Extech Instruments TKG100, TKG150 User Manual
USER GUIDE
TKG100
Digital Ultrasonic Thickness
Gauge
TKG150
Digital Ultrasonic Thickness
Gauge with Datalogger
Extech Instruments .
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WARRANTY
FLIR Systems, Inc. warrants this Extech Instruments brand device to be free
of defects in parts and workmanship for two years from date of shipment (a six
month limited warranty applies to sensors and cables). If it should become
necessary to return the instrument for service during or beyond the warranty period,
contact the Customer Service Department for authorization. Visit the website
www.extech.com for contact information. A Return Authorization (RA) number
must be issued before any product is returned. The sender is responsible for
shipping charges, freight, insurance and proper packaging to prevent damage in
transit. This warranty does not apply to defects resulting from action of the user
such as misuse, improper wiring, operation outside of specification, improper
maintenance or repair, or unauthorized modification. FLIR Systems, Inc. specifically
disclaims any implied warranties or merchantability or fitness for a specific purpose
and will not be liable for any direct, indirect, incidental or consequential damages.
FLIR‟s total liability is limited to repair or replacement of the product. The warranty
set forth above is inclusive and no other warranty, whether written or oral, is
expressed or implied.
The information in this document is subject to change without notice and describes
only the product defined in the introduction of this documentation. This document
is intended for the use of Extech Instruments customers only (a Flir Systems, Inc.
brand) for the purposes of the agreement under which the document is submitted,
and no part of it may be reproduced or transmitted in any form or means without
the prior written permission. For information address: Flir Commercial Systems,
Inc. 9 Townsend West, Nashua NH, 03063 U.S.A.
The information or statements given in this document concerning the suitability,
capacity, or performance of the mentioned hardware or software products cannot
be considered binding but shall be defined in the agreement made between Flir
Systems and the customer. However, Flir Systems has made all reasonable efforts to
ensure that the instructions contained in the document are adequate and free of
material errors and omissions. Flir Systems will, if necessary, explain issues which
may not be covered by the document.
Other product names mentioned in this document may be trademarks of their
respective companies, and they are mentioned for identification purposes only.
Copyright 2013 Flir Systems, Inc., All Rights Reserved
Printed in the United States of America
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LIABILITY
Ultrasonic testing is a function of using the proper equipment
(electronics, transducer, cable and couplant combination) for the
inspection and a qualified operator who knows how to use this manual,
the instruments and all calibration procedures. The improper use of this
equipment, along with the improper calibration can cause serious
damage to components, factories, facilities, personal injury and even
death.
ALL FLIR SYSTEMS ULTRASONIC THICKNESS GAUGES ARE
NOT INTRINSICALLY SAFE AND SHOULD NOT BE USED IN
ANY HAZARDOUS OR EXPLOSIVE AREAS.
It is understood that the operator of this equipment is a well-trained
inspector qualified by either their own company or another outside
agency to issue Ultrasonic Level I, 40 hour class room training in
Ultrasonic Theory. Flir Systems and any of its employees or
representatives shall not be held responsible for improper use of this
equipment for its intended use. Proper training, a complete
understanding of Ultrasonic wave propagation, thorough reading of this
manual, proper transducer selection, correct zeroing of the transducer,
correct sound velocity, proper test blocks, proper cable length, proper
couplant selection all play a factor in successful ultrasonic thickness
gaging. Special care should be taken when test pieces have rough or
painted surfaces, particularly those applications where the test piece is
thin to begin with as doubling of the echoes is possible even if the
transducer is capable of measuring the desired thickness. As transducers
wear or heat up, results can be either too thin due to a lack of sensitivity
as a result of wear or too thick due to heating up of the transducer,
referred to as “drift.”
