GE SpotChecker User manual

SpotChecker
Technical Reference and Operating Manual
Ident No. 49 131
Rev. 2.0

This Issue 02, 03/2009 applies to the version 1.0
Subject to change without notice.

1 Introduction 7
1.1 Safety information 8
Power supply 8
Software 8
Defects/errors and exceptional stresses 9
Further information 9
1.2 Important information on ultrasonic
testing 10
Preconditions for testing with ultrasonic
test equipment 10
Operator training 10
Technical test requirements 11
Limitations of testing 11
Ultrasonic wall thickness measurement 11
Effect of the test object’s material 12
Effect of temperature variations 12
Measurement of remaining wall thickness 12
Ultrasonic evaluation of flaws 13
Flaw boundary method 13
Echo display comparison method 13
Limitations of software 14
1.3 The SpotChecker 16
Special features 16
1.4 Standard package 18
1.5 Required accessories 19
1.6 Spare parts requirements 20
2 Initial start-up and basics 25
2.1 Overview of instrument 26
Front panel 26
Back panel 27
2.2 Installing the instrument 28
2.3 Connecting a probe 29
2.4 Power supply 30
Operation using external power supply 30
Operation using batteries 31
Contents
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Inserting batteries 31
Checking the battery charge level 31
Exchanging batteries 32
Charging batteries 32
2.5 Power on/Power off 33
Starting the operation 33
Closing the operation and shutting down 33
2.6 Interfaces 34
USB 34
Network 34
WLAN 34
Bluetooth 35
2.7 Trackballs and touchscreen 36
Trackballs 36
Touchscreen 36
2.8 Remote control 37
Assigning the remote control to a receiver 38
Key assignment 38
2.9 Software installation 39
Re-installation SpotChecker 39
Updates 39
Installation procedure 39
License after re-installation 40
2.10 Basic settings 41
Selecting language 41
Restricting program access 41
Activating the password protection 42
Deactivating the password protection 42
2.11 Data backup 43
Saving data to external data media 44
Uploading data from external data media 44
2.12 Online Help 45
Context-sensitive Help 45
Starting the Online Help 45
Buttons: 46
Starting the Online Help without
the software 46
Contents
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Printing 47
Printing a complete chapter 47
3 Individual inspection reports 49
3.1 Ultrasonic inspection of spot welds
within automotive industry 50
Basic principle 50
Comparison of ultrasonic inspection
with other inspection methods 51
3.2 The software SpotChecker 54
Overview 54
Application ranges 55
Structured inspection plan: 56
Evaluation with UltraCAR 57
General procedure –
linear inspection plans 58
The evaluation assistance tools 59
Evaluation Assistance I 59
Evaluation Assistance II 60
Evaluation Assistance III 61
Evaluation Assistance IV 62
A-scan and Racer view 63
Automatic A-scan freeze 65
Graphical marking of relevant echoes 66
Interface echo gate 66
Reference A-scan 67
Other inspection methods 68
3.3 Dialog probes 69
4 Care, maintenance, errors 71
4.1 Cleaning the instrument 72
4.2 Maintenance 72
4.3 Care of batteries 72
Charging batteries 73
Storage of batteries 73
4.4 Errors 73
Contents
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5 Technical specifications 75
5.1 Specification of the interfaces 76
4-pin LEMO 0S connection +15V 76
5.2 Specifications SpotChecker 77
Enclosure 77
Connections 78
Power supply 78
Ultrasound 79
Settings and evaluation 79
6 Annex 83
6.1 EC declaration of conformity 84
6.2 Manufacturer/Service addresses 86
6.3 Disposal 87
General view of the device 88
Recycling data of SpotChecker 90
7 Index 93
Contents
6Issue 02, 03/2009 SpotChecker

