Acoustic control systems A1525 SOLO User manual

TFM Ultrasonic Flaw Detector A1525 SOLO
Operation Manual
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ACOUSTIC
CONTROL
SYSTEMS
TFM ULTRASONIC
FLAW DETECTOR
Acoustic Control Systems – ACS Group
Saarbrücken, Germany 2019
А1525
SOLO
OPERATION MANUAL

TFM Ultrasonic Flaw Detector A1525 SOLO
Operation Manual
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ACOUSTIC
CONTROL
SYSTEMS

TFM Ultrasonic Flaw Detector A1525 SOLO
Operation Manual
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CONTENTS
1 DEVICE DESCRIPTION AND OPERATION........................................................................................................... 6
1.1 DEVICE PURPOSE .................................................................................................................................................................................6
1.1.1 TFM flaw detector purpose and field of use...........................................................................................................6
1.1.2 Operation conditions...............................................................................................................................................................6
1.2 SPECIFICATIONS....................................................................................................................................................................................7
1.2.1 Main device parameters........................................................................................................................................................7
1.3 DEVICE STRUCTURE AND OPERATION..............................................................................................................................9
1.3.1 Device structure ..........................................................................................................................................................................9
1.3.2 Main Interface ..............................................................................................................................................................................10
1.3.3 Instrument operation modes - Overview...............................................................................................................10
1.3.4 Basic Display Features...........................................................................................................................................................14
1.3.5 Keyboard...........................................................................................................................................................................................15
1.3.6 Use of Icons ....................................................................................................................................................................................17
2 INTENDED USE..............................................................................................................................................................18
2.1 OPERATING LIMITATIONS..............................................................................................................................................................18
2.2 DEVICE PREPARATION FOR USE............................................................................................................................................18
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2.3 OPERATING DEVICE MODES .....................................................................................................................................................19
2.3.1 Setup for TOMOGRAPH mode........................................................................................................................................19
2.3.2 Setup for FLAW DETECTOR mode.............................................................................................................................32
2.4 TOMOGRAPH mode..........................................................................................................................................................................54
2.4.1 Device screen in TOMOGRAPH mode .....................................................................................................................56
2.4.2 Gating within a Frame.........................................................................................................................................................56
2.4.3 Tomograph Display Features – Continued..........................................................................................................58
2.4.4 Sensitivity setting using SAC (Spatial Amplitude Correction)..............................................................60
2.4.5 Tomograph Frame evaluation modes.....................................................................................................................66
2.4.6 Magnify (Zoom) control ......................................................................................................................................................67
2.4.7 TOMOGRAPH Freeze mode ............................................................................................................................................68
2.4.8 TOMOGRAPH Scanner mode........................................................................................................................................70
3 MAINTENANCE.............................................................................................................................................................. 77
3.1 Power supply and power consumption..............................................................................................................................77
3.2 Maintenance frequency .................................................................................................................................................................77
3.3 Potential problems .............................................................................................................................................................................77
3.4 Storage .........................................................................................................................................................................................................77
4. TRANSPORTATION.....................................................................................................................................................78
Manufacturer:

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2.3 OPERATING DEVICE MODES .....................................................................................................................................................19
2.3.1 Setup for TOMOGRAPH mode........................................................................................................................................19
2.3.2 Setup for FLAW DETECTOR mode.............................................................................................................................32
2.4 TOMOGRAPH mode..........................................................................................................................................................................54
2.4.1 Device screen in TOMOGRAPH mode .....................................................................................................................56
2.4.2 Gating within a Frame.........................................................................................................................................................56
2.4.3 Tomograph Display Features – Continued..........................................................................................................58
2.4.4 Sensitivity setting using SAC (Spatial Amplitude Correction)..............................................................60
2.4.5 Tomograph Frame evaluation modes.....................................................................................................................66
2.4.6 Magnify (Zoom) control ......................................................................................................................................................67
2.4.7 TOMOGRAPH Freeze mode ............................................................................................................................................68
2.4.8 TOMOGRAPH Scanner mode........................................................................................................................................70
3 MAINTENANCE.............................................................................................................................................................. 77
3.1 Power supply and power consumption..............................................................................................................................77
3.2 Maintenance frequency .................................................................................................................................................................77
3.3 Potential problems .............................................................................................................................................................................77
3.4 Storage .........................................................................................................................................................................................................77
4. TRANSPORTATION.....................................................................................................................................................78
This operation manual contains specifications, device, and operating
principle descriptions for the correct use of the A1525 SOLO ultrasonic
flaw detector.
Before operating this device, please carefully review this manual.
Only properly trained and qualified personnel should operate this device.
Please check local codes and regulations regarding any required certifi-
cations needed before use.
The manufacturer continually upgrades this device, thereby increas-
ing reliability and operational convenience. Consequently, these new fea-
tures may result in significant changes not mentioned in this manual
version. Consult with your local agent or the factory if there are questions
regarding operational characteristics not found within this manual.
ACS-Solutions GmbH
Science Park 2
66123 Saarbrucken, Germany
Phone: [phone]
Fax: [phone]
Е-mail: inf[email protected]
Website: www.acs-international.com
Issue date: 04.07.2019
Manufacturer:

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1.1.1 TFM flaw detector purpose and field of use
The A1525 SOLO TFM flaw detector is the world’s lightest and smallest TFM phased array instrument. It can also be operated
as a conventional pulse-echo handheld ultrasonic devices used for general-purpose testing. This unique device utilizes phased array
transducers and the Total Focusing Method (TFM) of signal processing to generate a tomographic image (or frame) instead of the
traditional S-Scan display seen on conventional phased array flaw detectors. This image is much easier to interpret and provides
non-technical users with the ability to understand the information presented on screen and how it relates to the part being inspected.
When the instrument is purchased with the optional single-axis encoder, D-Scan and C-Scan data can be collected for accurate
location mapping and sizing. A D-Scan shows a cross-section view of the indication through the weld, and a C-Scan shows the
corresponding top (plan) view of the indication. This information can be recorded for later review and analysis.
The A1525 SOLO is an excellent transition instrument for conventional UT inspectors to learn the benefits of phased array
imaging. It is also ideal as a light and portable screening tool providing initial imaging scans for more in-depth investigations with
AUT or other NDT methods as required.
1.1.2 Operating conditions
The A1525 SOLO is designed for operation under the following environmental conditions:
– at temperatures from -10 to + 55 ˚С; 14.0 °F to 131 °F
– at relative air humidity to 95 % at a maximum + 35 ˚С (95 °F).
DEVICE
DESCRIPTION
AND
OPERATION
1.1 DEVICE PURPOSE
1
SAFETY SYMBOLS USED IN THIS MANUAL:
Symbol Description
Indicates a potential threat. Failure to avoid it can result in death or serious injury.
Indicates a potential threat. Failure to avoid it may result in minor injury.
Indicates a potentially harmful situation. If it is not avoided, the device or something in its vicinity may be damaged.

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Parameter name Value
Velocity value range, m/sec 1,000-10,000
Operating transducer frequencies, MHz 1.0 – 10.0
Operating frequencies deviation from rated, % ± 10
Thickness range (in steel) with a longitudinal transducer, mm 4-900
Permissible basic absolute error limits for thickness Tcalibration with a longitudinal transducer, mm ±(0.01·T+0.2)
Defect depth calibration range (in steel) with a longitudinal transducer, mm 7-180
Permissible basic absolute error limits for defect depth D with a longitudinal transducer, mm ±(0.01·D+0.2)
Defect coordinate ranges (in steel) with a shear wave transducer 60°, mm:
Depths D
Surface Distance SD
3 - 40
5 - 75
Permissible basic absolute error limits for defect coordinates with a shear wave transducer 60 °, mm:
Depths D
Surface Distance SD
±(0.03·D+1)
±(0.03·SD+1)
Defect coordinate ranges (in steel) with a shear wave transducer 70 °, mm:
Depths D
Surface Distance SD
3 - 40
7 - 100
Table 1
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1.2 SPECIFICATIONS
1.2.1 Main device parameters
The main device parameters are given in Table 1.

