Foerster CIRCOGRAPH Ro 35 L User manual

CIRCOGRAPH®
Sensor system Ro 35 L
6.461.21
Operating Instructions

INTRODUCTION
These Operating Instructions are intended to be read, understood and
observed in all points by the persons responsible for operating the equip-
ment.
The complete Operating Instructions consist of the following sections:
1 Safety
2 Description
3 Installation
4 Operation
5 Maintenance
Knowledge of the Operating Instructions is essential for avoiding equip-
ment faults and for ensuring trouble-free operation.
It is therefore of the utmost importance that the entire Operating Instruc-
tions are made known to and understood by all the appropriate persons.
Our Service Department or one of our Representatives will be happy to
receive any suggestions for further improvements to these Operating In-
structions. They will also be pleased to provide rapid and comprehensive
answers to questions not covered by these Operating Instructions.

Copyright
© 2008 INSTITUT DR. FOERSTER GmbH & Co. KG.
In Laisen 70, D-72766 Reutlingen
These Operating Instructions contain copyrighted information. All rights
reserved, INSTITUT DR. FOERSTER GmbH & Co. KG.
These operating instructions are intended for assembly, operating and
monitoring personnel. Copying, reproduction or translation of these oper-
ating instructions into other languages in whole or in part requires the ex-
press written approval of INSTITUT DR. FOERSTER GmbH & Co. KG.

SENSOR SYSTEM Ro 35 L
CONTENTS
6.461.21 - 2008/06 I
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 35 L.....................................................................................2-7
2.4 Technical Data............................................................................................................2-13
2.5 Dimension sheet ........................................................................................................2-14
2.6 Environmental conditions ...........................................................................................2-16
2.7 Standard Components................................................................................................2-17

SENSOR SYSTEM Ro 35 L
CONTENTS
II 6.461.21 - 2008/06
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 ..................................................................................................4-4
4.3 Adjusting nominal diameter..........................................................................................4-5
4.3.1 Preparation .......................................................................................................4-5
4.3.2 Removing nozzle holder...................................................................................4-6
4.3.3 Changing nozzles.............................................................................................4-8
4.3.4 Adjusting probe clearance................................................................................4-9
4.3.5 Adjusting roller guide......................................................................................4-13
4.4 Rotational speed preselection....................................................................................4-13
4.5 Switching on motor.....................................................................................................4-14
4.6 Application drawing line .............................................................................................4-15
5MAINTENANCE ....................................................................................................... 5-1
5.1 Maintenance schedule .................................................................................................5-1
5.2 Cleaning .......................................................................................................................5-2
5.3 Removing and installing test heads..............................................................................5-3
5.3.1 Removing test heads........................................................................................5-3
5.3.2 Installing test heads..........................................................................................5-5
5.3.2 Installing test heads..........................................................................................5-6
5.4 List of parts subject to wear..........................................................................................5-8

SENSOR SYSTEM Ro 35 L
SAFETY 1.1 Dangers posed by this machine
6.461.21 - 2008/06 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.

SENSOR SYSTEM Ro 35 L
1.3 Use as intended SAFETY
1-2 6.461.21 - 2008/06
1.3 Use as intended
The sensor system is suitable only for non-destructive testing of round
material.
Diameter range: see 2.4 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 components.
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
See 2.6 Environmental conditions.

SENSOR SYSTEM Ro 35 L
SAFETY 1.6 Danger sources
6.461.21 - 2008/06 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.

SENSOR SYSTEM Ro 35 L
1.9 Personal safety equipment SAFETY
1-4 6.461.21 - 2008/06
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: see 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.

SENSOR SYSTEM Ro 35 L
SAFETY 1.13 Declaration of Conformity
6.461.21 - 2008/06 1-5
1.13 Declaration of Conformity
DECLARATION of CONFORMITY
Manufacturer: INSTITUT DR. FOERSTER GmbH & Co. KG Phone [phone]
In Laisen 70 Fax [phone]
72766 REUTLINGEN [e-mail]
GERMANY www.foerstergroup.de
Product: CIRCOGRAPH® Sensor system Ro 35 L
Type: 6.461.21
We declare, that this product complies with the requirements of following European Directives
and corresponding Standards:
• European Directive 2006/95/EC: Safety of electrical apparatus
• European Standard EN 61010
August 21, 2007
INSTITUT DR. FOERSTER
Division TS - Test Systems
Dr. Jürgen Schröder

SENSOR SYSTEM Ro 35 L
1.13 Declaration of Conformity SAFETY
1-6 6.461.21 - 2008/06
Notes:

SENSOR SYSTEM Ro 35 L
DESCRIPTION 2.1 Application
6.461.21 - 2008/06 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 6.430 testing and evaluation
electronic equipment and a suitable mechanical handling system.
 Diameter range of test material 5 to 35 mm
 Preferably continuous testing, also separate piece testing
 Surface free of scale, wherever possible bright
 Testing without physical contact at rotational speeds up to 9,000 rpm
 End condition free of projecting burrs
 Max. test material temperature +80 °C
 Test heads with track width 2.5 and 5 mm [BS]
 Quick change nozzles inside and outside
 Blower facility for cooling and maintaining cleanliness
Testing capacity
 surface flaw testing, preferably longitudinal flaws
 flaw detectability for bright material surface from flaw depth of approx.
30 µm
 test speed of up to 3 m/s for gapless testing (rotational speed =
9,000 rpm and four test heads with 5 mm track width)

