NOVOTEST UD2301 User manual

ULTRASONIC FLAW DETECTOR
NOVOTEST UD2301
Operating Manual
2014

Development and manufacturing of non-
destructive testing units and system
Ultrasonic Flaw Detector NOVOTEST UD2301
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CONTENTS
1. List of Abbreviations used.………………………………………….2
2. Introduction.………………………………………………………….2
3. Operating Conditions.……………………………………………….3
4. Specifications.…………………………………………………….….4
5. Operating principle.………………………………….…………..….5
6. Operation of the device.…………………………………………….7
7. Basic settings of flaw detector.…………………………………...22
8. Device memory.………………………………………………...….29
9. Calibration of the flaw detector.……………………...………..….30
10. Maintenance.…………………………………………………….....35
11. Precautions and trouble shouting.……………………...….…….35
12. Manufacturer’s guarantee and service maintenance.……….....35

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1. List of Abbreviations used
The manual has the following abbreviations and symbols:
AFS –automatic signaling of defects;
TVG –time varied gain;
NDT –nondestructive testing;
CB –calibration block;
US –ultrasonic.
2. Introduction
2.1. Appointment of flaw detector
Flaw detector is designed for testing of products for the presence of
defects such as discontinuity and homogeneity of materials, semi-
finished products and welds for measuring depth and coordinates of
defects, measure the thickness and sound velocity in the material.
Flaw detector implements shadow, echo and mirror-shadow testing
methods. Flaw detector allows user to create, record and stored in
nonvolatile memory temporary implementation of pulsed ultrasonic
signals to subsequent transmitting to the PC for analysis and
presentation in the form of a document. Integrated liquid crystal
display (LCD) provides a mapping of ultrasonic signals in the form of
A-scan, as well as images of cross sections of testing objects in the
form of B-scans.
Flaw detector can be used in mechanical engineering, aerospace,
metallurgy, mounting hardware, power equipment, as well as for the
testing of transportation facilities.
2.2. Testing
For proper ultrasonic testing user must have testing methods for
similar products and special requirements for ultrasonic testing.
These requirements include: the definition of the task of testing,
selection of suitable control techniques (testing schemes), the

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selection of transducers, an assessment of the known conditions of
control in such materials, the selection of the minimum size of the
reflector for this type of product, reject level and so on.
2.3. Velocity of ultrasonic vibrations
Accuracy of measurement of thickness and position of defects
depends on the correct setting of the ultrasonic velocity in the
material. Velocity of ultrasound is dependent on the physical
characteristics of the material and its temperature.
3. Operating Conditions
The device is designed to operate in the following environmental
conditions:
- The temperature from -15 to +50 °C;
- Relative humidity to 95% at a maximum temperature of +35 °C.
The location of the flaw detector must be protected from direct
exposure to dust, moisture and corrosive environments. The field
strength of radio noise at the location of the flaw detector should not
exceed the value of the infringing operation, i.e. creator of the flaw
detector at the amplifier input voltage greater than half the maximum
sensitivity. At high field strength of radio interference must be taken
measures to shielding placements of flaw detector from the external
electromagnetic field.
Operating position of the flaw detector may be any convenient for
the user. To avoid moisture condensation inside the flaw detector
when moving it from a cold to a warm place, it is necessary to
sustain flaw detector for at least 4 hours before turning on in the
premises.

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4. Specifications
Operating Frequency Range
from 1 to 10,0 MHz
The range of measured time intervals
(duration of scanning)
from 6 to 1000 µs
Velocity range
1000 - 9999 m / s
The error of measurement of time
intervals
not exceed ± 0,025 µs
Maximum permissible error of
measurement of the amplitudes of the
signals at the receiver input in the
range from 0 to 110 dB
not exceed ± 0,5 dB;
Testing gain range
125 dB
Averaging over the quantity of starts
from 1 to 16
Digitally reconfigurable bandpass filter with tunable center
frequency of the filter from 1 Hz to 10 MHz
The range of variation of temporal
sensitivity adjustment (TVG)
40 dB
Number of control points TVG
15
The duration of the excitation pulse to
the load
from 0,0 to 0,5 µs
The amplitude of the excitation pulse to
the 50 Ohm load, not less
100, 200, 300
Operating frequency range of the
receiver on the level -3 dB
from 1 to 10 MHz
Deviation of the amplitudes of input
signals in the range from 10 to 100% of
the screen height not more than
1 dB
Scanning
from 1 to 1000 µs
Delay of scanning
from 0 to 2000 µs
Range of measurement of time
intervals
from 0 to 1000 µs
Setting a delay in the prism of the
from 0 to 15 µs

