dr. Juergen Schroeder Product: CIRCOGRAPH®...
  • Page 14 1.13 Declaration of Conformity SAFETY Notes: 6.452...

  • Page 15: Functional Description

    FUNCTIONAL DESCRIPTION 2.1 Application 2 FUNCTIONAL DESCRIPTION 2.1 Application Non-destructive testing of ferromagnetic, austenitic and non- ferromagnetic round materials (wires, bars and tubes) for surface flaws in ® conjunction with the CIRCOGRAPH DS testing and evaluation electronic equipment and a suitable mechanical handling system. Diameter range of test material 5 to 65 mm Preferably continuous testing, also separate piece testing Surface free of scale, wherever possible bright...

  • Page 16: Mode Of Operation

    2.2 Mode of operation FUNCTIONAL DESCRIPTION 2.2 Mode of operation The sensor system operates on the basis of the eddy current principle in accordance with EN 12084. Rotating systems are used to detect longitu- dinal surface defects. Probes rotate at high speed and without physical contact around the test piece.

  • Page 17: Construction

    2.3 Construction Fig. 2.1 Test equipment configuration, top: CIRCOGRAPH DS / MOC SB, bottom: Ro 65 entry side / exit side CIRCOGRAPH DS test electronics and the connection cables are re- quired for a complete test system, besides the sensor system which scans the test material and generates the eddy-current signal.
  • Page 18 2.3 Construction FUNCTIONAL DESCRIPTION Fig. 2.2 CIRCOGRAPH Sensor system Ro 65, main view, legend ref. to Chp. 2.7 Roller guide Clamping ring Entry nozzle Outer sleeve Exit nozzle 5 -30 Roller guide Inner sleeve Throughput Fig.2.3 CIRCOGRAPH Sensor system Ro 65, basic components 6.452...
  • Page 19 FUNCTIONAL DESCRIPTION 2.3 Construction In order to withstand the rough conditions of use, the rotating head has been designed to be dust-protected, robust and reliable by means of complex constructional measures such as labyrinth seals and dirt deflec- tors. The chamber surrounding the test zone serves the purpose of contact and burst protection as well as dust collection.

  • Page 20: Test Heads

    2.3 Construction FUNCTIONAL DESCRIPTION 2.3.1 Test Heads The test heads are both the heart of the sensor system and its most criti- cal components. They consist of an eddy-current probe with field, measuring and clear- ance 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 21: Rotating Head Ro 65

    FUNCTIONAL DESCRIPTION 2.3 Construction 2.3.2 Rotating Head Ro 65 The rotating head is the main component of the sensor system. It consists of: Rotor Transmitter Drive Housing Rotating head electronics The operating side is to be selected as right or left in the order! Fig.
  • Page 22 2.3 Construction FUNCTIONAL DESCRIPTION Transmitter Wear-resistant rotating transmitter in disc-type construction with two field transmitters, four measuring channels and a clearance channel. Consisting of a rotor and stator, it transmits the field current for the rotat- ing probes from the stator to the rotor and, in the opposite direction, transmits the test signal to the test electronics for evaluation.
  • Page 23 FUNCTIONAL DESCRIPTION 2.3 Construction Drive Indestructible 3-phase drive with a cage motor in conformance with stan- dards. External motor control MOC SB for power supply to the drive: Rotational speed switchable 3,000 or 6,000 rpm, with electrical breaking. Minimized bearing wear through adaptation of rotational speed to test speed For applications with changing testing speeds.
  • Page 24 2.3 Construction FUNCTIONAL DESCRIPTION Protective nozzles standard They protect the test heads from damage, particularly during entry and exit of the test material, provided that the straightness conditions and the end properties are observed. Protective nozzles are available in nominal sizes of 5.0 to 67 mm. They limit the maximum eccentricity of the test material within the zone to be tested to a narrow dimension within which the clearance compensa- tion can fully compensate the sensitivity fluctuations.
  • Page 25 2.3 Construction Entry and exit nozzles must always be used in pairs with the same nomi- nal value. Protective nozzles can be ordered from INSTITUT DR. FOERSTER or can be manufactured by the customer on the basis of drawings. WARNING! Operation without protective nozzles is not permitted for damage and safety reasons.
  • Page 26 2.3 Construction FUNCTIONAL DESCRIPTION Roller guide The centric roller guides have two advantages: In set-up mode, a calibration piece with reference flaws can be held cen- trically outside the testing section and the test electronics can be adjusted simply, since the rotating probes periodically scan the test flaw and dis- play the signal quasi-statically.