SENSOR SYSTEM Ro 35 L
2.2 Mode of operation DESCRIPTION
2-2 6.461.21 - 2008/06
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 rotating
system generates a high number of consecutive signals that reliably indi-
cate a flaw of a certain length.
The test speed is a result of the number of rotating probes, integrated in
the rotating head (2 or 4 test levers), the track width of all probes, and the
rotational 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.
Two types of motor controls are available:
MOC E (economy version) with one constant rotational speed at
4500 rpm and manual brake system.
MOC SB with two switchable speeds 4,500 and 9,000 rpm and electrical
brake system.
Signal generation during
rotary testing
Test tracks and flaw signals
of a rotating probe
Test tracks of two rotating
probes offset by 180º
Test tracks of four rotating
probes offset by 90º

SENSOR SYSTEM Ro 35 L
DESCRIPTION 2.3 Construction
6.461.21 - 2008/06 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.
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 CIRCOGRAPH DS

SENSOR SYSTEM Ro 35 L
2.3 Construction DESCRIPTION
2-4 6.461.21 - 2008/06
Nozzle Holder Outside Nozzle Outside Nozzle Inside Nozzle Holder Inside
Fig. 2.2 CIRCOGRAPH sensor system Ro 35 L
Roller guide left
∅4.5 – 35
6.461.01-5001
Roller guide right
∅4.5 – 35
6.461.01-5011
Throughput
preferred direction
(both directions possible)

SENSOR SYSTEM Ro 35 L
DESCRIPTION 2.3 Construction
6.461.21 - 2008/06 2-5
In order to withstand the rough conditions of use, the rotating head has
been designed to be dust-protected, robust and reliable by means of
complex constructional measures such as labyrinth seals and dirt deflec-
tors.
The chamber surrounding the test zone serves the purpose of contact
and burst protection as well as dust collection. This chamber is provided
with a connection facility for a suction connector for an external extraction
system (to be provided by customer).
The sensor system consists of the following compulsory components:
 rotating head Ro 35 L
 test heads, track width 2.5 and 5 mm
 protective nozzles
The following options are available for adaptation to particular material
conditions:
 roller guides

SENSOR SYSTEM Ro 35 L
2.3 Construction DESCRIPTION
2-6 6.461.21 - 2008/06
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.
Due to high centrifugal forces (acceleration up to 4,500 g!) and the rough
environmental conditions at the testing location, the probes are protected
by a ceramic armor, nevertheless replacement of probes is possible.
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 test speed.
The following table shows these relationships and gives typical examples
for a practical selection:
Maximum test speed
[m/s]
Decreasing
sensitivity to short
flaws
Track width BS
[mm]
Test head type
0.75
1.5 2.5 6.461.21-2025
1.5
3.0
5.0 6.461.21-2050
n = 4,500 rpm
n = 9,000 rpm
Tab. 2.1 Test head selection
Rotating disc with test heads
Probe
Test head

SENSOR SYSTEM Ro 35 L
DESCRIPTION 2.3 Construction
6.461.21 - 2008/06 2-7
2.3.2 Rotating Head Ro 35 L
The rotating head is the main component of
the sensor system.
It consists of:
 rotor
 transmitter
 drive
 housing
 rotating head electronics
The test direction can be selected as
right or left (viewed in the throughput
direction).
Rotor
The rotor consists of a hollow shaft,
a rotor disc and the movable part of
the transmitter.
The rotor is driven by the motor
by means of a high-power profile
flat belt. It is supported in the
housing by two high-speed
bearings.
The high-precision rotating disc
for holding the test heads is fitted
on the front side.
A pivot-mounted spiral disc with an
actuating gear and automatic blocking
facility is fitted in the rotating disc for
precise and simultaneous test head
diameter adjustment.
DANGER!
Never run the rotating head without test heads!
Fig. 2.3 Rotating head Ro 35 L
Fig. 2.4 Rotating disc with test heads
View through the opened adjust-
ment side, housing flange and
cover of rotating disc removed

SENSOR SYSTEM Ro 35 L
2.3 Construction DESCRIPTION
2-8 6.461.21 - 2008/06
Transmitter
Wear-resistant rotating transmitter in disc-type construction with a field
transmitter, two measuring channels and a clearance channel.
Consisting of a rotor and stator, it transmits the field current for the rotat-
ing probes from the stator to the rotor and, in the opposite direction,
transmits the test signal to the test electronics for evaluation.
Rotating head electronics
The rotating head electronics amplifies the probe signals and the field cur-
rent. It is installed in a robust box on the connection side of the bearing
housing to permit ease of maintenance. The cable to the test electronics
is connected using MIL plug connectors.
Fig. 2.5 Signal path