Waygate Technologies CL5 Operating Manual

CL 5

Operating Manual

Ident-Nr. 021-002-296

Issue 01

Issue 01, 04/2005 applies to software version XX.04.XX

CL 5 Issue 01, 04/05 0-1

Contents

1 General Information........................... 1-1

1.1 Supplying Power to the CL 5................. 1-2

1.2 Powering On and Off the Instrument .... 1-4

1.3 Key Features of the CL 5........................ 1-4

CL 5 Precision Thickness

Measurement Base Instrument .............. 1-5

Instrument Options .................................. 1-6

1.4 Whats in this Manual ............................ 1-6

2 Understanding the Keypad,

Menu System, and Displays ............. 2-1

2.1 Keypad Features .................................... 2-2

2.2 Interpreting Display Screens ................. 2-2

2.3 Working with the Configuration

Display .................................................2-10

3 Setting Up the CL 5 ........................... 3-1

3.1 Connecting a Probe and Loading a

Setup File ............................................. 3-3

3.2 Configuring the Instrument ................... 3-6

3.2.1 Setting Instrument Gain ................ 3-8

3.2.2 Setting Update Rate ..................... 3-8

3.2.3 Setting Nominal Thickness ........... 3-8

3.3 Instrument Calibration........................... 3-9

3.4 Setting the Maximum and Minimum

Alarms .................................................. 3-9

3.5 Creating and Erasing Custom Setup

Files .....................................................3-11

3.6 Locking and Unlocking Instrument

Settings ...............................................3-14

4 Measuring Thickness ........................ 4-1

4.1 Selecting the Displayed View ................ 4-2

4.2 Normal Measurement Mode

(No A-Scan) .......................................... 4-3

4.3 Min Scan and Max Scan Measurement

Mode..................................................... 4-6

0-2 Issue 01, 04/05 CL 5

Contents

4.4 Differential/Rate-of-Reduction

Measurement Mode ............................. 4-8

4.5 Thickness + A-Scan Measurement

Mode (Optional) ..................................4-10

4.6 Velocity Measurement Mode

(Optional) ............................................. 4-8

5 Using the Optional Data Recorder ... 5-1

5.1 Creating a New Data Recorder File ....... 5-2

5.2 Recalling and Erasing Stored Data

Recorder Files ...................................... 5-4

5.3 Recording Thickness and Velocity

Measurements in Data Recorder

Files ...................................................... 5-5

5.3.1 Recording A-Scans in Data

Recorder Files .............................. 5-6

5.3.2 Navigating Through Data

Recorder Files .............................. 5-6

5.4 Printing a Report.................................... 5-6

6 I/O Features........................................ 6-1

6.1 Transmitting Data to an External

Device ..................................................... 6-2

6.2 Setting Communication Speed

(Baud Rate) and Connecting to a PC... 6-4

6.3 Remote Commands ............................... 6-4

7 Specifications

7.1 Instrument Specifications ..................... 7-2

7.2 A-Scan Option Features ......................... 7-5

7.3 Velocity Measurement Option

Features................................................ 7-5

7.4 Data Recorder Option Features ............. 7-6

7.5 CL 5 Probe/Transducer

Specifications....................................... 7-6

CL 5 Issue 01, 04/05 0-3

Contents

8 Maintenance

Care of the Instrument .................................... 8-2

9 Appendix............................................ 9-1

9.1 Resetting the Operating Software ......... 9-2

9.2 Upgrading the Operating Software ....... 9-2

9.3 EMC Documentation .............................. 9-3

9.4 Manufacturer/Service Addresses .......... 9-5

10 Index ................................................. 10-1

0-4 Issue 01, 04/05 CL 5

Important Notice

The following information must be read and understood by any user of a GE Inspection Technologies ultrasonic thickness gauge. Failure to follow these instructions can lead to errors in thickness measurements or other test results. Decisions based on erroneous results can, in turn, lead to property damage, personal injury or death.

