GE DM5E User manual

GE
Sensing & Inspection Technologies Ultrasonic
P/N 1259551 Rev. 1
February 2009
DM5E
Operating Manual

GESensingInspection.com
©2009 General Electric Company. All rights reserved.
Technical content subject to change without notice.
DM5E
Corrosion Thickness Gauge
Operating Manual
P/N 1259551 Rev. 1
February 2009

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Contents
DM5E Operating Manual iii
Chapter 1. General Information
1.1 Supplying Power to the DM5E. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Powering the Instrument ON and OFF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3 Key Features of the DM5E. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3.1 DM5E Corrosion Thickness Measurement Base Instrument . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.4 Contents of this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Chapter 2. Understanding the Keypad, Menu System & Displays
2.1 Keypad Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Interpreting the Display Screens. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.3 Working with the Configuration Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Contents
iv DM5E Operating Manual
Chapter 3. Setting Up the DM5E
3.1 Connecting a Probe and Loading a Setup File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.2 Configuring the Instrument. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.2.1 Setting the Instrument Gain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.2.2 Setting the Update Rate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.2.3 Specifying the Nominal Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.3 Instrument Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.4 Setting the Maximum and Minimum Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.5 B-SCAN Display Range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.6 Locking and Unlocking Instrument the Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Chapter 4. Measuring Thickness
4.1 Selecting the Displayed View Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.2 Normal Measurement View Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.3 Min Scan and Max Scan Measurement View Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.4 Differential/Rate-of-Reduction Measurement View Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.5 B-SCAN Measurement View Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.6 Dual Multi Measurement View Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Contents
DM5E Operating Manual v
Chapter 5. Using the Optional Data Recorder
5.1 Creating a New Data Recorder File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.2 Recalling and Erasing Stored Data Recorder Files. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.2.1 Recalling a Data Recorder File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.2.2 Erasing a Data Recorder File. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.3 Recording Thickness Measurements in Data Recorder Files. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.3.1 Storing Minimum of B-Scan in Data Recorder Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.3.2 Navigating Through Data Recorder Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Chapter 6. I/O Features
6.1 Connecting the DM5E to a PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Chapter 7. Specifications
7.1 Instrument Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
7.2 Data Recorder Option Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
7.3 DM5E Probe/Transducer Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Contents
vi DM5E Operating Manual
Chapter 8. Maintenance
8.1 Care of the instrument. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
8.2 Proper Cable Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
8.3 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Appendix A. Supplemental Information
A.1 Resetting the Operating Software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
A.2 Firmware Updates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
A.3 Web Site Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
A.4 EMC Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
A.5 Manufacturing & Customer Service Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Appendix B. Environmental Compliance
B.1 Waste Electrical and Electronic Equipment (WEEE) Directive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
B.2 Battery Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
B.2.1 What do the Markings Mean? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
B.2.2 The Risks and Your Role in Reducing Them . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

DM5E Operating Manual vii
Preface
Important Notice
The following information must be read and understood by any user of a GE Sensing & Inspection Technologies ultrasonic thickness gauge.
Failure to follow these instructions can lead to errors in thickness measurements or other test results. Decisions based on erroneous results
can, in turn, lead to property damage, personal injury or death.
General Warnings
Proper use of ultrasonic test equipment requires three essential elements:
•Selection of the correct test equipment
•Knowledge of the specific “test application requirements”
•Training on the part of the instrument operator
This operating manual provides instruction in the basic setup and operation of the thickness gauge. There are, however, additional factors
which affect the use of ultrasonic test equipment. Specific information regarding these additional factors is beyond the scope of this manual.
The operator should refer to textbooks on the subject of ultrasonic testing for more detailed information.

Preface
viii DM5E Operating Manual
Operator Training
Operators must receive adequate training before using ultrasonic test equipment. Operators must be trained in general ultrasonic testing
procedures and in the setup and performance required by a particular test. Operators must understand:
•Sound wave propagation theory
•Effects of the velocity of sound of the test material
•Behavior of the sound wave where two different materials are in contact
•Areas covered by the sound beam
More specific information about operator training, qualification, certification, and test specifications is available from various technical
societies, industry groups, and government agencies.