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Table 1
Parameter Value
Permissible basic absolute error limits for defect coordinate with a shear wave transducer 70°, mm:
Depths D
Surface ranges SD
±(0.03·D+1)
±(0.03·SD+1)
Defect coordinate ranges (in steel) with a phased array of longitudinal waves, mm 10 - 90
Permissible basic absolute error limits for defect depth D with a phased array of longitudinal waves, mm ±(0.03·D+1)
Defect coordinates ranges (in steel) with a phased array of shear waves, mm:
Depths D
Surface Distance SD
6 - 80
6 - 80
Permissible basic absolute error limits for defect coordinates with a phased array of shear waves, mm:
Depths D
Surface Distance SD
±(0.03·H+1)
±(0.03·L+1)
Amplifier adjustment range, dB 0 - 80
Permissible basic absolute error limits for signal amplitude ratio on receiver input, dB ± 0.5
Power supply Lithium Battery
Rated power value of a battery, V 11.2
Continuous operation time from a battery at normal environmental conditions, hours 8
Overall dimensions of an electronic unit, mm 258х164х110
Weight of an electronic unit, kg, no more 1.9
Mean-time-between-failures, hours 30 000
Mean lifetime, years, at least 8
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1.3.1 Device structure
The flaw detector includes an electronic unit to which a phased array transducer (PA)
is connected by cables and an AC power adapter.
1.3.1.1 Electronic unit
Figure 1 shows the basic unit connected to a shear wave phased array transducer.
Instrument settings are controlled with a membrane keyboard. Indication of signals, cal-
ibration data, and instrument state are displayed and indicated with LEDs on the device
case. Device power is supplied from alithium-ion battery or from the AC power adapter
plugged into the bottom of the unit. In addition to the AC power connection, there is also a
USB port for connection to a PC. At the top of the instrument case, there are connections
for the transducer and one for the optional encoder (purchased separately).
1.3.1.2 Power Supply/Battery Charger
The power supply unit provides an external (15V) power source and is also used to
charge the lithium-ion battery pack. Once the instrument is fully charged, it can be used for
approximately 8 hours under normal operating conditions. The instrument can be operated
during charging. Please allow 8 hours to charge a fully depleted battery.
To avoid device damage, it is recommended that the power supply be connected to the
instrument before it is connected to a power outlet.
THE BATTERY IS NOT ACCESSIBLE BY THE END USER. DO NOT
ATTEMPT TO OPEN THE INSTRUMENT. THIS WILL VOID THE EQUIPMENT WARRANTY.
1.3 DEVICE STRUCTURE AND OPERATION
Figure 1

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1.3.2 Main Interface
The A1525 SOLO is designed for ease of use and quick access to the most commonly used features. The icon-based menu
layout allows the new user to learn the operation process quickly. These design features make the instrument ideal to easily
transition from conventional ultrasonic testing to phased array inspection.
Aer basic calibration is performed, these settings can be easily saved and named to allow for fast recall. The name can
be job-specific or can relate to the type of component being examined. Once the setup files are in memory, they are quickly
retrieved at a later date for similar inspections.
1.3.3 Instrument operation modes - Overview
There are three operating modes of the A1525 SOLO: TOMOGRAPH, FLAW DETECTOR, and
SCANNER. These modes are selected by pressing the mode key located at the bottom
right on the keypad.
The TOMOGRAPH mode is the main method of inspection for this instrument and is de-
signed for real-time inspection imaging, but the scan is not captured or encoded. This is a
manual scanning mode and is used in the same manner as conventional A-Scan ultrasonic
inspection. However, instead of an oscilloscope display showing the time of flight and ampli-
tude, the phased array image (tomograph showed in Figure 2 below) displays a cross-sectional
view of the part under examination. Both the X-axis position from the transducer and the Z-axis
depth of the indication are displayed at the top. In addition, the sensitivity in decibels (dB) is
also displayed along with a visual indication of severity in the form of a color bar.
In the above example, a weld overlay is displayed to help visualize the surface position
(X-Axis) and depth (Z-Axis) of the indications displayed in the phased array image (frame).
Also, the color denotes the severity in relation to the scale shown on the right of the screen.
FIGURE 2 TOMOGRAPH MODE
X-Axis Position Z-Axis (Depth) Amplitude