  • Page 27: Technical Data

    FUNCTIONAL DESCRIPTION 2.4 Technical Data 2.4 Technical Data Diameter range test material continuously adjustable 5 to 65 mm Rotational speed 3,000 or 6,000 rpm MOC SB motor control Switchable with. Brake Deceleration times from 6,000 rpm without braking approx. 360 sec with braking approx.

  • Page 28: Dimension Sheet

    2.5 Dimension sheet FUNCTIONAL DESCRIPTION 2.5 Dimension sheet Entry side Fig. 2.9 Dimension sheet I 6.452...
  • Page 29 FUNCTIONAL DESCRIPTION 2.5 Dimension sheet Fig. 2.10 Dimension sheet 2 6.452...

  • Page 30: Environmental Conditions

    -20° C to +70° C max. relative humidity 95 %, condensation not permissible maximum storage duration approx. 12 months (extension possible after intermediate check by FOERSTER employee) Emissions The A-weighted sound pressure level at intervals of 1 m from the ma- chine's surface and at 1.60 m height is for maximum rotational speed...

  • Page 31: Standard Components

    FUNCTIONAL DESCRIPTION 2.7 Standard Components 2.7 Standard Components Legend No Part name Part-No Order-No Rotating head Ro 65 6.452.01-1301 1656660 Test cable DS 10M, CIRCOGRAPH-DS 6.460.01-9921 1650785 Motor cable 10M 6.460.01-9931 1638343 Grounding cable 10M 6.460.01-9911 1588818 Test head N, BS=2 x 2.5 6.452.01.2311 1447017 Test head N, BS=2 x 5...
  • Page 32 2.7 Standard Components FUNCTIONAL DESCRIPTION Notes: 6.452...

  • Page 33: Installation

    INSTALLATION 3.1 Setup and Connection 3 INSTALLATION 3.1 Setup and Connection NOTE! The sensor system must be mounted on a horizontally shiftable lifting table in order to be able to change the dimensions or to carry out ser- vice work outside of the testing section. Requirements of the lifting table: It must be designed accordingly for the weight and function of the sen- sor system...
  • Page 34 Motor cable 10 m 6.460.01-9931 Testing cable 10 m 6.460.01-9921 Test Electronics Fig. 3.3 Connection 2-channel rotating head to CIRCOGRAPH DS NOTE! Protective conductor connection (PE) according to EN 61010 (VDE 0411) Connect the protective conductor terminal of the electronic cabinet and the other system components, e.

  • Page 35: Operation

    OPERATION 4.1 Dimension change 4 OPERATION 4.1 Dimension change The following steps must be carried out during conversion: Set test head to new nominal value of test material Insert suitable protective nozzles Set roller guides to test diameter Centre sensor system in the testing section Preparation Select protective nozzles for new test piece measurement.

  • Page 36: Selection And Installation Of The Protective Nozzles

    4.2 Selection and installation of the protective nozzles OPERATION Move rotating head into testing section. Insert test material. 4.2 Selection and installation of the protective nozzles 4.2.1 Selection of the protective nozzles Function of the protective nozzles Guarantee protection from damage during entry, even for test pieces with larger diameters, impermissible curvatures or deformed fronts or ends.

  • Page 37: Required Tools

    OPERATION 4.2 Selection and installation of the protective nozzles 4.2.2 Required tools Usage Tool Order-No Nozzle exchange Hexagon screwdriver, warped 012 558 0 and diameter set- a/f 2,5 mm (extended) ting Hexagon screwdriver, warped 012 559 8 a/f 3 mm (extended) Hexagon screwdriver, warped 012 560 1 a/f 4 mm (extended)

  • Page 38: Adjusting Nominal Diameter

    4.3 Adjusting nominal diameter OPERATION 4.3 Adjusting nominal diameter 4.3.1 Preparation Select protective nozzles according to Chapter 4.2. Switch off drive and wait for standstill. Move test material out of the sensor system. Move sensor system out of the testing section. Opening the roller guides Turn the locking bolt in ccw direction up to the stop.

  • Page 39: Removing Entry Nozzle

    OPERATION 4.3 Adjusting nominal diameter 4.3.2 Removing Entry Nozzle Unscrew three Allen screws M 6 x 22 DIN 912 (A). Open and remove the clamping ring (8). Remove the nozzle (7) out of the housing flange (6). Allen screws (A) Fig.4.2 Changing the entry nozzles, legend ref.