Introduction 1
SpotChecker Issue 02, 03/2009 7

Safety information1.1
The SpotChecker has been designed and tested ac-
cording to DIN EN 61 010 Part 1, Safety requirements
for electrical measuring, control and lab equipment,
and was technically in perfectly safe and faultless con-
dition when leaving the manufacturing works.
In order to maintain this condition and to ensure a
safe operation, you should urgently read the following
safety information before putting the instrument into
operation. When connecting other equipment to the
SpotChecker, such as the power supply unit, follow
particularly all safety instructions that apply to these
devices.
A Attention:
The SpotChecker is an instrument for materials
testing. Any use for medical applications or other
purposes is not allowed!
The SpotChecker may only be used in industrial
environments!
Power supply
The power supply for the SpotChecker is carried out
via one or two batteries or via a connected power sup-
ply unit. The power supply unit may only be used in-
side buildings and may not be exposed to moisture or
liquids. Follow all safety instructions that are applica-
ble for the power supply unit used.
A Attention:
Never open the housing of the power supply unit. The
power supply unit does not contain any user-service-
able parts.
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 in-
tended combination.
Introduction Safety information
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Further information
A Attention:
Observe the documentation for the other equipment
connected to the SpotChecker, such as computer or
power supply unit. The documentation contains impor-
tant safety instructions and information about permit-
ted uses.
The SpotChecker software provides extensive online
help which is always available to you when working
with the system. In this operating manual you will find
any additional information that you might require.
If you have any questions about the use of your test
equipment, please contact your nearest representative
of GE Sensing & Inspection Technologies.
If you install additional software on the computer, GE
Sensing & Inspection Technologies will not bear any
responsibility regarding the influence this may have on
SpotChecker operation. The existing software drivers
may be overwritten in such a case.
Defects/errors and exceptional stresses
If you have reason to believe that a safe operation of
your SpotChecker is no longer possible, you have to
disconnect the instrument and secure it against unin-
tentional reconnection.
A safe operation is e.g. no longer possible
❚ if the instrument shows visible damages,
❚ if the instrument no longer operates perfectly,
❚ after prolonged storage under adverse conditions
(e.g. exceptional temperatures and/or especially
high air humidity, or corrosive environmental condi-
tions),
❚ after being subjected to heavy stresses during
transportation.
Safety information Introduction
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Important information on ultra-1.2
sonic testing
Please read the following information before using
your SpotChecker. It is important that you understand
and observe this information to avoid any operator er-
rors that might lead to false test results. This could re-
sult in personal injuries or damages to property.
Preconditions for testing with ultrasonic test
equipment
In this operating manual you will find essential infor-
mation on how to operate your test equipment. In ad-
dition, there are a number of factors that affect the
test results. A description of these factors would go
beyond the scope of an operating manual. Let us
therefore only mention the three most important re-
quirements for a safe ultrasonic inspection in this con-
nection:
❚ the operator training,
❚ the knowledge of special technical test require-
ments and limits,
❚ the choice of appropriate test equipment.
Operator training
The operation of an ultrasonic test device requires a
proper training in ultrasonic test methods.
A proper training comprises for example adequate
knowledge of:
❚ the theory of sound propagation,
❚ the effects of sound velocity in the test material,
❚ what happens to the sound wave at the interface
between two different materials,
❚ the propagation of the sound beam,
❚ the influence of sound attenuation in the test ob-
ject, and the influence of surface quality of the test
object.
Lack of such knowledge could lead to false test results
with unforeseeable consequences. You can contact
for example NDT societies or organizations in your
country (DGZfP in Germany; ASNT in the USA), or
GE Sensing & Inspection Technologies, for informa-
tion concerning existing possibilities for the training of
ultrasonic inspectors as well as on the qualifications
and certificates that can finally be obtained.
Introduction Important information on ultrasonic testing
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Technical test requirements
Every ultrasonic test is subject to specific technical
test requirements. The most important ones are:
❚ the definition of the scope of inspection,
❚ the choice of the appropriate test method,
❚ the consideration of material properties,
❚ the determination of the limits for recording and
evaluation.
It is the task of those with overall responsibility for
testing to ensure that the inspector is fully informed
about these requirements. The best basis for such in-
formation is experience with identical test objects. It is
also essential that the relevant test specifications are
clearly and completely understood by the inspector.
GE Sensing & Inspection Technologies organizes spe-
cialized training courses in the field of ultrasonic test-
ing at regular time intervals. The scheduled dates for
these courses will be given to you on request.
Limitations of testing
The information obtained from ultrasonic tests only re-
fers to those parts of the test object which are covered
by the sound beam of the probe used.
Any conclusions from the tested parts to be applied to
the untested parts of the test object should be made
with extreme caution.
Such conclusions are generally only possible in cases
where extensive experience and proven methods of
statistical data acquisition are available.
The sound beam can be completely reflected from
boundary surfaces within the test object so that flaws
and reflection points lying deeper remain undetected.
It is therefore important to make sure that all areas to
be tested in the test object are covered by the sound
beam.
Ultrasonic wall thickness measurement
All ultrasonic wall thickness measurements are based
on a time-of-flight measurement. Accurate measure-
ment results require a constant sound velocity in the
test object. In test objects made of steel, even with
Important information on ultrasonic testing Introduction
SpotChecker Issue 02, 03/2009 11

