The following information must be read and understood by any user of a GE Sensing & 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 setup 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.
DM5E Operating Manualvii
Preface
Operator Training
Operators must receive adequate training before using ultrasonic test equipment. Operators must be trained in general ultrasonic testing
procedures and in the setup and performance required by a particular test. Operators must understand:
•Sound wave 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.
viiiDM5E Operating Manual
Preface
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.
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.
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
Before performing calibration with a contact probe, the probe zero procedure must be performed first. If the zero procedure is not performed
or if it is performed improperly, inaccurate thickness readings will result.
Temperature variations change the sound velocity of materials and transducer delay lines and, therefore, calibrations. All calibrations should
be performed on-site 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.
Ultrasonic thickness gauges will, under certain conditions, display readings which are twice (or in some cases, three times) the actual
material thickness 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 a 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.
xiiDM5E Operating Manual
Preface
Safety Information
IMPORTANT: The DM5E is an instrument for materials testing. Any use for medical applications or other purposes is not allowed. The
DM5E may only be used in industrial environments.
IMPORTANT: For battery operation of the DM5E, two “AA” size batteries are needed. You should only use the products recommended by
us for battery operation. Use of well-known battery brands is highly recommended.
IMPORTANT: Disposal of all components of the DM5E and its batteries must be done in compliance with all applicable regulations. See
Appendix B, Regulatory Compliance, for detailed information.
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.
DM5E Operating Manualxiii
Preface
Defects/Errors and Exceptional Stresses
If you have reason to believe that safe operation of your DM5E is no longer possible, you must disconnect the instrument and secure it
against unintentional reconnection. Remove the batteries if necessary.
Safe operation is no longer possible if conditions such as the following exist:
•The instrument shows visible damages
•The instrument no longer operates perfectly
•The instrument has been subjected to prolonged storage under adverse conditions such as exceptional temperatures and/or especially
high air humidity, or corrosive environmental conditions
•The instrument has been 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 Sensing & Inspection
Technologies, has established a number of Factory Trained Service Centers. For the location of the nearest facility, see the back cover of
this manual.
xivDM5E Operating Manual
Chapter 1. General Information
Chapter 1. General Information
The DM5E is an ultrasonic corrosion thickness measurement device. The instrument is available in three versions:
•DM5E Basic
•DM5E with Dual Multi functionality
•DM5E DL with Dual Multi and Data Recorder
This chapter introduces the key features of the DM5E, and 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 in subsequent
chapters of this manual.
1.1Supplying Power to the DM5E
The instrument is powered by two “AA” size batteries, providing up to approximately 100 hours of service life. To install the batteries,
remove the battery-compartment cover as shown in Figure 1 on page 2.
IMPORTANT: You cannot charge or power the DM5E through its USB port.
DM5E Operating Manual1
Chapter 1. General Information
1.1Supplying Power to the DM5E (cont.)
Rear of Instrument
Install 2 “AA” batteries
in compartment as shown
Figure 1: DM5E Connections and Batteries (shown with battery cover removed)
2DM5E Operating Manual
Top of Instrument
Probe Cable Connection
I/O Device Connection
(mini USB)
Chapter 1. General Information
1.1Supplying Power to the DM5E (cont.)
When the battery indicator is in the last quarter, as indicated by the display-screen symbol , replace the batteries as soon as possible. The
DM5E automatically shuts OFF when the batteries are too weak for reliable operation. However, your settings are saved and restored when
the instrument is turned ON again. When testing in remote locations, always carry spare batteries.
1.2Powering the Instrument ON and OFF
Power the instrument ON by pressing and holding until the instrument display activates. Press and hold while the instrument is
ON to turn it OFF.
1.3Key Features of the DM5E
•Large hollow/filled thickness digits
•Alarm bar graph
•Standard and custom parameter setups
•Supports new set of DA5xx probes
•Alphanumeric naming of data files (DM5E DL)
DM5E Operating Manual3
Chapter 1. General Information
1.3Key Features of the DM5E (cont.)