General Warnings

Proper use of ultrasonic test equipment requires three essential elements:

 Selection of the correct test equipment.

 Knowledge of the specific test application

requirements.

 Training on the part of the instrument operator.

This operating manual provides instruction in the basic set up and operation of the thickness gauge. There are, however, additional factors which affect the use of ultrasonic test equipment. Specific information regarding these additional factors is beyond the scope

of this manual. The operator should refer to textbooks on the subject of ultrasonic testing for more detailed information.

Operator Training

Operators must receive adequate training before using ultrasonic test equipment. Operators must be trained in general ultrasonic testing procedures and in the set up and performance required by a particular test. Operators must understand:

 Soundwave propagation theory.

 Effects of the velocity of sound of the test material.

 Behavior of the sound wave where two different

materials are in contact.

 Areas covered by the sound beam.

More specific information about operator training, qualification, certification, and test specifications is available from various technical societies, industry groups, and government agencies.

CL 5 Issue 01, 04/05 0-5

Important Notice

Testing Limitations

In ultrasonic testing, information is obtained only from within the limits of the sound beam. Operators must exercise great caution in making inferences about the test material outside the limits of the sound beam. For example, when testing large materials it may be impossible or impractical to inspect the entire test piece.

When a less-than-complete inspection is to be performed, the operator must be shown the specific areas to inspect. Inferences about the condition of areas not inspected, based on data from the evaluated areas, should only be attempted by personnel fully trained in applicable statistical and probability techniques. In particular, materials subject to erosion or corrosion, in which conditions can vary significantly in any given area, should only be evaluated by fully trained and experienced operators.

Sound beams reflect from the first interior surface encountered. Because of part geometry and overlapped flaws or overlapped surfaces, thickness gauges may measure the distance to an internal flaw rather than to the back wall of the material. Operators must

take steps to ensure that the entire thickness of the test material is being examined.

Ultrasonic Thickness Measurement Critical Operating Procedures

The following operating procedures must be observed by all users of ultrasonic thickness gauges in order to minimize errors in test results.

1. Calibration of Sound Velocity

The principle of operation of an ultrasonic thickness gauge is that the instrument measures the time of flight of an ultrasonic pulse through the test piece and multiplies this time by the velocity of sound in the material. Thickness measuring error is minimized by ensuring that the sound velocity to which the instrument is calibrated is the sound velocity of the material being tested. Actual sound velocities in materials often vary significantly from the values found in published tables. In all cases, best results are obtained if the instrument is calibrated on a velocity reference block made from the same material as the test piece; this block should be flat and smooth and as thick as the maximum thickness of the test piece.

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Important Notice

Operators should also be aware that the sound velocity may not be constant in the material being tested; heat treating, for example, can cause significant changes in sound velocity. This must be considered when evaluating the accuracy of the thickness provided by this instrument. Instruments should always be calibrated before testing, and the calibration should be checked after testing, to minimize testing errors.

2. Probe Zero Procedure

When performing a one-point calibration with a contact probe, the probe zero procedure must be performed as described in this manual. The probe zero block should be clean, in good condition, and without noticeable wear. Failure to properly perform the probe zero procedure will cause inaccurate thickness readings.

3. Effects of Temperature on Calibration

Temperature variations change the sound velocity of materials and transducer delay lines and, therefore, calibrations. All calibrations should be performed onsite, and with test blocks at the same temperature as the test piece, to minimize errors due to temperature variations.

4. Transducer Selection

The transducer used in testing must be in good condition without noticeable wear of the front surface. Badly worn transducers will have a reduced effective measuring range. The specified range of the transducer must include the complete range of thicknesses to be tested. The temperature of the material to be tested must be within the transducers temperature range.

5. Use of Couplants

Operators must be familiar with the use of ultrasonic couplants. Testing skills must be developed so that couplant is used and applied in a consistent manner to minimize variations in couplant layer thickness and errors in test results. Calibration and actual testing should be performed under similar coupling conditions, using a minimum amount of couplant and applying consistent pressure on the transducer.

