Acs Pengauge a1207 User manual

A1207 PenGauge

Acoustic Control Systems – ACS Group

Saarbrücken, Germany 2022

This instruction manual contains essential information on how to use this ACS product safely and effectively.

Before using this product, thoroughly review this instruction manual. Use the product as instructed.

Revision 1.1.0

Thickness Gauge

1. Operation manual 4

1.1 Scope of delivery ........................................................................................................... 4

1.2 Description and operation of the instrument ............................................................. 5

1.2.1 The intended use of the instrument ......................................................................... 5

1.2.1.1 Intended use and operation range ........................................................................................................ 5

1.2.1.2 Operation conditions .............................................................................................................................. 6

1.2.2 Technical specifications ........................................................................................... 6

1.2.3 Instrument design and operation principle .............................................................. 6

1.2.3.1 Instrument design ..................................................................................................................................... 7

1.2.3.2 Operation principle ................................................................................................................................. 8

1.3 Intended use ................................................................................................................... 8

1.3.1 Operating restrictions .............................................................................................. 8

1.3.2 Factors influencing the operation of the instrument and accuracy of the readings..... 8

1.3.2.1 State of the surface ................................................................................................................................... 8

1.3.2.2 Putting the piezoelectric transducer onto the surface ...................................................................... 9

1.3.2.3 Non-parallelism or eccentricity ............................................................................................................ 9

1.3.2.4 Acoustic properties of the material ...................................................................................................... 9

1.3.2.4.1 Sound dispersion ................................................................................................................................ 9

1.3.2.4.2 Variation of velocity .......................................................................................................................... 9

1.3.3 Making the instrument ready for operation ........................................................... 10

1.3.3.1 Surface preparation ............................................................................................................................... 10

1.3.3.2 Switching On/Off the instrument ........................................................................................................ 10

1.3.3.3 Select the measurement units .............................................................................................................. 10

1.3.3.4 Adjustment of the instrument .............................................................................................................. 11

1.3.3.4.1 Current ultrasonic sound velocity ................................................................................................ 11

1.3.3.4.2 Edit current ultrasonic sound velocity ........................................................................................ 11

1.3.3.4.3 Measure the ultrasonic sound velocity in the sample of known thickness ......................... 11

1.3.3.4.4 Calibration mode ............................................................................................................................. 12

1.4 Maintenance ................................................................................................................ 13

1.4.1 Accumulator battery ............................................................................................... 13

1.4.2 Recharging the accumulator .................................................................................. 13

1.4.3 Replacement of the transducer capsule ................................................................ 14

1.4.4 Common troubleshouting and remedies ................................................................ 15

1.5 Storage .......................................................................................................................... 15

1.6 Transportation ............................................................................................................. 15

1.7 Appendix A ................................................................................................................... 15

2. Firmware installation 18

3. Application software 19

3.1 Introduction ................................................................................................................. 19

3.2 Application tabs ........................................................................................................... 19

3.3 Connection to a Bluetooth device ............................................................................. 19

3.4 Thickness measurement .............................................................................................. 22

3.4.1 Display mode .......................................................................................................... 23

3.4.2 A-Scan mode ........................................................................................................... 28

3.4.3 B-Scan mode ........................................................................................................... 31

3.5 Settings ......................................................................................................................... 36

3.6 Service address ............................................................................................................. 41

Index

Operation manual

1 Operation manual

1.1 Scope of delivery

The following section describes the scope of delivery for A1207 PenGauge.

A1207 PenGauge Scope of delivery

Part

Amount

Location

Electronic unit A1207 PenGauge with

one build-in transducer

Operation manual

Reference block for functional tests

Power charger

USB cable

Strap

Couplant

Optional transducers (if ordered)

{

Warranty certificate

inside case |

Calibration certificate

inside case |

1.2 Description and operation of the instrument

The present operation manual (from now on referred to as "operation manual") contains:

technical specifications,

description of design,

and operation principle of the А1207 Ultrasonic Thickness Gauge (from now on

referred to as "thickness gauge" or “instrument”),

as well as information required for proper working with the instrument.

Carefully read the operation manual before working with the instrument.

Only properly trained personnel who carefully read the operational documentation and

understand general principles of the ultrasonic vibration propagation theory should be

allowed to work with the instrument.

Test problems must be identified, inspection layouts shall be chosen, conditions of

performing inspection using similar materials shall be estimated, etc., for proper

ultrasonic inspection.

Continuous improvement of the instrument functions and its reliability and usability

sometimes results in minor changes that are not reflected in the current version of the

operation manual. Therefore, they do not affect the technical specifications of the

instrument.