  • Page 40: Adjusting Nominal Diameter

    4.3 Adjusting nominal diameter OPERATION 4.3.3 Adjusting nominal diameter Housing flange Unscrew three Allen screws M 6 x 10 DIN 912 (C). Turn ccw and remove housing flange. Allen screws (C) Fig. 4.3 Housing flange NOTE! Mass housing flange approx. 7 kg! 6.452...
  • Page 41 OPERATION 4.3 Adjusting nominal diameter Recommended settings bright material raw from rolling track width BS Test heads according the opposite Fe - Nfe - Aust table are set to the test piece nominal diameter with respect to 6.452.01-2311 6.452.03-2311 2 x 2.5 mm the selected nozzle.
  • Page 42 4.3 Adjusting nominal diameter OPERATION Diameter setting WARNING! Do not adjust the nominal diameter to values higher than 65 mm! Overwinding can snap off the test heads from the cam disk and test heads will be clamped when reverse winding! Untighten two clamping screws (C), approx.
  • Page 43 OPERATION 4.3 Adjusting nominal diameter Remove exit nozzles Allen screws (D) Allen screws (E) Fig.4.6 Nozzle changing exit side, legend see Chapter 2.7 Nozzle 5 - 30 mm Untighten three Allen screws M 6 x 16 DIN 912 (E). Remove inner sleeve (12.1) with exit nozzle fitted (3) from outer sleeve (12.2).

  • Page 44: Fitting Protective Nozzles

    4.3 Adjusting nominal diameter OPERATION 4.3.4 Fitting protective nozzles Select nozzles according to Chapter. 4.2.1. NOTE! Clean all parts before fitting them carefully! Check for wear each time before using them! Do not use worn nozzles! Use only nozzle pairs with the same nominal diameter! Fig.
  • Page 45 OPERATION 4.3 Adjusting nominal diameter Exit nozzle 5 - 30 mm NOTE! The outer sleeve (12.2) is already in place. Fit the exit nozzle (3) onto the dovetail guide of the inner sleeve(12.1). Insert the inner sleeve(12.1) with exit nozzle (3) fitted into the outer sleeve (12.2).

  • Page 46: Setting The Roller Guides

    4.3 Adjusting nominal diameter OPERATION 4.3.5 Setting the roller guides Set the roller guide coarsely to the nominal diameter in accordance with the scale (in the case of new track rollers, the clear diameter of the track rollers corresponds exactly to the scale setting). Fig.

  • Page 47: Rotational Speed Preselection

    OPERATION 4.4 Rotational speed preselection 4.4 Rotational speed preselection MOC SB motor control Rotational speed switchable 3,000 or 6,000 rpm The motor control supplies the required voltages and currents and contain the necessary switching and safety devices (contactors, motor protection switches, protective circuits).

  • Page 48: Switching On Motor

    4.5 Switching on motor OPERATION 4.5 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 lo- cated on the motor control. The motor control is installed in a separate housing.

  • Page 49: Application Drawing Line

    OPERATION 4.6 Application drawing line 4.6 Application drawing line Function Protection of the test heads against unacceptable test material condi- tions. In particular, during entry and exit of drawing point or deformed nose or tail. Limitation of the deviation of the test material with respect to the rotat- ing head axis.
  • Page 50 4.6 Application drawing line OPERATION Selecting and fitting the protective nozzles WARNING! Do not slide the test material in or out without nozzles. This involves the risk of major damages! Never operate the system without protective nozzles installed! Auxiliary nozzle Entry nozzle robust Exit nozzle robust Test material -Ø...
  • Page 51 OPERATION 4.6 Application drawing line Recommended settings Test head Track width Bs Test heads according the opposite table are set to the test piece nomi- 6.452.03-2321 2 x 5 mm nal diameter with respect to the se- lected nozzle. Nozzle diameter DD [mm] Scale While considering this setup rec- ommendations a sufficient probe...
  • Page 52 4.6 Application drawing line OPERATION Notes: 6.452...

  • Page 53: Maintenance

    MAINTENANCE 5.1 Maintenance schedule 5 MAINTENANCE 5.1 Maintenance schedule WARNING! Risk of injury! Always switch off the drive and wait for the machine to stop before per- forming work of any kind! Do not touch or tamper with the sensor system, with the rotating unit operating! Deceleration times: without braking approx.

  • Page 54: Cleaning

    5.2 Cleaning MAINTENANCE 5.2 Cleaning WARNING! Do not use solvent cleaner, petrol or alcohol! Use commercially available cleaning agents. Observe the instructions for use from the respective cleaning agent manufacturer. Make sure the areas around the rotating parts are clean! Remove abrasion and dirt with an industrial vacuum cleaner.

