Foerster CIRCOGRAPH DS User manual

CIRCOGRAPH®DS
Sensor system Ro 130
6.453
Operating Instructions

SENSORSYSTEM Ro 130
6.453 – 01/2006 I
FOREWORD
These operating instructions were written to be read, understood and
complied with in full by those persons responsible for operating the ma-
chine.
The complete operating instructions consist of the following sections:
1 Safety
2 Description
3 Installation
4 Operation
5 Maintenance
Machine faults can only be avoided and fault-free operation of the ma-
chine can only be guaranteed through knowledge of the operating instruc-
tions.
It is therefore particularly important that all responsible persons are famil-
iar with and understand the full operating instructions.
Our service department or one of our representatives would be pleased to
receive suggestions about how to further improve these operating instruc-
tions. Any questions not covered by these instructions will also be dealt
with quickly and comprehensively.

SENSORSYSTEM Ro 130
II 6.453 – 01/2006
Copyright
© 2006 INSTITUT DR. FOERSTER GmbH & Co. KG.
In Laisen 70, D-72766 Reutlingen
Copyright 2006 Institut Dr. Foerster for Software:
So far software is supplied or installed on the system, it is subject to copy-
right laws. It may be used only for operating the related system in the
manner described in the sales documentation or in the User Manual. Any
use over and above this is expressively prohibited. Violations of this
clause shall entail liability to pay compensation for damages and may
also result in prosecution under criminal law
Copyright 2006 Institut Dr. Foerster for Documentation:
INSTITUT DR. FOERSTER GMBH & CO KG retains ownership of all
property rights to all information provided in this document. The docu-
ments shall support only operation and service of the delivered units. All
(direct and indirect) duplication and disclosure to unauthorized third par-
ties is strictly prohibited.

SENSORSYSTEM Ro 130
CONTENTS
6.453 – 01/2006 1
1SAFETY ................................................................................................................... 1-1
1.1 Dangers posed by this machine...................................................................................1-1
1.2 Safety information and tips...........................................................................................1-1
1.3 Use as intended ...........................................................................................................1-2
1.4 Dangers posed by accessories ....................................................................................1-2
1.5 Emissions.....................................................................................................................1-2
1.6 Danger sources............................................................................................................1-3
1.7 Workstations.................................................................................................................1-3
1.8 Authorised operators ....................................................................................................1-3
1.9 Personal safety equipment...........................................................................................1-4
1.10 Safety measures at the installation location.................................................................1-4
1.11 Protective safety devices .............................................................................................1-4
1.12 Behaviour in the event of an emergency......................................................................1-4
1.13 Declaration of conformity .............................................................................................1-5
2DESCRIPTION ......................................................................................................... 2-1
2.1 Application....................................................................................................................2-1
2.2 Mode of operation ........................................................................................................2-2
2.3 Construction .................................................................................................................2-3
2.3.1 Test Heads........................................................................................................2-6
2.3.2 Rotating Head Ro 130......................................................................................2-7
2.4 Technical Data............................................................................................................2-13
2.5 Dimension sheet ........................................................................................................2-14
2.6 Operating, storage and transport conditions ..............................................................2-16
2.7 Standard Components................................................................................................2-17

SENSORSYSTEM Ro 130
CONTENTS
26.453 – 01/2006
3INSTALLATION........................................................................................................ 3-1
3.1 Setup and Connection..................................................................................................3-1
4OPERATION............................................................................................................. 4-1
4.1 Dimension change .......................................................................................................4-1
4.2 Selection and installation of the protective nozzles......................................................4-2
4.2.1 Selection of the protective nozzles...................................................................4-2
4.2.2 Required tools ..................................................................................................4-3
4.3 Changing nominal diameter .........................................................................................4-4
4.3.1 Preparation .......................................................................................................4-4
4.3.2 Remove Entry Nozzle.......................................................................................4-5
4.3.3 Adjusting nominal diameter ..............................................................................4-7
4.3.4 Remove exit nozzles ......................................................................................4-10
4.3.5 Fitting protective nozzles................................................................................4-12
4.3.6 Setting the roller guides .................................................................................4-15
4.3.7 Positioning the transmitter system in the testing line......................................4-15
4.4 Rotational speed preselection....................................................................................4-16
4.5 Switching on motor.....................................................................................................4-17