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In the image above, red indicates the greatest reflected energy, whereas blue and black represent the least reflected energy.
There is a crosshair highlighting an indication present on the screen above. The data displayed in X,Y, and A relates to just
that one indication. This selection process can be manual, as shown above, or it can be automatic when gates are active. The
details of gating will be discussed in a later section.
The FLAW DETECTOR mode is used when a conventional single element or dual element transducer is required for the
examination. The array transducers do not function while the instrument is in this mode. This mode is the traditional
A-Scan display, which shows the time of flight and amplitude of the signals displayed on the screen.
It is assumed that the operator of this instrument fully grasps this style of inspection. Therefore, further explanation of
longitudinal contact testing and shear wave testing theory will not occur in this manual beyond the necessary steps used for
calibration. Those steps will be covered in a later section.
FLAW DETECTOR mode is selected by holding the mode key for 2 seconds when currently operating in the
TOMOGRAPH mode. The following window will appear on the screen.
To confirm the selection of FLAW DETECTOR mode press the
enter key
To cancel the mode change, press the escape key,
and you will return to the TOMOGRAPH mode.

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Once enter is pressed, a screen similar to that shown in Figure 3 on the
next page will be displayed (the signal shown in the center is representative and will not be on your display). The informa-
tion fields X, Z, and A are also displayed in a similar fashion as in the TOMOGRAPH mode. Once again, they represent the distance
to the indication, the depth of the indication, and the amplitude of the signal response of the indication.
Figure 3: FLAW DETECTOR MODE
X-Axis Position Z-Axis (Depth) Amplitude
Figure 4: SCANNER MODE
AmplitudeY-Axis PositionX-Axis Position Z-Axis (Depth)

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The SCANNER mode (next page) is only functional when paired with an optional single-axis encoded scanner.
Press the mode key briefly (do not hold the key or you will be presented
with the FLAW DETECTOR selection described earlier). Upon pressing the key, the unit will automatically switch to a screen,
as shown in Figure 4.
This mode of operation is used to create a scan file that shows the transducer’s relative position to the part under exam-
ination. The scan is recorded and can be played back at a later time for analysis. Should your inspection requirements mandate
thorough documentation including detailed positional coordinates, it is advisable to purchase this optional scanner.
The Y-axis is encoded to show the linear position of the indication along the weld (or another component under examination).
Optional Scanner

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1.3.4 Basic Display Features
A color TFT 640х480 pixel display is used on the A1525 SOLO.
The screen space in each mode is divided into several functional areas. Figure 5 shows the screen in TOMOGRAPH mode, and
the various features are labeled. Though some features change with the mode of operation, the basic design is similar throughout.
FIGURE 5 TOMOGRAPH FRAME FIGURE 6 TOMOGRAPH KEYBOARD
Measurement Bar
Gain, Sound Path
and Angle
Color bar for sensitivity
response
Tomograph Frame
Icon bar for selection of
instrument functions
Control/Function Keys F1 to F6
F1 F2 F3 F4 F5 F6
Mode Key
Increase/
Decrease Keys
Enter Key
Arrow Keys
Freeze Key
Escape Key
Setup Key
On/Off Key

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1.3.5 Keyboard
The A1525 SOLO keyboard is shown in Figure 6.
The green LED indicator in the top le corner of the device informs the user that the instrument is switched on.
The LED indicator shows a battery charging process. An orange/yellow color indicates the battery is charging, and
green – the charging process is complete.
The two red indicators under Function Key 5 monitor response for the first and second gates accordingly.
Main functions and parameters are controlled by icon selection keys - function
keys (F1-F6), placed under the display, the corresponding icon is located over each.
Active parameters are selected and edited by the command keys placed on the le and right of the display. Their actions
are similar for different operating device modes and are designed for intuitive recognition by an operator, i.e., their symbols are
typical for the action.
An autorepeat mode is implemented for some keys. The lon-
ger the key is held, the faster the given parameter increases or
decreases.
For switching between TOMOGRAPH / FLAW-DETECTOR
modes, press the key, in the open mode selection win-
dow (Figure 7) select an operating mode by the arrow keys.
To confirm the selection, press the key, to cancel the
mode
change press the key. Device key functions are de-
scribed in Table 2.
1
FIGURE 7