•Lockout feature with password access
•Large LCD display with backlight and adjustable contrast
•Importing of data recorder files directly into Microsoft Excel (DM5E DL)
•Approximately 100 hours of operation with 2 “AA alkaline batteries
•Easy-to-use, single-level menu system
•Multiple display screen languages
•User-selectable measurement resolution to 0.001 inch (0.01 mm)
•Normal (thickness), MinScan, MaxScan, and Differential/Rate of Reduction Measurement modes are standard
•Timed B-Scan
•Optional Dual Multi function (DM5E and DM5E DL)
•Optional data recorder (DM5E DL) stores up to 50,000 thickness measurements in data recorder file
1.3.1DM5E Corrosion Thickness Measurement Base Instrument
1.3.1aContents of the DM5E Base Instrument
•DM5E instrument
•2 “AA” batteries
•Plastic carrying case
•Couplant sample
•Upgrade Utility Program on CD-ROM (requires mini-USB to PC cable)
•Operating manual in CD-ROM
•Operating instruction card
•Certificate of conformity
Note: A mini-USB to PC cable is only included with the DM5EDL version. This cable can be purchased separately for use with the
DM5E Basic or DM5E version.
DM5E Operating Manual5
Chapter 1. General Information
1.3.1bInstrument Versions
•DM5E Basic
•DM5E with Dual Multi functionality
•DM5E DL with Dual Multi and Data Recorder
1.4Contents of this Manual
This DM5E Operating Manual is divided into eight chapters and one appendix. All chapters apply to all instrument versions, except for two
functions:
•Data Recorder, which is described in Chapter 5, applies only to the DM5E DL version
•Dual Multi mode applies only to the DM5E with Dual Multi functionality and to the DM5E DL
Note: Any DM5E can be retrofitted to incorporate the above functions.
6DM5E Operating Manual
Chapter 2. Understanding the Keypad, Menu System & Displays
Chapter 2. Understanding the Keypad, Menu System & Displays
The DM5E'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: The DM5E's display screen contents varies depending on the optional features installed and the operational settings selected. The
display screens shown in this chapter are typical of those found in all the instrument configurations.
2.1Keypad Features
The instrument's keypad includes a combination of dedicated keys and virtual function keys. The key functions, as illustrated in Figure 2 on
page 8, are as follows:
•Arrow Keys - Use to adjust the value of the selected parameter and for on-screen navigation.
•Function Keys - Use to activate any functional control shown in the display directly above the key.
•Cal/On Key - Press once to launch the calibration process or to make on screen selections. Press and hold to power the instrument
ON and OFF.
•Mode Key - Press to activate the standard display modes and any optional display modes that are installed.
DM5E Operating Manual7
Chapter 2. Understanding the Keypad, Menu System & Displays
2.1 Keypad Features (cont.)
Select a probe setup
Select, adjust and confirm
operating settings
Thickness measurement display
Figure 2: DM5E Keypad and Key Functions
Press to activate standard display modes
(shown here) and the optional display
modes (if installed). Optional display modes
include Data Recorder Contents.
Press to activate the functional control
(when present) above the key.
Press to launch the calibration process
or make on-screen selections. Press and
hold to power the instrument ON or OFF.
Press to adjust the value of the selected
parameter and for on-screen navigation.
8DM5E Operating Manual
Chapter 2. Understanding the Keypad, Menu System & Displays
2.2Interpreting the Display Screens
This section describes the layout of the DM5E's primary display modes including:
•Measurement Display Mode - Indicates measured thickness, contains status icons, displays data recorder location and file name (when
this option is installed and activated). Figure 3 on page 10 shows four representative display screens. The display's appearance varies
based on the installed instrument options as well as instrument display settings. Additional measurement view modes are available when
the Dual Multi or Data Recorder options are installed.