DM5E Operating Manual ix
Preface
Testing Limitations
In ultrasonic testing, information is obtained only from within the limits of the sound beam. Operators must exercise great caution in making
inferences about the test material outside the limits of the sound beam. For example, when testing large materials it may be impossible or
impractical to inspect the entire test piece.
When a less-than-complete inspection is to be performed, the operator must be shown the specific areas to inspect. Inferences about the
condition of areas not inspected, based on data from the evaluated areas, should only be attempted by personnel fully trained in applicable
statistical and probability techniques. In particular, materials subject to erosion or corrosion, in which conditions can vary significantly in
any given area, should only be evaluated by fully trained and experienced operators.
Sound beams reflect from the first interior surface encountered. Because of part geometry and overlapped flaws or overlapped surfaces,
thickness gauges may measure the distance to an internal flaw rather than to the back wall of the material. Operators must take steps to
ensure that the entire thickness of the test material is being examined.

Preface
xDM5E Operating Manual
Ultrasonic Thickness Measurement Critical Operating Procedures
The following operating procedures must be observed by all users of ultrasonic thickness gauges in order to minimize errors in test results.
1. Calibration of Sound Velocity
The principle of operation of an ultrasonic thickness gauge is that the instrument measures the time of flight of an ultrasonic pulse through
the test piece and multiplies this time by the velocity of sound in the material. Thickness measuring error is minimized by ensuring that the
sound velocity to which the instrument is calibrated is the sound velocity of the material being tested. Actual sound velocities in materials
often vary significantly from the values found in published tables. In all cases, best results are obtained if the instrument is calibrated on a
velocity reference block made from the same material as the test piece; this block should be flat and smooth and as thick as the maximum
thickness of the test piece.
Operators should also be aware that the sound velocity may not be constant in the material being tested; heat treating, for example, can
cause significant changes in sound velocity. This must be considered when evaluating the accuracy of the thickness provided by this
instrument. Instruments should always be calibrated before testing, and the calibration should be checked after testing, to minimize testing
errors.
2. Probe Zero Procedure
Before performing calibration with a contact probe, the probe zero procedure must be performed first. If the zero procedure is not performed
or if it is performed improperly, inaccurate thickness readings will result.

DM5E Operating Manual xi
Preface
Ultrasonic Thickness Measurement Critical Operating Procedures (cont.)
3. Effects of Temperature on Calibration
Temperature variations change the sound velocity of materials and transducer delay lines and, therefore, calibrations. All calibrations should
be performed on-site and with test blocks at the same temperature as the test piece, to minimize errors due to temperature variations.
4. Transducer Selection
The transducer used in testing must be in good condition, without noticeable wear of the front surface. Badly worn transducers will have a
reduced effective measuring range. The specified range of the transducer must include the complete range of thicknesses to be tested. The
temperature of the material to be tested must be within the transducer's temperature range.
5. Use of Couplants
Operators must be familiar with the use of ultrasonic couplants. Testing skills must be developed so that couplant is used and applied in a
consistent manner to minimize variations in couplant layer thickness and errors in test results. Calibration and actual testing should be
performed under similar coupling conditions, using a minimum amount of couplant and applying consistent pressure on the transducer.

Preface
xii DM5E Operating Manual
Ultrasonic Thickness Measurement Critical Operating Procedures (cont.)
6. Doubling
Ultrasonic thickness gauges will, under certain conditions, display readings which are twice (or in some cases, three times) the actual
material thickness being measured. This effect, commonly known as “doubling,” can occur below the minimum specified range of the
transducer. If the transducer being used is worn, doubling is possible at a thickness greater than the minimum of the specified range.
When using a new transducer, any reading which is less than twice the minimum specified range of the transducer may be a “doubled”
reading, and the thickness of the material being tested should be verified by the use of other methods. If the transducer shows any sign of
wear, doubling may occur at a second echo, or other echo signal combinations may produce a readable signal. The instrument reading and
apparent thickness are up to about twice the actual value, resulting in a thickness greater than twice the minimum of the specified range.
This thickness should be determined by calibrating the instrument/transducer combination on reference blocks that represent the complete
range of possible thicknesses that may be encountered in testing. This is particularly important when a test piece is being ultrasonically
measured for the first time or in any case where the history of thickness of the test specimen is unknown.