varying alloying constituents, this condition is mostly
fulfilled: the variation in sound velocity is so slight that
it is only of importance for high-precision measure-
ments. In other materials, e.g. nonferrous metals or
plastics, the sound velocity variations may be even
larger and thus affect the measuring accuracy.
Effect of the test object’s material
If the test object’s material is not homogeneous, the
sound may propagate at different sound velocities in
different parts of the test objects. In this case, an av-
erage sound velocity should be taken into account for
the range calibration. This is achieved by means of a
reference block whose sound velocity corresponds to
the average sound velocity of the test object.
If substantial sound velocity variations are to be ex-
pected, then the instrument calibration should be re-
adjusted to the actual sound velocity values at shorter
time intervals. Failure to do so may lead to false thick-
ness readings.
Effect of temperature variations
The sound velocity within the test object also var-
ies as a function of the material’s temperature. This
can cause appreciable errors in measurements if the
instrument has been calibrated on a cold reference
block and is then used on a warm or hot test object.
Such measurement errors can be avoided either by
warming the reference block to the same temperature
before calibrating, or by using a correction factor ob-
tained from tables.
Measurement of remaining wall thickness
The measurement of the remaining wall thickness on
plant components, e.g. pipes, tanks and reaction ves-
sels of all types which are corroded or eroded from
the inside, requires a perfectly suitable gauge and
special care in handling the probe.
The inspectors should always be informed about the
corresponding nominal wall thicknesses and the likely
amount of wall thickness losses.
Introduction Important information on ultrasonic testing
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Ultrasonic evaluation of flaws
In present-day test practice, there are basically two
different methods of flaw evaluation:
If the diameter of the sound beam is smaller than the
extent of the flaw, then the beam can be used to ex-
plore the boundaries of the flaw and thus determine its
area.
If, however, the diameter of the sound beam is larger
than the size of the flaw, the maximum echo response
from the flaw must be compared with the maximum
echo response from an artificial flaw provided for com-
parison purposes.
Flaw boundary method
The smaller the diameter of the probe’s sound beam,
the more accurately the boundaries (and therefore
the flaw area) can be determined by the flaw bound-
ary method. If, however, the sound beam is relatively
broad, the flaw area determined can substantially dif-
fer from the actual flaw area. Care should therefore
be taken to select a probe which will give a sufficiently
narrow beam at the position of the flaw.
Echo display comparison method
The echo from a small, natural flaw is usually smaller
than the echo from an artificial comparison flaw, e.g.
circular disc flaw of the same size. This is due, for in-
stance, to the roughness of the surface of a natural
flaw, or to the fact that the beam does not impinge on
it at right angles.
If this fact is not taken into account when evaluating
natural flaws, there is a danger of underestimating
their magnitude.
In the case of very jagged or fissured flaws, e.g. shrink
holes in castings, it may be that the sound scatter-
ing occurring at the boundary surface of the flaw is so
strong that no echo at all is produced. In such cases,
a different evaluation method should be chosen, e.g.
by using the backwall echo attenuation in the evalua-
tion.
The distance sensitivity of the flaw echo plays an im-
portant part when testing large components. Attention
should be paid here to choosing artificial comparison
flaws which are as far as possible governed by the
same “distance laws” as the natural flaws to be evalu-
ated.
Important information on ultrasonic testing Introduction
SpotChecker Issue 02, 03/2009 13