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probe
Automatic signaling of defects (AFS)
dual-gate
Setting range of AFS gates
from 0 to 2000 µs
Adjusting thresholds of AFS gates
from 0 to 100 %
высоты экрана
Detection of signals
positive half-wave, radio
mode
Dimensions (WxHxD)
80х162х38 mm;
Weight, not more
250 g (without batteries)
Mean time between failures
not less than - 3000
hours
Ultrasound probes used - ultrasonic piezoelectric transducers for
pulse flaw detectors.
The dimensions of the operating area of the screen is 48 x 74 mm.;
Electrical power is supplied from the following sources:
- AC power from 100 to 250 V, a frequency of (50 ± 1) MHz;
- AA batteries 1,5 V (3 pcs.).
5. Operating principle
Operating principle of flaw detector is based on the ultrasonic
contact NDT method, which uses the properties of ultrasonic
vibrations to reflect from the borders between materials with different
acoustic impedance. The ultrasonic transducer emits ultrasonic
impulse into the tested object. Reflected from the defects or the
product surface the echo signals are received by the ultrasonic
transducer. The resulting electrical signals are subject to
amplification, digitization, processing and output to the display.
Displays echoes received by the flaw detector is performing as
scanning of type A (A-scan) as well as images of cross sections of
tested objects in form of B-scan.

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5.1. Electronic unit of flaw detector
Flaw detector makes the formation of electrical pulses to excite the
piezoelectric transducer, gain derived from the piezoelectric
transducer signals, processing and visualization of the formation and
representation measurements in digital form, saving data in non-
volatile memory and transfer it to PC.
The appearance of the electronic unit is shown on picture 6.1.
Operation of flaw detector makes by keyboard. Visualization of
signals and display of measurement results, the state of flaw
detector and other information is shown on the LCD.
Connecting the probe is carried out by the coaxial cable through the
connectors LEMO, which are located on top side of the devices
body.
The device is powered by a three batteries type AA, or the included
in set external charger connected to the mini-USB connector located
on the bottom of the electronic unit of the flaw detector.
5.2. Probes
Flaw detector is designed to operate with the contact, dual element
and separated ultrasonic transducers with an operating frequency in
the range from 1 to 10.0 MHz.
The device uses a generator of bipolar sounding pulses with
adjustable duration, which provides compatibility with both probes:
have integrated terminating inductance and without them, allowing
operation operate with most types of probes on the market.
Depending on the type of probe it is used two types of cables and,
correspondingly, two ways to connect the probe:
- Ultrasonic transducers (type S) are connected via single cable
LEMO-LEMO to the left LEMO connector;
- Dual element transducers (type D) are connected by a double
cable 2LEMO-2LEMO. Right connector is used to connect the

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receiver of the piezoelectric element, the left - transmitter of the
piezoelectric element.
6. Operation of the device
The basis of flaw detector operation is founded on the ability of
ultrasonic vibrations spread into tested object and reflect from
internal defects and object sides. The received signal is amplified
and then converted into digital form processed by the
microprocessor and the graphics and digitally displayed on the
display.
Visualization of signals, display of measurement results, state of the
flaw detector and other information are shown on the LCD. Exterior
of the flaw detector is shown on picture 6.1.
Picture 6.1 Exterior of the flaw detector

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6.1. Controls
Controls of the flaw detector presents as a keyboard.
The keyboard has 10 keys:
- switching on/off –press and hold for at least 3 seconds to
turn on or off the device.
-"freezing” of the screen.
-screen rotation 90°.
- menu options.
- cancel the action and return to the previous menu.
- cursor movement, decrease the selected parameter.
- cursor movement.
- cursor movement, increase the selected parameter.
- cursor movement.
- enter.
To change the value of the selected parameter use the buttons
or to select the parameter, by key (decrease

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the value of the selected parameter) or (increasing the value
of the selected parameter) to set the required value.
To change the discreteness of the selected parameter value
changes, as well as to confirm the selected action use key .
Selected discreteness displays as one of the icons near
the variable parameter.
6.2. Preparing to work with the device
Read this instruction manual and follow its instructions.
Flaw detector must be protected from direct exposure to dust,
moisture, corrosive environments, and must be sufficiently lit by light
sources.
The field strength of the external interference at the location of the
flaw detector must not exceed values that violate its performance. At
high field strength of external interference must be taken to shielding
placements of the flaw detector, as well as its power supply and
connected cables.
When operating from AC power to the flaw detector must be
supplied mains with voltage from 100 to 250 V and with frequency of
(50 ± 1) Hz.
If in the power supply network arise switching noise in power supply
network of the flaw detector must enable network filter.
To avoid moisture condensation inside the body, when moving from
a cold environment to a warm, device must be hold in the warmth for
4 hours to dry completely.
At air temperatures below 10°C after switching on flaw detector must
be warmed for at least 15 minutes.