SENSORSYSTEM Ro 130
CONTENTS
6.453 – 01/2006 3
5 MAINTENANCE ....................................................................................................... 5-1
5.1 Maintenance schedule .................................................................................................5-1
5.2 Cleaning .......................................................................................................................5-2
5.3 Removing and fitting the test heads.............................................................................5-2
5.4 Replacing parts subject to wear ..................................................................................5-5
5.5 Maintenance of the roller guides ..................................................................................5-6
5.5.1 Lubrication........................................................................................................5-6
5.5.2 Replacing the track rollers................................................................................5-7
5.5.3 Removing the roller guide levers ......................................................................5-8
5.6 Checking and changing the cone belt ..........................................................................5-9
5.7 List of parts subject to wear........................................................................................5-13

SENSORSYSTEM Ro 130
CONTENTS
46.453 – 01/2006
Notes:

SENSORSYSTEM Ro 130
SAFETY 1.1 Dangers posed by this machine
6.453 – 01/2006 1-1
1 SAFETY
1.1 Dangers posed by this machine
The sensor system features protective safety devices. It has been sub-
jected to a safety test and safety acceptance test. In the event of operat-
ing errors or misuse, the machine may pose dangers and risks to
 the life and limb of the operator,
 the machine and other operator’s valuables and
 efficient operation of the machine
All persons involved in installation, commissioning, operation, servicing
and maintenance of the machine must
 be appropriately qualified and
 must strictly follow the information provided in these operating instruc-
tions.
Your safety is at stake!
1.2 Safety information and tips
The following symbols are used in these operating instructions:
DANGER!
This warns against dangers to persons. These sections provide you
with information on what to do and what not to do in order to prevent
personal injury.
WARNING!
These sections indicate possible damage to the test system. They pro-
vide information on what to do and what not to do in order to prevent
damage to property.
NOTE!
These sections provide tips for the user on how to use the system bet-
ter and also provide other useful information.

SENSORSYSTEM Ro 130
1.3 Use as intended SAFETY
1-2 6.453 – 01/2006
1.3 Use as intended
The sensor system is suitable only for non-destructive testing of round
material.
Diameter range: refer to Technical Data
Smaller diameters and larger diameters may not be admitted into the
sensor system under any circumstances.
Material with a cross-section which is anything other than round may not
be admitted into the sensor system under any circumstances.
The sensor system may be operated only in conjunction with a suitable
conveying mechanism and a lifting table.
On no account may you convert or modify the sensor system arbitrarily,
for reasons relating to safety.
DANGER!
Masses rotating at high speed pose a serious danger to your life if the
machine is operated incorrectly. Never touch the rotating sensor com-
ponents.
NOTE!
The information on operation, servicing and maintenance prescribed in
these operating instructions must be followed strictly.
1.4 Dangers posed by accessories
Transport mechanisms, lifting table and external control equipment must
not render the protective safety devices of the sensor system inoperable.
1.5 Emissions
Refer to 2.4 Technical Data

SENSORSYSTEM Ro 130
SAFETY 1.6 Danger sources
6.453 – 01/2006 1-3
1.6 Danger sources
The sensor system operates with a rotating test system and an attached
roller guide system during operation. A person coming into contact with
the roller guide or the rotating test system may suffer very serious injuries.
Switch off the drives before you put your hands into or touch the sensor
system. Wait for all motions to cease!
Before carrying out servicing and cleaning work, switch off the drive for
the sensor system and conveying mechanisms and disconnect the power
supply (secure the master switch in position OFF).
Never remove protective safety devices or render them inoperable by
making modifications to the system.
1.7 Workstations
The workstation is located on the electronic equipment cabinet or on the
operating panel of the sensor system
Do not carry out any work or tamper in any other way with the sensor sys-
tem when it is rotating.
1.8 Authorised operators
Only authorised personnel may work on the sensor system.
Please comply with the minimum legal age!
The operator is responsible for the safety of third parties in the work area.
The scopes of authority for the various activities on the sensor system
must be clearly defined and complied with.
Untrained personnel pose a safety risk!
The operator must
 make the operating instructions available to the machine operator and
 make sure that the machine operator has read and understood them.