6. Doubling

Ultrasonic thickness gauges will, under certain conditions, display readings which are twice (or, in some cases, three times) the actual material thickness

CL 5 Issue 01, 04/05 0-7

Important Notice

being measured. This effect, commonly known as doubling, can occur below the minimum specified range of the transducer. If the transducer being used is worn, doubling is possible at a thickness greater than the minimum of the specified range.

When using a new transducer, any reading which is less than twice the minimum specified range of the transducer may be a doubled reading, and the thickness of the material being tested should be verified by the use of other methods. If the transducer shows any sign of wear, doubling may occur at a second echo or other echo signal combinations may produce a readable signal. The instrument reading and apparent thickness are up to about twice the actual value, resulting in a thickness greater than twice the minimum of the specified range. This thickness should be determined by calibrating the instrument/transducer combination on reference blocks that represent the complete range of possible thicknesses that may be encountered in testing. This is particularly important when the test piece is being ultrasonically measured for the first time or in any case where the history of thickness of the test specimen is unknown.

Safety Information

Attention:

The CL 5 is an instrument for materials testing. Any use for medical applications or other purposes is not allowed.

The CL 5 may only be used in industrial environments.

The CL 5 can be operated with batteries or while plugged into an electrical outlet using the AC charger.

The power supply unit has the electrical safety class II.

Batteries:

For the battery operation of the CL 5, we recommend the use of a lithium-polt battery pack provided. Operation using alkaline batteries, NiMH or NiCAD cells is possible. You should only use the products recommended by us for the battery operation. Do not attempt to use any lithium batteries that are not provided with the instrument. Do not attempt to charge the provided batteries on an outside charger.

0-8 Issue 01, 04/05 CL 5

Important Notice

Software:

According to the current state of the art, software is never completely free from errors. Before using any software-controlled test equipment, please make sure that the required functions operate perfectly in the intended combination.

Defects/errors and exceptional stresses

If you have reason to believe that a safe operation of your CL 5 is no longer possible, you have to disconnect the instrument and secure it against unintentional reconnection. Remove the batteries if necessary.

A safe operation is no longer possible e.g.:

 The instrument shows visible damages

 The instrument no longer operates perfectly

 After prolonged storage under adverse conditions like

exceptional temperatures and/or especially high air humidity, or corrosive environmental conditions.

 Being subjected to heavy stresses during

transportation

Service

Every effort has been made to provide you with a reliable product. However, should service become necessary, GE Inspection Technologies, has established a number of Factory Trained Service Centers. For the location of the nearest facility refer to section

9.4 of this manual.

CL 5 Issue 01, 04/05 1-1

General Information 1

1-2 Issue 01, 04/05 CL 5

General Information Supplying Power to the CL 5

The CL 5 is an ultrasonic precision thickness measurement device. Its available with optional live A-Scan display, acoustic velocity measurement capability, and a data recorder in which as many 10,000 thickness measurements per file can be stored.

This chapter of your manual introduces the key features of the CL 5 and the contents of this operating manual. The next chapter explains the keypad functions and display-menu contents. Closely reviewing the material in these two chapters will help you make better use of the more detailed information found throughout the rest of this manual.

In this chapter, youll learn

 How to install batteries or connect the AC power

adapter to the instrument (Section 1.1)

 How to Power on and off the instrument

(Section 1.2)

 The features of the instrument and base instrument

package contents (Section 1.3)

 The general content of each chapter in this manual

(Section 1.4)

1.1 Supplying Power to the CL 5

 The instrument is powered by a Lithium (Li) battery

pack.

 It will also accept three AA size Alkaline, NiCAD,

or NiMH (nickel metal hydride) battery types.

 The Lithium battery, which is recommended, will

provide up to approximately 25 hours of service life. This pack (and only this pack) may be recharged in the instrument using the charger provided with your instrument.

 When other types of rechargeable batteries are

used, they must be removed from the instrument for charging.