The ultrasonic wave is attenuated in any material. This
sound attenuation is very low, e.g. in parts made of
fine-grained steel, likewise in many small parts made
of other materials. However, if the sound wave travels
larger distances through the material, a high cumula-
tive sound attenuation can result even with small at-
tenuation coefficients. There is then a danger that
echoes from natural flaws appear too small. For this
reason, an estimate must always be made of the ef-
fects of attenuation on the evaluation result and taken
into account if applicable.
If the test object has a rough surface, part of the inci-
dent sound energy will be scattered at its surface and
is not available for the test. The larger this initial scat-
tering, the smaller the flaw echoes appear, and the
more errors occur in the evaluation result.
It is therefore important to take the effect of the test
object’s surfaces on the height of the echo into ac-
count (transfer correction).
Limitations of software
Based on the present state of the art, software cannot
be completely free of faults. Any software-controlled
equipment should therefore be checked before and af-
ter use in order to ensure that the necessary functions
operate perfectly.
Always carry out a check by means of a calibration
standard both before and after the test.
Introduction Important information on ultrasonic testing
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Important information on ultrasonic testing Introduction
SpotChecker Issue 02, 03/2009 15

The SpotChecker1.3
The SpotChecker is a compact ultrasonic instrument
for manual testing. The consistent use of large-scale
integrated components enables to carry out essential
functions of the system in a purely digital and conse-
quently reproducible mode.
The gates can be set either to echo flank or peak val-
ue of the positive or negative half-wave to make the
measurement settings easier with wall thickness mea-
surements.
The provided application software runs under the
powerful operating system Windows XP. An operator
interface optimized for use with detailed Online Help
enables you to master the function range of the sys-
tem in no time at all.
The software for the user interface is supplied addi-
tionally on a CD-ROM for the case of a possible com-
puter failure or a necessary new installation.
The system uses standard and dialog probes: the lat-
ter are automatically recognized.
Special features
❚ No additional computer hardware required, USB
interfaces for printer, external mouse/keyboard and
data communication with a computer
❚ Easy to operate via touchscreen and two trackballs
for both left- and right-handed operation
❚ 8.4" TFT color display (SVGA, 800 × 600 pixels)
❚ Operating time approx. four hours by means of
two lithium-ion batteries with internal and external
charging possibilities
❚ Program-specific assignment of functions to func-
tion keys and remote control
❚ Optional integrated radio receiver for remote
control
❚ Optional integrated WLAN interface
❚ Optional Bluetooth interface
❚ Flexible use with handle and prop-up stand
❚ Compact housing dimensions
❚ Weight: 3,2 kg with two batteries
Introduction The SpotChecker
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The SpotChecker Introduction
SpotChecker Issue 02, 03/2009 17

1.4 Standard package
Product code Description Order No.
SpotChecker Portable ultrasonic flaw detector SpotChecker, 36 763
incl.
Carrying case 36 764
Lithium-ion battery 10.8 V, 4.8 Ah 109 412
Power supply unit 36 777
USB cable B-A, 1 m 109 397
Product CD SpotChecker 36 778
Driver CD 36 779
Windows multilanguage CD 35 602
Operating manual German/English, Manufacturer’s certificate 49 131
Introduction Standard package
18 Issue 02, 03/2009 SpotChecker

Required1.5 accessories
Product code Description Order No.
Spot-BAT Lithium-ion batteries 10.8 V, 4.8 Ah 109 412
Spot-Chrg External battery charger 36 748
Required accessories Introduction
SpotChecker Issue 02, 03/2009 19

1.6 Spare parts requirements
Product code Description Order No.
Housing, upper part
Housing, upper part Spotchecker 36 767
Keypad Spotchecker 36 738
Backlight inverter 109 413
Cable, backlight inverter 36 775
Trackball, left 6 p. 109 407
Cable, trackball left 6 p. 36 772
Trackball, right 10 p. 109 408
Cable, trackball right 10 p. 36 773
LCD module 800 × 600 109 411
Cable, LCD module 36 776
Introduction Spare parts requirements
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