1.2.1 The intended use of the instrument

1.2.1.1 Intended use and operation range

Thickness gauges are pocket-type portable ultrasonic gauges of general-purpose.

The instruments are designed to perform wall thickness measurements of boilers,

containers, pressure-operated vessels, hull plates, and other items made of black and

non-ferrous metals, as well as small-diameter metal and plastic pipes (from 20 mm) with

even and corroded surfaces with roughness Rz160 and minimum bending radius from

10 mm.

One can use the instrument under laboratory, field, and workshop conditions in various

industries. Please be sure to perform the surface pre-treatment using couplant. Contact

lubricants can be as follows: multiple oils, water, glycerin, special contact liquids, and

ultrasonic testing gels, etc.

Operation manual

1.2.1.2 Operation conditions

The instrument is designed to work under the following conditions:

ambient air temperature ranges from - 30 to +50 С;

relative air humidity up to 95 % at +35 С.

1.2.2 Technical specifications

The table below lists the main instrument parameters.

Table 1: Key instrument parameters

Parameter

Value

Measurement range of the

thickness (steel), mm

from 0.8 to 75.00 (double-crystal transducer)

from 25 to 100.00 (double-crystal transducer)

Sampling rate of the thickness

indication, mm:

from 0.80 to 9.99 mm

from 10.0 to 100.0 mm

0.01

0.1

Setting range of ultrasound

velocity, m/s

from 1000 to 9000

Type of the built-in transducer

double-crystal or single element

Frequency of the built-in

transducer, MHz

7 (double-crystal) or 5 (single element)

Diameter of the work surface of

the built-in transducer, mm

8 (double-crystal) or 10 (single element)

Power

built-in LiPol rechargeable battery

Nominal battery voltage, V

3.7

Period of continuous operation of

the instrument powered from the

completely charged accumulator

under normal environmental

conditions, min.

16 h

Overall dimensions, max.

125 × 25 × 15 mm

Maximum weight, g

Average time between failures,

min.

18 000 h

Average service life, min.

5 years

1.2.3 Instrument design and operation principle

Operation manual

1.2.3.1 Instrument design

А1207 Ultrasonic Thickness Gauge is a pocket-type one-piece case (see figure below)

with a built-in accumulator battery and a built-in double-crystal transducer or single-

crystal transducer (if requested).

Lab

Description

On/Off Key

Capsule of the piezoelectric transducer

Tip

Tuning keys

Digital display

USB port

{

Eyelet for strap

The instrument's design allows the replacement of the worn-out capsule of the built-in

transducer by unscrewing the tip detaching the transducer capsule from the instrument

without extra tools (see Replacement of the transducer capsule ).

The key is used to:

switch the instrument On/Off;

toggle between the measurement units (millimeters/inches).

The setting keys and are used to switch:

the velocity adjustment mode;

the calibration mode.

The digital measurement results, the ultrasound velocity, the accumulator battery state,

and the current measurement units (see figure below) are displayed on the screen.

The USB connector is used to connect the power adaptor 220 V – USB to charge the

built-in accumulator battery.

Operation manual

Lab

Description

Thickness measurement result

Accumulator charge level

Measurements units

1.2.3.2 Operation principle

The instrument measures the time of the double movement of ultrasonic pulses through

the inspected object from one surface to another. This time is converted to the thickness

value using a known velocity value.

The piezoelectric transducer integrated into the instrument’s case sends ultrasonic

pulses into the inspected object and receives their reflections. The transducer is put on

the surface of the tested object in the point where the thickness should be measured.

1.3 Intended use

1.3.1 Operating restrictions

The instrument is designed to be operated under conditions listed in the section

Operation condition .

1.3.2 Factors influencing the operation of the instrument and accuracy of the

readings

1.3.2.1 State of the surface

Loose or exfoliating rust, corrosion, or dirt on the surface of the object to be tested can

influence the transmission of the ultrasonic sound in the material. Hence such surface

should be cleaned of the rust and scale followed by applying more contact fluid as

compared to the fluid amount required for the smooth surface.

Thorough cleaning of the rough corroded surfaces will increase the accuracy of the

measurements and prolong the transducer's lifetime.

If there is a thick layer of paint on the surface or the paint starts to pill off, then remove it

since the thick paint layer reduces the signal and can produce a false echo, thus resulting

in false measurement results. The measurements can be executed through the thin paint

Operation manual

layer (0.1-0.3 mm). At that, the result of the measurements will include the thickness

value of the paint layer.