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Table of Contents
Table of Contents ........................................................................................ 4
1 Getting Started ......................................................................................... 7
About the TKG Series ............................................................................. 7
Probe Zero................................................................................................ 8
Keypad Functions .................................................................................. 10
Function Keys ........................................................................................ 11
Display Screen ....................................................................................... 11
Battery Power ......................................................................................... 13
Monitoring the Battery from the Display ........................................ 13
Replacing the Batteries ................................................................... 13
2 Basic Gauge Operations ...................................................................... 14
Power on the Gauge ............................................................................. 14
Performing a Reset (TKG100) ............................................................. 16
Performing a Reset (TKG150) ............................................................. 17
About Screen ......................................................................................... 19
3 Calibrating the Gauge/Making Measurements ................................ 20
Velocity Calibration Only ....................................................................... 20
Velocity and Zero Calibration ............................................................... 21
Zero Calibration Only ............................................................................ 22
Delay Line Calibration ........................................................................... 23
5
Automatic Zero ....................................................................................... 24
Measurement Mode with a Datalogger (TKG150) ....................... 26
Measurement Mode without a Datalogger (TKG100) .................. 27
4 Measurement Mode Setup Options ................................................. 29
Using the Clock ...................................................................................... 31
Setting LCD Contrast ............................................................................ 33
Understanding a LOS Reading ............................................................ 33
Using the Hold Option ........................................................................... 34
Using the Fast Option ........................................................................... 35
Using the Gain Option (TKG150 only) ................................................ 38
Using the Diff Option ............................................................................. 39
Using the Alarm Option ......................................................................... 40
‘Vibra’ Alarm (TKG150 only) ........................................................... 44
Using the Echo-to-Echo Option (TKG150 only) ................................. 47
5 Special Gauge Functions ..................................................................... 48
Using the Save Option (TKG150 only) ................................................ 48
Using the Freeze Option ....................................................................... 50
6 Using Datalogger Directory Mode (TKG150) ................................... 55
Selecting a Custom Linear File ...................................................... 63
Selecting a Custom Grid File .......................................................... 63
Reviewing a File .................................................................................... 65
Reviewing a Linear File ................................................................... 66
Reviewing a Grid File ...................................................................... 67
Renaming a File ................................................................ ..................... 67
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Copying a File ........................................................................................ 71
Deleting a File ........................................................................................ 74
7 Technical Specifications ...................................................................... 76
8 Software Options ................................................................................... 79
B-Scan (TKG150 only) .......................................................................... 80
9 Technical Assistance ............................................................................ 81
7
1 Getting Started
About the TKG Series
The TKG100 and TKG150 are portable, digital,
handheld thickness gauges. The TKG series of ultrasonic
thickness gauges are specifically designed to measure the
remaining wall thickness of primarily steel structures.
Vibralarm (vibrates gauge below/above
minimum/maximum thickness value)
Illuminating keypad for easy to view go-no go
thickness values (patent pending)
Automatic transducer replacement intelligence
built in (patent pending)
Unique, programmable left-hand/right-hand
operation (patent pending)
Up to 200 hour battery life with 2 AA batteries
Small, easy to hold, ergonomic, custom molded,
durable case with rubber keypad
Automatic zero capability
Gain boost
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The TKG100 is a base gauge offering a simple user
interface packaged in the same custom molded highdensity plastic case with rubber keypad as the other more
sophisticated models. This gauge offers reliable, accurate
thickness readings on mostly steel structures with access
to only one side.
The TKG150 contains all the same features of the
TKG100 plus:
50,000 (expandable to 100,000) reading
datalogger capacity with complete setup
tracking
Three pre-set files for linear, grid (row advance)
and grid (column advance)
Echo-to-Echo
B-scan
Probe Zero
When turning on the TKG100 or TKG150 (for the sake
of this manual, with the exception of the datalogger, Bscan, and Echo-to-Echo features, the two model
numbers are interchangeable for the basic operation and
calibration), the gauge does an automatic zeroing of the
transducer (after the user selects the transducer from the
list) thus eliminating the need for an on-block zero. The
TKG100 and TKG150 will electronically zero the
transducer upon power up and at a particular time during
normal operation. This feature ensures the transducer is
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working in accordance with electronic zeroing
procedures. This feature is particularly important on high
temperature materials and when the transducer becomes
worn.
Important Notice: Please make sure the transducer
is not coupled to the test piece when the gauge is first
turned on and that there is no couplant on the end of
the transducer. The transducer should also be at room
temperature, clean without any noticeable wear.
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Keypad Functions
The figure below shows the full keypad of the TKG
Series thickness gauges. Refer to the following table that
lists the function of each key on the keypad.
Key
Function
Up arrow key
Down arrow key
Left arrow key
Right arrow key
On/Off symbol (under the F1 key)
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MENU/OK key
F1 key
F2 key
F3 key
Function Keys
Function keys, or F keys, such as F1, F2, and F3 have
various gauge functions and may change depending on
the display screen. View the bottom of the display screen
for the function that corresponds with the appropriate F
key. For example, F1 may correspond with the Save
function, F2 with the Freeze function, or F3 with the
Directory function (Dir).
Display Screen
The gauge has a graphic style Liquid Crystal Display
(LCD). Viewing the screen is best from straight above or
slightly below the surface rather than from side to side. If
external temperatures are below 32F (0C), the display
may be slow to update information.
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The TKG series is designed to show the parameters
selected in the center of the display screen.