DM5E Operating Manual xiii
Preface
Safety Information
IMPORTANT: The DM5E is an instrument for materials testing. Any use for medical applications or other purposes is not allowed. The
DM5E may only be used in industrial environments.
IMPORTANT: For battery operation of the DM5E, two “AA” size batteries are needed. You should only use the products recommended by
us for battery operation. Use of well-known battery brands is highly recommended.
IMPORTANT: Disposal of all components of the DM5E and its batteries must be done in compliance with all applicable regulations. See
Appendix B, Environmetal Compliance, for detailed information.
Software
According to the current state of the art, software is never completely free from errors. Before using any software-controlled test equipment,
please make sure that the required functions operate perfectly in the intended combination.

Preface
xiv DM5E Operating Manual
Defects/Errors and Exceptional Stresses
If you have reason to believe that safe operation of your DM5E is no longer possible, you must disconnect the instrument and secure it
against unintentional reconnection. Remove the batteries if necessary.
Safe operation is no longer possible if conditions such as the following exist:
•The instrument shows visible damages
•The instrument no longer operates perfectly
•The instrument has been subjected to prolonged storage under adverse conditions such as exceptional temperatures and/or especially
high air humidity, or corrosive environmental conditions
•The instrument has been subjected to heavy stresses during transportation
Service
Every effort has been made to provide you with a reliable product. However, should service become necessary, GE Sensing & Inspection
Technologies, has established a number of Factory Trained Service Centers. For the location of the nearest facility, see the back cover of
this manual.

Chapter 1. General Information
DM5E Operating Manual 1
Chapter 1. General Information
The DM5E is an ultrasonic corrosion thickness measurement device. The instrument is available in three versions:
•DM5E Basic
•DM5E with Dual Multi functionality
•DM5E DL with Dual Multi and Data Recorder
This chapter introduces the key features of the DM5E, and the next chapter explains the keypad functions and display-menu contents.
Closely reviewing the material in these two chapters will help you make better use of the more detailed information found in subsequent
chapters of this manual.
1.1 Supplying Power to the DM5E
The instrument is powered by two “AA” size batteries, providing up to approximately 100 hours of service life. To install the batteries,
remove the battery-compartment cover as shown in Figure 1 on page 2.
IMPORTANT: You cannot charge or power the DM5E through its USB port.

Chapter 1. General Information
2DM5E Operating Manual
1.1 Supplying Power to the DM5E (cont.)
Figure 1: DM5E Connections and Batteries (shown with battery cover removed)
Rear of Instrument
I/O Device Connection
(mini USB)
Probe Cable Connection
Install 2 “AA” batteries
in compartment as shown
Top of Instrument

Chapter 1. General Information
DM5E Operating Manual 3
1.1 Supplying Power to the DM5E (cont.)
When the battery indicator is in the last quarter, as indicated by the display-screen symbol , replace the batteries as soon as possible. The
DM5E automatically shuts OFF when the batteries are too weak for reliable operation. However, your settings are saved and restored when
the instrument is turned ON again. When testing in remote locations, always carry spare batteries.
1.2 Powering the Instrument ON and OFF
Power the instrument ON by pressing and holding until the instrument display activates. Press and hold while the instrument is
ON to turn it OFF.
1.3 Key Features of the DM5E
•Large hollow/filled thickness digits
•Alarm bar graph
•Standard and custom parameter setups
•Supports new set of DA5xx probes
•Alphanumeric naming of data files (DM5E DL)

Chapter 1. General Information
4DM5E Operating Manual
1.3 Key Features of the DM5E (cont.)
•Lockout feature with password access
•Large LCD display with backlight and adjustable contrast
•Importing of data recorder files directly into Microsoft Excel (DM5E DL)
•Approximately 100 hours of operation with 2 “AA alkaline batteries
•Easy-to-use, single-level menu system
•Multiple display screen languages
•User-selectable measurement resolution to 0.001 inch (0.01 mm)
•Normal (thickness), MinScan, MaxScan, and Differential/Rate of Reduction Measurement modes are standard
•Timed B-Scan
•Optional Dual Multi function (DM5E and DM5E DL)
•Optional data recorder (DM5E DL) stores up to 50,000 thickness measurements in data recorder file
•Field upgrades available
•Compatible with UltraMATE©and UltraMATE LITE©software programs