If there is a thick layer of paint on the surface or the paint starts to pill off, then remove it

since the thick paint layer reduces the signal and can produce a false echo resulting in

false measurement results.

1.3.2.2 Putting the piezoelectric transducer onto the surface

The piezoelectric transducer should be tightly pressed to the surface of the tested item to

provide a good transmission of the ultrasonic sound into the material.

When measuring the wall thicknesses of the cylindrical objects, minimal diameters, we

recommend using viscous lubricant (viscous contact liquid) and applying more liquid to

the point of contact.

Tightly pressing the piezoelectric transducer to the tube's surface and watching the

instrument's readings, lean the transducer from side to side in the plane perpendicular to

the tube's axis. At that move, the transducer gradually along the tube's wall. Do not slide

along the wall to decrease the wearing of the working surface of the piezoelectric

transducer.

If scanning is required, e.g., when searching for local thin areas of the material, then do it

as gently as possible, do not apply strong pressure, and use clean contact grease only

on the pre-cleaned surface.

The instrument's readings when the transducer is leaning from the middle position will be

increased a little. The minimum steady reading of the instrument contacting the tube’s

wall with the middle of the working surface of the piezoelectric transducer will be

considered the actual value of the measured thickness. If the transducer strongly leans

from this position, then the instrument's readings could increase in discrete steps.

The tested objects with double convex curvature (tubes’ bends, spherical coverings and

so on) are the most difficult for inspection since they can be contacted in a single point

only. If so, the transducer should contact the object in the middle of its working surface.

1.3.2.3 Non-parallelism or eccentricity

If the external and internal surfaces of the inspected material are not parallel or are

eccentric to each other, then the reflected wave (echo – signal) will deviate from the

required direction, and the accuracy of the readings will decrease.

1.3.2.4 Acoustic properties of the material

Some properties of the constructive materials can essentially limit the measurement

accuracy and measurable thickness range, and they can also increase the measurement

error.

1.3.2.4.1 Sound dispersion

In some materials (some types of stainless steel, cast-iron, composites), the sound

energy is being dispersed (on the crystallite molding or additions in the composites). This

effect reduces the possibility of the quality receipt of the signal reflected from the

backside of the tested object, thus limiting the abilities of the ultrasound measurements.

1.3.2.4.2 Variation of velocity

Sound velocity can vary essentially when the sound goes from one point to another in

some materials. This effect in some types of cast stainless steel and copper is caused

Operation manual

by the relatively big size of the grains and by the anisotropy of the sound velocity with

respect to the grain orientation.

1.3.3 Making the instrument ready for operation

1.3.3.1 Surface preparation

Carefully clean the surface of an inspected object from dirt, friable rust, and scale before

measurements. Apply a sufficient amount of the lubricant to the area of inspection.

1.3.3.2 Switching On/Off the instrument

To switch on the thickness gauge, shortly press the key.

On the instrument's screen, a moving message with the manufacturer name and

firmware version is displayed for several seconds.

The instrument will switch into the measurement mode. The horizontal strokes, the

accumulator battery state, and the current measurement units are displayed on the

screen.

To switch off the thickness gauge, press and hold the key for more than two seconds.

The instrument will automatically switch off in 5 minutes if neither keys are pressed, nor

the measurement process goes.

1.3.3.3 Select the measurement units

Select the measurement units: metric or imperial.

METRIC ("mm" shall be indicated) – the instrument measures the thickness in mm; the

instrument uses m/s for velocity.

IMPERIAL ("in" shall be indicated) – the instrument measures the thickness in inches (in);

the instrument uses inch/ms (in/ms) for velocity.

To select the measurement units, while switching on the instrument, press and hold the

key until the screen changes the displayed measurement values from "mm" (metric

system) to "in" (imperial system) or vice-versa.

Operation manual

1.3.3.4 Adjustment of the instrument

1.3.3.4.1 Current ultrasonic sound velocity

To view current ultrasonic sound velocity (see figure below) shortly press (hold no longer

than 2 seconds) the or key while in the measurement mode.

1.3.3.4.2 Edit current ultrasonic sound velocity

To edit the current ultrasonic sound velocity value, do the following:

press (hold longer than 2 seconds) the or key while in the measurement mode, at

that the current velocity value will start blinking;

set the required velocity value using the or key;

The velocity value will stop blinking in three seconds, and the instrument will switch to the

measurement mode. At that, the instrument saves velocity value.

The instrument saves the set velocity value when off.