The top part of the display screen for TKG150 model
shows the File name, ID number, AA, and 0001 for grid
column and row. The lower part of the display acts as an
interactive tool that allows you to decide how you want
to proceed with the information that is displayed on the
screen. The middle part of the screen shows the
thickness value, In, mm or usec, Echo-to-Echo symbol,
LOS for loss of signal, Freeze, Fast, Min or Max, Alarm
indicator, Differential mode, Low, Med or High gain and
percent remaining battery life.
F1 F2 F3
F1 F2 F3
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Battery Power
Monitoring the Battery from the Display
The TKG series constantly displays the percent battery
life on the bottom right hand corner of the display
screen. When the gauge gets below 20 %, the indicator
will flash.
Replacing the Batteries
To replace the batteries, unscrew the battery door on the
bottom of the gauge and slide out the two “AA”
batteries. Replace with two new “AA” batteries paying
attention that both positive ends are facing towards the
top of the gauge.
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2 Basic Gauge Operations
Power on the Gauge
To power on any of the TKG series thickness gauges
follow these steps:
1. Press and hold the F1 key for more than 3
seconds. The power symbol is under the F1 key
printed on the keypad as shown below.
2. The following (or similar) will appear on the
display screen of the thickness gauge:
3. The next screen that appears automatically is
the transducer selection screen also referred to
as Home screen in the manual.
Power symbol
under the F1 key
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4. Use the up and down arrow keys to select a
transducer and press OK key. (Please note that
the transducer selection will automatically
display the transducer last used prior to shut
off.
5. Press F1 to select the Setup option.
6. Press F2 to select the Reset option.
7. Press F3 to select the Bklite option.
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Performing a Reset (TKG100)
You can reset the TKG100 gauge settings back to the
default settings by performing a gauge reset.
Note: Performing a reset permanently deletes all of
the saved parameters from the gauge and replaces the
settings with default values.
To perform a reset, follow these steps:
1. From the Home screen (transducer select
screen), press the F2 Reset key. The following
Reset screen appears:
2. Press the OK button and the ARE YOU
SURE? Prompt will appear. Press YES, NO, or
BACK using the F1 F2 F3 function buttons as
desired.
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Performing a Reset (TKG150)
You can reset both the TKG150 DATABASE and
PARAMETER settings back to their default settings in
one gauge reset or you can reset the PARAMETER and
DATABASE data individually.
Note: Performing a reset permanently deletes all of
the saved parameters from the gauge and replaces the
settings with default values.
To perform a reset, follow these steps:
1. From the Home screen (transducer select
screen), press the F2 Reset key. The following
Reset screen appears:
2. Use the up and down arrow keys to select
DATABASE, PARAMETERS, or ALL and
then press MENU/OK.
3. The ARE YOU SURE? Prompt will appear.
Press YES, NO, or BACK using the F1 F2 F3
function buttons as desired.
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4. Note that performing a Database Reset clears
all the files in the database and keeps the first
three: Linear, Row increment and Col
increment database files with cleared readings.
All the user created files in the database will be
cleared and deleted.
5. After performing a Reset, the Home screen
appears automatically.
Backlight
The backlight can be turned On or Off by pressing F3 –
Bklite. Backlight can also be turned On, Off or set on
Auto using the Bklight option in the Setup Menu.
Note: Leaving the backlight on will reduce battery life.
If you set the backlight to Auto, the backlight will turn
on during active readings and hold for 15 seconds or
unless otherwise specified.
Note: If the backlight is set to Auto and you have the
gauge in Hold mode, the backlight will shut off after 15
seconds. If you would like the hold to remain lit, then
you must enable the backlight on instead of using
Auto.
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About Screen
You can find information about any of the TKG series
thickness gauges such as the model number, version
number and contact information from the gauge‟s About
screen. To go to the About Screen, follow these steps:
1. From the Home screen (transducer select
screen), press the F2 – Reset key. The Reset
screen will appear.
2. Press the F3 – About key. The following About
screen appears.
3. Press the F1 – Exit key to return to the Reset
selection screen.
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3 Calibrating the Gauge
Calibrating is the process of adjusting the gauge for a
specific material and transducer before testing material to
make sure that all measurements are accurate. You must
always calibrate before measuring material for standard
accuracy.
To measure a thickness of unknown material you need to
know the velocity of the sound in the unknown material.
To find the velocity of the sound you can use one of the
following methods:
Velocity calibration only
Velocity and zero calibration
Zero calibration only
Delay line calibration
Velocity Calibration Only
If you are working with a test piece of known thickness
but unknown material, then you can calibrate the velocity
of the sound in the unknown material by measuring the
time of flight from main-bang to the first back echo. By
using the known thickness you can calculate velocity of
the sound for the unknown material.