•Probe Setup Display Mode - Allows the user to select a standard preloaded instrument setup, each of which is matched to a specific
probe model (see Figure 4 on page 11).
•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 (see Figure 5 on page 12). When installed and activated, the data recorder option allows
users to create data recorder files, store thickness readings, and navigate through file contents.
•Configuration Display Mode - Instrument controls are accessed through this screen. The controls listed on the configuration display
screen vary depending on the installed options (see Figure 6 on page 13). The contents of the Configuration display depends on the
instrument's installed-option configuration.
DM5E Operating Manual9
Chapter 2. Understanding the Keypad, Menu System & Displays
2.2 Interpreting the Display Screens (cont.)
Figure 3: Measurement Display Mode
10DM5E Operating Manual
2.2 Interpreting the Display Screens (cont.)
Chapter 2. Understanding the Keypad, Menu System & Displays
Figure 4: Probe Setup Display Mode
DM5E Operating Manual11
Chapter 2. Understanding the Keypad, Menu System & Displays
2.2 Interpreting the Display Screens (cont.)
Figure 5: File Display Mode
12DM5E Operating Manual
2.2 Interpreting the Display Screens (cont.)
Chapter 2. Understanding the Keypad, Menu System & Displays
Figure 6: Configuration Display Mode
DM5E Operating Manual13
Chapter 2. Understanding the Keypad, Menu System & Displays
2.3Working with the Configuration Display
By repeatedly pressing , you can access the Configuration display and you can adjust the following DM5E settings:
•VIEW MODE - In base-model units this parameter offers five settings. See Section 4.1 on page 36 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 (see Section 3.4 on page 30).
•MAXIMUM ALARM - Enables and sets the maximum alarm value (see Section 3.4 on page 30).
•UNITS - Sets the units of measurement to inches or millimeters (see Section 3.2 on page 21).
•NOMINAL THICKNESS - Sets 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 (see Section 3.2.3 on page 25).
•RESOLUTION - Controls the format (number of decimal places) of the thickness measurement that is displayed and stored in a Data
Recorder file.
•UPDATE RATE - Sets the rate at which the measurement reading is updated (see Section 3.2.2 on page 24).
14DM5E Operating Manual
Chapter 2. Understanding the Keypad, Menu System & Displays
2.3 Working with the Configuration Display (cont.)
•BACKLIGHT - Turns the display backlight feature to ON, OFF, or AUTO (AUTO switches backlighting ON whenever a key is pressed or
the probe is connected).
•CONTRAST - Select this control and then press or to adjust the display contrast level.
•LANGUAGE - Sets the instrument display language (see Section 3.2 on page 21).
•BSCAN MINIMUM - Sets the minimum value that can be drawn when BSCAN is processing (see Section 3.2.1 on page 23).
•BSCAN MAXIMUM - Sets the maximum value that can be drawn when BSCAN is processing (see Section 3.2.1 on page 23).
•DUAL MULTI - Used to switch between Dual Multi and IP test modes, when Dual Multi option is allowed (see Section 3.2 on page 21).
•READING HOLD - Can be set to hold the last measurement value when the probe is uncoupled in measurement mode (see Section 3.2 on
page 21).
DM5E Operating Manual15
Chapter 2. Understanding the Keypad, Menu System & Displays
2.3 Working with the Configuration Display (cont.)
•TIME - Used to set the current time (see Section 3.2 on page 21).
•DATE - Used to set the current date (see Section 3.2 on page 21).
•GAIN - Used to select a different level of gain (LOW/HIGH/AUTO/DEFAULT) (see Section 3.2.1 on page 23).
•RADIX - Selects a period (.) or comma (,) to be used as a decimal point (see Section 3.2 on page 21).
•AUTO POWER DOWN - When set to ON, this control conserves battery life by powering the instrument OFF if no key presses or
measurements occur for the set number of minutes. When set to OFF, the instrument is only powered OFF when is pressed and
held.
16DM5E Operating Manual
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