SENSORSYSTEM Ro 130
1.9 Personal safety equipment SAFETY
1-4 6.453 – 01/2006
1.9 Personal safety equipment
You are to wear ear plugs, if the A-weighted equivalent sound pressure
level at the workstations of the sensor system is greater than 85 dB(A).
Sound pressure level for this equipment: refer to 2.4 Technical Data
1.10 Safety measures at the installation location
The sensor system must be installed stably on a machine foundation pro-
vided for it and must be firmly anchored to the foundation. If this is not
done, this will pose a potentially lethal risk.
NOTE!
Ensure that the area surrounding the workstation is always clean and
unobstructed by issuing appropriate in-company instructions and con-
ducting inspections.
1.11 Protective safety devices
The CIRCOGRAPH sensor system is shut down
 when opening the housing (safety switch on the rotor cover)
 with the switch on the operating panel or on the electronic equipment
cabinet
 with the EMERGENCY-STOP switch on the operating panel
(EMERGENCY-STOP has to be linked with motor control)
The protective safety devices
 are installed to ensure the safety of the operating staff
 may not be modified, removed or bypassed by making modifications to
the sensor system under any circumstances.
1.12 Behaviour in the event of an emergency
In an emergency, please immediately press the red EMERGENCY-STOP
switch. Have authorised personnel remedy the cause of the fault immedi-
ately.

SENSORSYSTEM Ro 130
6.453 – 01/2006 1-5
1.13 Declaration of conformity
We declare, that this product complies with the requirements of following
European Directives and corresponding standards:
 European Directive 89/392/EEC: Safety of machines
 European Standards EN 12100, EN 60204
 European Directive 73/23/EEC: Safety of electrical apparatus
 European Standard EN 61010
 European Directive 89/336/EEC: Electromagnetic Compatibility
 European Standard EN 61326-1
February 23, 2005
INSTITUT DR. FOERSTER
Division TS - Test Systems
Dr. Jürgen Schröder

SENSORSYSTEM Ro 130
1-6 6.453 – 01/2006
Notes:

SENSORSYSTEM Ro 130
DESCRIPTION 2.1 Application
6.453 – 01/2006 2-1
2 DESCRIPTION
2.1 Application
Non-destructive testing of ferromagnetic, austenitic and non-
ferromagnetic round materials (wires, bars, and tubes) for surface flaws in
conjunction with the CIRCOGRAPH®DS testing and evaluation electronic
equipment and a suitable mechanical handling system.
 Diameter range of testing material 10 to 130 mm
 Preferably piece testing
 Surface free of scale, wherever possible bright
 Testing without physical contact at rotational speeds up to 3,000 rpm
 End condition free of projecting burrs
 Max. test material temperature +80 °C
 Test heads with tracking width 2x2.5 – 2x5 – 2x10 mm [BS]
Testing capacity
 surface flaw testing, preferably longitudinal flaws
 flaw detectability for bright material surface from flaw depth of approx.
50 µm
 testing speed of up to 2 m/s for gapless testing (rotational speed =
3,000 rpm and two test heads with 2x10 mm track width)