To perform any calibration, first go to the measure mode
and press Menu/OK. Then select the Calibration option
from the Menu screen and press OK. The following
Calibration mode screen (or similar) should appear. To
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exit the calibration screen without performing any
calibration, press OK. To proceed to the Velocity
calibration, follow the following instructions.
Cal screen for TKG100 non-datalogger version
While measuring the thicker step, select VEL by pressing
F3. After selecting VEL, you can take the transducer off
the test block. If the displayed measurement is different
than the known value of the step, use the up or down
arrow key to adjust the displayed value to the known
value of the step. Press OK to perform the calibration.
The unit will briefly display the calibrated velocity value
in the top of the screen and then return to measure
mode.
Velocity and Zero Calibration
If you have a test step block of known thicknesses but
unknown material, then you can calibrate the zero and
velocity of the sound in the unknown material by
measuring the time of flight from the main-bang to the
first back echo for thinner step and thicker step.
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To calibrate both: velocity and zero at the same time first
go to the Calibration mode as shown in Velocity
Calibration Only section. While measuring the thicker
step, select VEL by pressing F3. After selecting VEL you
can take the transducer off the test block. If the displayed
value is different than the known value of the step, adjust
the value by pressing up or down arrow keys and press
F1/CAL. Then while measuring the thinner step select
ZERO by pressing F2. After selecting ZERO you can
take the transducer off the test block. If measured value
is different than the known value of the step, adjust the
measured value by pressing up or down arrow key and
then press OK. The unit will briefly display the calibrated
zero value and then return to Measure mode. Note that
the order of Velocity and Zero calibration could be
reversed. If Velocity calibration is performed after Zero
calibration, the calibrated velocity value will be displayed
at the end of the calibration process.
Zero Calibration Only
If you have a test step block of known thickness and
known velocity of sound in the material, then you can
calibrate the zero by measuring the time of flight from
main-bang to the first back echo for the thinner step.
The calibrated zero is the calculated zero minus the
measured zero.
To accurately measure a thickness of unknown material
you need to know the velocity of the sound in the
unknown material and the errors introduced by the cable
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and electronics. This is called delay line and zero
calibrated value for the transducer.
To perform a zero calibration, go to the Cal mode as
shown in Velocity Calibration Only section. Then while
measuring the thinner step, select ZERO by pressing F2.
After selecting ZERO, you can take the transducer off
the test block. If the displayed measurement is different
than the known value of the step, use the up or down
arrow key to adjust the displayed value to the known
value of the step. Press OK to perform the calibration.
The unit will briefly display the calibrated zero value in
the top of the screen and then return to measure mode.
Delay Line Calibration
Delay line calibration is done every time the thickness
gauge is powered on and a transducer is selected, or
when a different transducer is selected during normal
operation.
Delay line calibration is performed by measuring the
echo of the transducer itself when it is not placed on any
material and there is no couplant on the transducer
surface.
Under normal usage, the surface of the transducer wears
over time, which reduces sensitivity of the transducer.
When you power on any of the TKG series thickness
gauges and select a transducer, the gauge performs
automatic calculations and warns you (patent pending) if
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the sensitivity of the transducer is too low and whether
the transducer should be replaced.
Automatic Zero
To perform an Automatic Zero or Auto Zero, you must
first select a transducer option from the Transducer
selection screen and press the Menu/OK key.
To continue the Auto Zero, follow these steps:
1. Follow the instructions given on each display
screen; the first of which will prompt you to
wipe off any couplant from the transducer and
wait three seconds. The waiting time is shown
in the changing pie-clock graphic on the display
screen.
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2. After three seconds the gauge automatically
begins to zero the transducer. During the delay
line calibration a screen appears displaying the
message “Performing Auto Zero”.
3. A warning message will appear on the display
screen if the delay line is below the acceptable
limit for accurate thickness measurements. You
will need to replace the transducer or select the
F1 key to acknowledge the warning message
and continue using the same transducer, which
may have a worn surface.
4. After three seconds or after acknowledging the
warning message, the display shows the
instrument parameters for 3 seconds before
going to
Measurement
mode.
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4 Measurement Mode
Measurement Mode with a Datalogger
(TKG150)
For the TKG150 series datalogger the display screen in
Measurement
mode will look similar to the screen
below:
To continue in
Measurement
mode, follow these steps:
1. Press the F1 key to select the Save T option.
(See: Save section.)
2. Press the F2 key to select the Freeze option.
(See: Freeze section.)
3. Press the F3 key to select the Dir (Directory)
option. (See: Directory section.)
4. Press the Menu / OK key to select the Menu
option. (See: Menu section.)
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