1.3.3.4.3 Measure the ultrasonic sound velocity in the sample of known thickness

To measure the ultrasound velocity in the sample of known thickness, do the following:

set in the instrument the ultrasonic sound velocity value in the sample of the known

thickness (see Edit current ultrasonic sound velocity );

place the instrument onto the surface of the sample with a layer of the coupling

media pre-applied;

measured thickness value will be blinking;

adjust the velocity value by means of the or keys, so that the known

thickness value is displayed as the measurement value;

take the instrument from the sample, the measured resulting velocity value will be

blinking on the screen;

Operation manual

The velocity value will stop blinking in three seconds, and the instrument will switch to the

measurement mode. At that, the measured velocity value will be saved.

If there is no material sample, though the tested item is accessible from both sides, you

can measure its thickness in the place convenient for inspection (using a micrometer),

and then adjust the instrument in a way similar to adjustment using a sample of known

thickness.

1.3.3.4.4 Calibration mode

For a single-crystal transducer, calibration mode consists of two stages. The first stage

is turning off the noise threshold. The second stage is determining the latency value in the

transducer using the calibration sample (5 mm calibration block) included in the delivery

kit. The second stage is not obligatory. It shall be executed after the replacement of the

transducer.

For a double-crystal transducer, calibration mode consists only of a single-stage -

determining the latency value in the transducer using the calibration sample (5 mm and

25 mm calibration block) included in the delivery kit.

Before calibration, clean the transducer!

To enter the calibration mode, simultaneously press and hold (longer than 2 seconds) the

and keys. The blinking message "dUAL" or "SnGL" is displayed on the screen

depending on the transducer built-in on the device.

The noise threshold will be determined automatically.

Within three seconds after the instrument has entered the calibration mode, place the

instrument onto the surface of the calibration sample with a layer of the coupling media

pre-applied.

The instrument shall remain on the sample until the calibration is completed. The

procedure is indicated by a countdown.

If the calibration result is negative, the screen will display “FAIL” (see figure below). If so,

restart the calibration on the sample. Otherwise, the instrument will go to the

measurement mode.

For a single-crystal transducer, calibration is performed on one step of the calibration

sample - 5 mm.

For a double-crystal transducer, calibration is performed on two steps of the calibration

sample - 25 mm and immediately 5 mm.

Operation manual

After calibration on the 5 mm for a single-crystal transducer or 25 mm for a double-

crystal transducer the determined velocity value in the instrument is shown on the

display.

The determined velocity value by the calibration procedure is not saved in the device

memory! Notice the velocity value and manually set it in the instrument if needed!

The maintenance of the instrument includes cleaning it from dirt and dust and recharging

the accumulator.

1.4 Maintenance

1.4.1 Accumulator battery

The rechargeable battery of the instrument is designed for operation over a wide range of

temperatures. The battery capacity decreases at negative temperatures. The capacity is

lower by approximately 15% than at normal temperatures.

If the battery is almost dead when the power is on, its state will be indicated by the

blinking unshaded battery symbol. The instrument will automatically switch off when the

accumulator battery is dead.

The rechargeable battery has built-in protection against overcharge, over-discharge,

excess current, and temperature.

The rechargeable battery is designed for the entire warranty period of the instrument

operation.

The rechargeable battery shall be replaced by the service centers only.

Replacing the battery by the operator immediately voids the warranty for the instrument!

1.4.2 Recharging the accumulator

The accumulator is charged via the external charger or from the PC via USB.

When the charger is connected to the instrument, the battery filling sign starts blinking.

During the charging process, the blinking symbol "moves" to the top of the battery sign.

The period of charging depends on the discharge level. The full charge takes about 4-5

hours. Repeated recharge is allowed.

One can use the instrument during charging. In this case, the charging time will be 2-3

times longer.

Don't store the instrument with discharged battery to prevent its functional loss!

Operation manual

1.4.3 Replacement of the transducer capsule

The user can independently replace the worn out piezoelectric transducer capsule

without any additional tools. The figure below shows a sample of a capsule.

To replace the capsule of the transducer, proceed as follows:

Switch off the instrument;

Unscrew the tip;

Disconnect the capsule from the instrument (see figure below).

Reinsert a new capsule;

Screw in the tip

After the capsule is replaced, calibrate the device using the calibration sample (see

Calibration mode ).

Operation manual

1.4.4 Common troubleshouting and remedies

Operators experiencing troubles during the instrument operation or having any questions

relating to its operation, please immediately contact the manufacturer's representatives.

1.5 Storage

А1207 Ultrasonic Thickness Gauge should be shelf stored in the bag included in the

delivery kit of the instrument.