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Key Key function in various operating modes
TOMOGRAPH SCANNER FLAW- DETECTOR SETUP
Switching the device ON/OFF Hold the key for over 0.5 sec
Enter SETUP mode Exit SETUP mode
Quick Press
Previous operating
mode selection
Enter TOMOGRAPH
mode
Enter TOMOGRAPH
mode Exit SETUP mode
Hold - Operating mode selection (TOMOGRAPH/FLAW DETECTOR)
Tomogram brightness
adjustment (in dB) N/A Cursor movement Active parameter value adjustment
N/A Reset the encoded
scan N/A Exit changing parameters marked with ▶, without saving
Cursor movement on
the tomogram
Cursor movement on
the tomogram or the
scan during replay
Range adjustment -
horizontal arrows
Gain (dB) adjustment
- vertical arrows
Parameter selection for adjustment
(vertical arrows)
Enter / Exit parameter editing mode
Enter Freeze mode – used to save files Deleting the configuration
N/A Turning on / off scan-
ning with encoder
Turning on / off refer-
ence level
Start parameters setting, marked
with ▶.
Memory erase during system
parameters adjustment
Icon selection and function control keys
1

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1.3.6 Use of Icons
The device interface is characterized by an icon-based menu, as shown in Figure 8, placed in six rectangular windows at
the bottom of the screen. Icons represent symbols associated with test object or property. Each mode has it’s own icon set.
Icons can be passive or active. An active state of the current icon selected signifies that the corresponding device proper-
ties or parameters can be edited (or have been edited). In the above example, the ZOOM feature is activated so that the display
can be decreased or enlarged.
FROM THIS POINT FORWARD, NUMBERING FROM F1 TO F6 (LEFT TO RIGHT) WILL BE USED WHEN
DESCRIBING ICON SELECTION FOR A GIVEN FUNCTION KEY.
F1 F2 F3 F4 F5 F6
FIGURE 8: TOMOGRAPH MODE ICON BAR

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INTENDED USE
2.1 OPERATING LIMITATIONS
The device is designed for operation under environmental conditions specified in clause 1.1.2.
2.2 DEVICE PREPARATION FOR USE
Before operating the instrument for inspection, remove the protective film that was used during manufacturing and transport.
It can remain if the end-user prefers to keep it in place, but removal will increase image contrast and brightness on the display.
2.2.1 Switching device ON/OFF
To switch the device ON, press the key, and the LED below the F1 key lights up green. The "ACS LLC" logo appears for
10 seconds on the screen, pressing the key again will turn the device OFF.

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2.3 OPERATING DEVICE MODES
2.3.1 Setup for TOMOGRAPH mode
SETUP mode is designed for device parameters setting.
Figure 9 shows the main screen in SETUP mode for operating in the TOMOGRAPH mode.
Select an icon using the function keys F1 through F6
The le column contains the configuration list, and the right column contains the associated parameters and values.
To edit the parameter values, press the key.
Icon functions in SETUP mode during editing are displayed below in Table 3.
FIGURE 9
Table 3
Key Icon Function
F1 Calibration parameters setup
F2 Transducer array parameters selection and setup
F3 Transducer array elements operation checking
F4 Weld configuration settings
F5 -N/a
F6 System parameters setup. Global parameters for all operating
modes

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The various keys used for manipulation are shown in Table 4.
Table 4
Key Function
Move up and down for editing parameter selection
Parameter value editing
Exit parameter editing
Exit SETUP mode
Operating mode window call and exit SETUP mode during operating mode change
2.3.1.1 Calibration parameters editing
Calibration parameter names and allowed values are given in Table 5.
Table 5
Parameter Value Description
Sound Velocity, in/µsec 0.039 to 0.591 in .001 steps Transducer selection for use
Thickness, inches 0.1 to 9.8 in 0.1 steps Material Thickness
Attenuation, dB/in Material dependent Loss of sound energy
Inspection Technique IE Test method
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