To install batteries, remove the battery-compartment cover as shown in Figure 1-1. After inserting the Li pack or three AA batteries according to the polarity indicated in the battery compartment, replace the compartment cover. Instructions on specifying battery type are found in Section 3.2.

CL 5 Issue 01, 04/05 1-3

Supplying Power to the CL 5

General Information

FIGURE 1-1Insert batteries as shown here. Notice the location of the External Power Connector to which the instruments Li battery packs charger be connected.

1-4 Issue 01, 04/05 CL 5

. Note:

When the battery indicator is in the last quarter as indicated by the display-screen symbol

, replace the batteries as soon as possible. The CL 5 automatically shuts off when batteries are too weak for reliable operation. However, settings are saved and restored when the instrument is turned on again. When testing in remote locations, always carry spare batteries.

. Note:

The instrument can be operated while the Li battery packs charger is connected. This charger is connected to the instrument though the connector shown in Figure 1-1. When the charger is powering the instrument,

appears on the display screen. The charger may only be connected when the GE Inspection Technologies Li battery pack is installed in the instrument.

1.2 Powering On and Off the Instrument

After a power source has been provided, power on the instrument by pressing and holding

until the

instrument turns on. Press and hold when the instrument is on to turn if off.

1.3 Key Features of the CL 5

 Large Hollow/filled thickness digits

 Alarm Bar Graph

 Standard and Custom parameter setups

 Supports delay and contact probes

 Alphanumeric naming of data locations

 Lockout feature with password access

 Lightweight  .75 lbs (.34 Kg)

 Large LCD Display with Backlight and Adjustable

Contrast

General Information Powering On and Off the Instrument

CL 5 Issue 01, 04/05 1-5

 Approximately 25 hours life  with the Li battery

pack or 3 AA alkaline batteries  Easy-to-use, single-level menu system  Multiple display-screen languages  User-selectable measurement resolution to 0.0001

inch (0.001 mm)  Normal (thickness), Min-Scan, Max-Scan, and

Differential/Rate of Reduction Measurement Modes

are Standard  Optional A-Scan provides A-Scan plus Thickness  Optional Data Recorder stores up to 10,000 thick-

ness measurements with A-Scan images attached

in as many as 120 data recorder files

 Optional Velocity Measurement Mode includes an

electronically connected digital caliper for exact

measurement and automatic input of nominal

thickness

 Field upgrades available via the GE Inspection

Technologies web site

 Compatible with UltraMATE

and UltraMATE LITE

software programs

CL 5 Precision Thickness Measurement Base Instrument

Contents of the CL 5 Base Instrument

 CL 5 Instrument

 Lithium Battery Pack

 Lithium Battery Pack Recharger

 Plastic Carrying Case

 Wire Stand

 Two-Point Check Block (uncertified)

 Couplant Sample

 Firmware Upgrade CD-ROM (requires Serial PC

cable)

 Operating Manual

 Operating Instruction Card

 Certificate of Conformity

Key Features of the CL 5 General Information

1-6 Issue 01, 04/05 CL 5

Instrument Options

 A-Scan Upgrade Option

 Data Recorder Upgrade Option

 Velocity Measurement Option

1.4 Whats in this Manual

The CL 5 Operating Manual is divided into ten chapters. All chapters except 4 and 5 apply to all instruments. The last two sections of Chapter 4 apply only to instruments equipped with the A-Scan or Velocity measurement options. Chapter 5 applies only to instruments equipped with the Data Recorder option. Note that any CL 5 can be retrofitted to incorporate these options. Following is a summary of Chapters 1 through 10:

Chapter 1General Introduction

 Supplying Power to the instrument

 Powering on and off the instrument

 Overview of instrument features

 Explanation of the operating manual contents

Chapter 2Understanding the Keypad, Menu System, and Displays

 Operations performed by each key

 Navigating the display screens

 Overview of menu functions

 Explanation of display features (base model, data

recorder, and A-Scan equipped instruments)