  • Page 55: Removing And Fitting The Test Heads

    MAINTENANCE 5.3 Removing and fitting the test heads 5.3 Removing and fitting the test heads NOTE! Make sure the plug contacts are clean! Open housing flange. Untighten three Allen screws M 6 x 10 DIN 912 (C). Turn and remove housing flange. Fig.
  • Page 56 5.3 Removing and fitting the test heads MAINTENANCE NOTE! Use test heads as a set with the same specifications. The type number is found on the side of the test heads. Clean all parts, especially bolt (2), sealing ring (3), collared bushes (ref. to Fig.
  • Page 57 MAINTENANCE 5.3 Removing and fitting the test heads Fig. 5.3 Test heads fitted, lid (7) not assembled, spring in standard position Fig. 5.4 Test heads fitted, lid (7) not assembled, spring in position “drawing line” 6.452...

  • Page 58: Replacing Parts Subject To Wear

    5.4 Replacing parts subject to wear MAINTENANCE 5.4 Replacing parts subject to wear NOTE! Test heads with worn slide-on or protective strips can be repaired prop- erly only by the manufacturer! slide ring 1481649 collared bush 1196588 collared bush 1196588 tension spring 0163309 Fig.

  • Page 59: Maintenance Of The Roller Guides

    MAINTENANCE 5.5 Maintenance of the roller guides 5.5 Maintenance of the roller guides 5.5.1 Lubrication CLP 68 CLP 68 CLP 68 CLP 68 Fig. 5.7 Lubricating the roller guide The lubrication points marked with CLP 68 must be lubricated 1 x weekly with lubricant oil of ISO viscosity class 68 (DIN 51519) or similar.

  • Page 60: Replacing The Track Rollers

    5.5 Maintenance of the roller guides MAINTENANCE 5.5.2 Replacing the track rollers NOTES! Track rollers may be changed with the roller leaver either fitted or re- moved. Always change all three rollers at the same time! When roller leaver (4) fitted, open the roller guides to the maximum diameter.

  • Page 61: Removing The Roller Guide Levers

    MAINTENANCE 5.5 Maintenance of the roller guides 5.5.3 Removing the roller guide levers NOTE! The levers of the roller guide should be removed for replacement of the track rollers or for thorough maintenance and care of the roller guide. Remove retaining plates (6). Pull out bolts (5) of leaver (4).

  • Page 62: Checking And Changing The V-Ribbed Belt

    5.6 Checking and changing the V-ribbed belt MAINTENANCE 5.6 Checking and changing the V-ribbed belt Fig. 5.10 Checking the belt tension Set the belt’s bowing under load so that it does not whistle or lisp during accelera- tion. NOTE! For exact tensioning check with a spring balance! Fig.
  • Page 63 MAINTENANCE 5.6 Checking and changing the V-ribbed belt Loosen the clamping screws M8 x 25 DIN 912 (accessible through the 4 holes in the belt pulley). Fig. 5.12 Setting the belt tension, loosening the engine mount In order to tension the belt, adjust the hexagon screw M8 x 25 DIN 933 and lock with nut M8 DIN 934.
  • Page 64 5.6 Checking and changing the V-ribbed belt MAINTENANCE Changing the V-ribbed belt Unscrew the three fastening screws M8 x 16 DIN 6912 of the belt cover and remove the belt cover. Loosen the clamping screws M8 x 25 DIN 912 (ref. to Fig. 5.12). Loosen the hexagon screw M8 x 25 DIN 933 and lock M8 DIN 934 (ref.
  • Page 65 MAINTENANCE 5.6 Checking and changing the V-ribbed belt NOTE! Before the exit-side face plate is screwed on, the special washers fitted on the screws must be checked for damage (earth fault). They must be replaced by new ones if necessary. Fig.5.15 Special washer left: after tightening right:: initial condition...

  • Page 66: List Of Parts Subject To Wear

    5.7 List of parts subject to wear MAINTENANCE 5.7 List of parts subject to wear Name Part-No. Quantity fitted in the Recommended minimum Order-No. sensors system quantity on stock Rotating head 6.452.01-1301 V-ribbed belt 0160750 Poly-V 490; J4 F. Reiff V-seal 0164305 Sealing ring...
  • Page 67 INSTITUT DR. FOERSTER GmbH & Co. KG Division TS Semi-finished Product Testing In Laisen 70 72766 REUTLINGEN GERMANY Telephone: +49 7121 140-270 Fax: +49 7121 140-459 E-mail: ts@foerstergroup.de Internet: www.foerstergroup.de 6.452 UA06/EN Order no.: 182 689 1 Edition: 04/2011 Author:...

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