The arrangement of the instruments in warehouses shall enable their free movement and

unrestricted access to them.

The distance between the instruments and the walls, floor of the warehouse, and other

warehoused instruments shall be at least 100 mm.

The distance between the heating of a warehouse and the instruments shall be at least

0.5 m.

The storage room shall be free from the current-conducting dust, admixtures of

aggressive gases, and corrosive vapors able to attack the instruments.

1.6 Transportation

А1207 Ultrasonic Thickness Gauge should be transported in the bag included in the

delivery kit of the instrument.

The transportation conditions with regard to the impact of the external environment

climatic factors should correspond to storage conditions.

Any vehicle type can transport the packaged instruments for any distance without speed

restrictions.

One should fasten the packaged instruments properly in the transport vehicle. One

should protect the packaged instruments from precipitation and water splashes during

transportation in an open transport vehicle.

One should fix the packaged instruments properly and steadily to prevent shocks of

devices against each other and against vehicle walls during transportation.

The transportation conditions should conform to the technical conditions and regulations

applicable to each type of transportation.

If shipped by air, properly packed instruments should be placed in hermetically sealed

and heated compartments.

If the transportation conditions differ from the operation conditions, the instruments shall

be kept under normal environmental conditions for at least 2 hours before use.

1.7 Appendix A

The table below presents the propagation speeds of the longitudinal ultrasonic waves in

some materials.

Table 2: Sound velocities in some materials

Material

Velocity, m/s

Aluminium

6260

Aluminium alloy D16Т

6320

Operation manual

Bronze (phosphor

3530

Vanadium

6000

Bismuth

2180

Tungsten

5460

Ferrum

5850

Gold (Aurum)

3240

Constantan

5240

Concrete

2000 - 5400

Ragstone

5930

Gabbro 38

6320

Plaster stone

4790

Foliated granite

7870

Granite

4450

Toadstone 85

5800

Dolomite

4450

Limestone

6130

Brass

4430

Brass LS-59-1

4360

Magnesium

5790

Manganin

4660

Manganese

5561

Copper

4700

Molybdenum

6290

Nickel

5630

Stannum

3320

Osmium

5478

Lead

2160

Limestone 86

4640

Capron

2640

Quartz glass

5930

Labradorite 44

5450

Ice

3980

Marble

6150

Plexiglass

2670

Polystyrol

2350

Operation manual

Rubber

1480

Mica

7760

Acrylic plastic

2550

Silver (Argentum)

3600

Glass-ceramics

6740

Steel 20 GSNDM

6060

Steel HN77ТUR

6080

Steel 40HNМ А

5600

Steel HN70VМ ТU

5960

Steel HN35VТ

5680

Tantalum

4235

Chromium

6845

Zinc

4170

Silicate glass

5500

Steel H15N15GS

5400

Steel St3

5930

Thermazote

2920

Teflon

1350

Porcelain

5340

Ebonite

2400

Circonium

4900

Cast iron

3500 - 5600

Firmware installation

2 Firmware installation

1. Press and hold key.

2. Then press and hold key. On the display appears "Update".

3. Now you may release key.

4. While the key still pressed, connect the USB2.0 cable.

5. A new DRIVE appears (for example here - G:).

6. Copy newest (A1207_v3_43.bin) or desired firmware file to the new drive (here -

>G:).

7. Disconnect the USB2.0 cable.

Application software

3 Application software

3.1 Introduction

The application software for A1207 PenGauge operates on Android smartphones and

tablet PCs connected via Bluetooth with the same-named thickness gauge instrument by

ACS. The main purpose of the software is to extend the regular functionality of the A1207

PenGauge to include additional data processing and reporting features for better usability.

3.2 Application tabs

The application has five tabs. They are depicted at the bottom of the application. The

Table shows informational pictograms.

Pictogram

Description

Connectivity tab

Display tab

A-Scan tab

B-Scan tab

Settings tab

The pictograms are going yellow-colored by activating the corresponding tab.

3.3 Connection to a Bluetooth device

Open the application. It starts with the Connectivity tab. Under the Paired devices

(Android) or Online devices (iPhone) section, you will see a list of all A1207 paired device

(Android) online devices (iPhone) (see Figure 1).

Application software

Figure 1: Connectivity tab (left - Android, right - iPhone)

Only paired devices (Android) online devices (iPhone) will be listed. To pair a new device

with Android see the section Pairing devices.

Click on the desired device name to connect (see Figure 2).

You can connect only to one device simultaneously.

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