 Definition of icons

Chapter 3Setting Up the CL 5

 Install a probe and configure the instrument by

loading a setup file

 Set up the instrument display appearance (for base

model and A-Scan equipped instruments) and make other configuration settings

General Information Whats in the Manual

CL 5 Issue 01, 04/05 1-7

Whats in this Manual

General Information

 Adjust the instrument gain setting

 Specify the nominal material thickness

 Calibrate and zero the instrument/probe combination

 Set maximum and minimum alarm values

 Create and erase custom setup files

 Lock and unlock instrument controls

Chapter 4Measuring Thickness

 Specify and use the Normal measurement mode (No

A-Scan)

 Operate in Min-Scan and Max-Scan Measurement

mode

 Operate in Differential/Rate of Reduction

measurement mode

 Select and interpret the A-Scan plus Thickness

measurement mode (Optional)

 Magnify the displayed A-Scan using the Zoom

control

 Freeze the thickness reading and A-Scan

 Connect the digital caliper and measure acoustic

velocity (Optional)

Chapter 5Using the Optional Data Recorder

 Create, recall, and delete data recorder files

 Store A-Scan and thickness readings in data

recorder files

 Navigate data recorder file locations

 Attach notes to the data recorder file

 Print reports

Chapter 6I/O Technical Details

 Configure the instrument to communicate with PCs

and printers

 Thickness value format

 Remote control codes

1-8 Issue 01, 04/05 CL 5

Chapter 7Specifications

Chapter 8Maintenance

Chapter 9Appendix

 Reset the operating software

 Upgrade the operating software

 EMC documentation

 How to obtain service

Chapter 10Index

Whats in this Manual General Information

CL 5 Issue 01, 04/05 2-1

Understanding the Keypad,

Menu System, and Displays

2-2 Issue 01, 04/05 CL 5

Understanding the Keypad, Menu System, and Displays Keypad Features

The CL 5s display, keypad, and functional commands are easy to interpret and use. In this chapter youll find a brief explanation of all display and keypad features. Youll also find references to manual sections where more detailed information is available.

Note that the CL 5s display screen contents vary depending on the optional features installed and the operational settings selected. Display screens shown in this chapter represent those found in all instrument configurations including:

 Base Model

 A-Scan Option Installed

 Data Recorder Option Installed

 A-Scan and Data Recorder Options Installed

2.1 Keypad Features

The instruments keypad includes dedicated keys (

and ), arrow keys ( , , , ), and three

virtual function keys ( ). Key functions are described in Figure 2-1.

2.2 Interpreting Display Screens

This section of your manual describes the layout of the CL 5s primary display modes including the:

 Measurement Display Mode  Indicates measured

thickness, contains status icons, displays data recorder location and file name (when this option is installed and activated), and the live A-Scan display (when this option is installed and activated). Figure 2-2 shows four representative display screens.

CL 5 Issue 01, 04/05 2-3

Interpreting Display Screens

Understanding the Keypad, Menu System, and Displays

FIGURE 2-1Key Functions

2-4 Issue 01, 04/05 CL 5

Interpreting Display Screens

Understanding the Keypad, Menu System, and Displays

FIGURE 2-2MEASUREMENT DISPLAY MODE  The displays appearance varies based on installed instrument options as well as instrument display settings. NORMAL view mode is available in all instruments regardless of the installed options. Additional measurement view modes are available when the A-Scan or Data Recorder options are installed. Depending on the view selected, the display may contain the current thickness value, a live A-Scan, minimum thickness value, maximum thickness value, and differential value in the unit of measurement or as a percentage when compared to a nominal value.

CL 5 Issue 01, 04/05 2-5

Understanding the Keypad, Menu System, and Displays Interpreting Display Screens

 Probe Setup Display Mode  Allows the user to

select a standard preloaded instrument setup (each

matched to a specific probe model) or a custom

user-defined setup. Custom Setups are created

using this display screen. They can be downloaded

and then downloaded into any CL 5 instrument. The

contents of a Custom Setup file vary depending on

the instruments configuration. See Section 3.5 for

information on custom setups. (Figure 2-3).