SENSORSYSTEM Ro 130
2.2 Mode of operation DESCRIPTION
2-2 6.453 – 01/2006
2.2 Mode of operation
The sensor system operates on the basis of the eddy current principle in
accordance with EN 12084. Rotating systems are used to detect longitu-
dinal surface defects. Probes rotate at high speed and without physical
contact around the test piece. By feeding the material the probes scan the
surface in helical paths.
Due to the locally high resolution of the probes and the transverse move-
ment across the crack by each revolution, this is the most sensitive
method for detecting longitudinal defects.
Any time a probe crosses a crack , it generates a signal. Thus, the rotat-
ing system generates a high number of consecutive signals that reliably
indicate a flaw of a certain length.
The testing speed is a result of the number of rotating probes, integrated
in the Ro 130, the track width of all probes, and the rotating speed (rpm).
The helical path of all probes must be side by side to guarantee a fully
gapless scan.
The signals recorded by the probes are transferred from the sensor sys-
tem to the test electronics for evaluation.
The primary power supply and the secondary signal of the probes are
transmitted by rotating inductive transmitters without physical contact.
Signal generation during
rotary testing
Test tracks and flaw signals
of a rotating probe
Test tracks of two test heads
with 2 probes each
offset by 180º

SENSORSYSTEM Ro 130
DESCRIPTION 2.3 Construction
6.453 – 01/2006 2-3
2.3 Construction
CIRCOGRAPH DS test electronics and the connection cables are re-
quired for a complete test system, besides the sensor system which
scans the test material and generates the eddy-current signal.
A separate leaflet:
“CIRCOGRAPH DS System 6.430”, Order-No. 163 852 1
will inform you about the according test electronics.
Fig. 2.1 Test equipment configuration,
top: CIRCOGRAPH DS / MOC SB, bottom: Rotating head Ro 130 entry and exit side

SENSORSYSTEM Ro 130
2.3 Construction DESCRIPTION
2-4 6.453 – 01/2006
Roller guide Clamping ring - Nozzle - Adapter - Flange Nozzle - Nozzle holder - Inner and Outer sleeve Roller guide
Fig. 2.2 CIRCOGRAPH Sensor system Ro 130, main view, legend see Chap. 2.7
Flaw direction
Fig. 2.3 CIRCOGRAPH Sensor system Ro 130, basic components

SENSORSYSTEM Ro 130
DESCRIPTION 2.3 Construction
6.453 – 01/2006 2-5
In order to withstand the rough conditions of use, the Ro 130 has been
designed to be dust-protected, robust and reliable by means of complex
constructional measures such as labyrinth seals and dirt deflectors.
The chamber surrounding the test zone serves the purpose of contact
and burst protection as well as dust collection. This chamber is provided
to connect an external extraction system (to be provided by customer).
The Ro 130 sensor system consists of the following compulsory compo-
nents:
 rotating head Ro 130
 test heads
 protective nozzles
The following options are available for adaptation to particular material
conditions:
 Centric triple roller guides
 Nozzle holder and Protective Nozzles with connector for compressed
air (to keep the testing zone free of dust)

SENSORSYSTEM Ro 130
2.3 Construction DESCRIPTION
2-6 6.453 – 01/2006
2.3.1 Test Heads
The test heads are both the heart of the sensor system and its most criti-
cal components.
They consist of an eddy-current probe with field, measuring and clear-
ance windings which are installed in a precise mechanical holder and are
connected by means of a highly flexible special cable with a connection
plug.
As already mentioned in the ‘Mode of operation’ section, there is a
mathematical relationship between the number and track width of the test
heads, the rotational speed and the testing speed.
The following table shows these relationships and gives typical examples
for a practical selection:
Maximum testing speed Test head type
n = 1,500 rpm
n = 3,000 rpm
Number / Track
width TH / BS
Bright material
Fe - Nfe - Aust
rough rolled
Fe
Decreasing
sensitivity to short
flaws
0.25 m/s
0.5 m/s 2 TH / 2 x 2.5 mm 6.453.01-2311 6.453.03-2311
0.5 m/s
1.0 m/s 2 TH / 2 x 5.0 mm 6.453.01-2321 6.453.03-2321
1.0 m/s
2.0 m/s 2 TH / 2 x 10 mm 6.453.01-2331 6.453.03-2331
Tab. 2.1 Test head selection
Rotating disc with test heads
p
robe
Test head