 File Display Mode  Allows the user to create and

store thickness readings in data recorder files. This

feature is only available when the data recorder

option is installed and activated. Accompanying

A-Scans can be stored with thickness readings by

holding

below the SEND Function for three

seconds. (Figure 2-4)

 Configuration Display Mode  Instrument controls

are accessed through this screen. The controls listed on the configuration display screen vary depending on the installed options. (Figure 2-5)

2-6 Issue 01, 04/05 CL 5

Interpreting Display Screens

Understanding the Keypad, Menu System, and Displays

FIGURE 2-3PROBE SETUP DISPLAY MODE  Allows selection of a preloaded or Custom Setup file, which automatically recalls all parameter settings. Note that Custom Setups can be downloaded from an UltraMate© equipped PC to any instrument, or created using this display (see Section 3.5 for information on Custom Setup files).

CL 5 Issue 01, 04/05 2-7

Understanding the Keypad, Menu System, and Displays Interpreting Display Screens

FIGURE 2-4FILE DISPLAY MODE  When installed and activated, the data recorder option allows users to create data recorder files, store thickness readings (and accompanying A-Scans), and navigate through file contents as shown here. See Chapter 5 to work with Data Recorder files.

2-8 Issue 01, 04/05 CL 5

Interpreting Display Screens

Understanding the Keypad, Menu System, and Displays

FIGURE 2-5CONFIGURATION DISPLAY MODE  The contents of the Configuration display depend on the instruments installed-option configuration. All settings listed on the Configuration display are described in Section

2.3.

CL 5 Issue 01, 04/05 2-9

2.3 Working with the

Configuration Display

The Configuration display is accessed by pressing . With this screen displayed, you can adjust most CL 5

controls.

VIEW MODE  In base-model units this parameter offers 4 settings. In A-Scan equipped instruments this parameter allows the measurement and live A-Scan to be displayed. See Section 4.1 to select the view to be displayed.

DATA RECORDER  When the optional data recorder is installed, setting this parameter to ON activates the file recording capability and the data recorder file display.

MINIMUM ALARM  Enables and sets the minimum alarm value. (Section 3.4)

MAXIMUM ALARM  Enables and sets the maximum alarm value. (Section 3.4)

NOMINAL THICKNESS  Set the nominal thickness value that is then used to calculate and the differential and rate of reduction measurement values when selected by the VIEW MODE parameter. (Section 3.2.3)

RESOLUTION  Controls the format (number of decimal places) of the thickness measurement displayed, printed in a report, and stored in a Data Recorder file. (Section 3.2)

UPDATE RATE  Rate at which the measurement reading is updated. (Section 3.2.2)

BACKLIGHT  Turns the displays backlight feature to ON, OFF, or AUTO (AUTO switches backlighting on whenever a key is pressed or the probe is coupled)

CONTRAST  Sets the displays contrast level (select then press

or to change contrast)

LANGUAGE  Sets the instrument displays language (Section 3.2)

UNITS  Sets the unit of measurement to inches or millimeters (Section 3.2)

Understanding the Keypad, Menu System, and Displays Working with the Configuration Display Module

2-10 Issue 01, 04/05 CL 5

Working with the Configuration Display Module

Understanding the Keypad, Menu System, and Displays

RADIX  Selects a period (.) or comma (,) to be used

as a decimal point (Section 3.2)

COMM  Specifies the baud rate of the attached printer or PC

AUTO POWER DOWN  Selects the battery-life saving ON, which powers down the instrument if no key presses or measurement occur for four minutes, or the OFF setting, which will only power down the instrument

when

is pressed.

BATTERY TYPE  Select the installed battery type to ensure accurate remaining battery-life indication. Choose from Alkaline, NiMHD, or NiCAD. (See Section 1.1 to install batteries)

GAIN  Selects the default or reduced level of gain corresponding to the active setup file (Section 3.2.1)

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