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Controls and indicator of the flaw detector located on the front panel,
as shown in Picture 6.1.
Operating connectors are located at the top and bottom sides of the
devices body.
WARNING! To prevent damage of connectors and cables - follow
the instructions below!
Used in the device connectors consist of two parts: the instrument
socket and the cable plug (Pic. 6.2.).
Picture 6.2. Connector used in the device
A method of connecting and disconnecting the plug and socket
shown on Picture 6.2.1. When connecting user must ensured that
the points of red color (if any) are plotted on the plug and the socket
are jumped together.
CAUTION: When disconnecting the plug from the socket, hold its
body in the dotted area. Do not pull the cable!!
Picture 6.2.1 Manipulations with LEMO connectors

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6.3. Turning on the flaw detector
If operation will be carried out by an external power supply, it is
necessary to connect the power supply unit of the flaw detector to
the power connector, located on the down side of the devices body.
Operation of the device is possible during battery charging.
Before switching on flaw detector connect transducer. Connect the
power adapter supplied with flaw detector to the corresponding
connector. If you connect the battery and power supply, the flaw
detector is powered from the power supply, if the power supply is
disconnected, flaw detector automatically goes to battery supply.
To enable (disable) flaw detector press and hold it for at least
3 seconds to short beep.
When you turn on the device screen of main menu is displayed.
Picture 6.3. Main menu of the flaw detector.

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The main menu of flaw detector is consists of four sections:
- Measurements;
- Archive;
- Setup;
- Information.
6.4. Connecting the transducer to the flaw detector
Combined probe is connected to the left connector on the top panel
of flaw detector and set in parameter group "Probe" parameter
"DUAL" to "OFF".
Dual element transducers connect as follows: emitting plate of dual
probe connect to the left connector, and the receiving plate connect
to the right connector on top side of body of the flaw detector by
inserting the cable connectors until its click. Set the parameter group
"Probe" parameter "DUAL" to "ON".
6.5. The main modes of operation of the flaw detector
"Measurement" mode - goes to the measurement;
"Archive" mode - displays all stored measurement results and
settings;
"Settings" mode - in this mode you can set the following settings:
Time, Date, Language, Brightness, Palette, Sound, Auto off, Clear
SD;
"Information" mode - display information about the manufacturer.
To select the required mode, move cursor by keys to select mode,
and confirm selection by pressing the Enter button.
6.5.1"Measurement" mode
"Measurement" mode is the main mode (Pic. 6.5.1), designed for
ultrasonic testing.

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Picture 6.5.1 "Measurement" mode
All parameters for configuring the measuring part of flaw detector
divided into groups, depending on the selected group user gets
access to the various parameters.
Group
Parameters
Main
GAIN
VELOCI
TY
SCALE
RANGE
DELAY
F.FILT
FILTER
REJECT
Puls/recv
GAIN
RANGE
DELAY
RECTIF
Y
POWER
F.FILTE
R
FILTER
REJECT
Gates
GAIN
GATE
START
WIDTH
LEVEL
PARAM.
1
PARAM.
1
PARAM.
1
Functions
GAIN
DSG
TVG
REJECT
PEAK
B-SCAN
AVG
Probe
DUAL
DELAY
ANGLE
X.VAL
FREQ
PULSE
TVG
GAIN
RANGE
DELAY
TVG
CLEAR
POINT
POS.
+dВ
DGS
GAIN
DGS
POINT
POS.
dВ
A LEVEL
mm2
AFS
START
WIDTH
GATE
MEAS.
MODE
CONTR.
SEARC
H
ALLARM

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Block 1
PARAM.
1
PARAM.
2
PARAM.
3
Block 2
PARAM.
1
PARAM.
2
PARAM.
3
Block 3
PARAM.
1
PARAM.
2
PARAM.
3
Description of parameters of flaw detector
Groups
Parameters
Description
Main
GAIN
Setting of gain of received path from 0
to 126 dB, in steps of 0.5, 5 dB.
VELOCITY
Display the set velocity of ultrasonic
vibrations in the tested material.
Adjustment range from 1000 to 9999 m
/ s.
Accuracy of the measurement the
depth, coordinates of defects and
thickness are depends on the accuracy
of the velocity settings.
SCALE
Selection of the display unit parameter
settings. Has two meanings:
microseconds (µs) and mm.
RANGE
The duration of scanning - depth
sounding along the beam.
Adjustment range from 1 to 1000 µs.
Flaw detector processed only signals
that are under scanning.
DELAY
The "Delay" specifies the time delay
relative to the start of scanning of the
probe pulse.
Setting range from 0 to 1000 µs.
F.FILT
Selecting the central operating
frequency of receiver path (selection of
frequency range receiver path). It can
take values from 1 MHz to 10 MHz.

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FILTER
Turn on / off frequency filter.
REJECT
Parameter allows to set the minimum
level of the signals displayed on the
screen.
Puls/recv
GAIN
Setting of gain of received path from 0
to 126 dB, in steps of 0.5, 5 dB.
RANGE
The duration of scanning - depth
sounding along the beam.
Adjustment range from 1 to 1000 µs.
Flaw detector processed only signals
that are under scanning.
DELAY
The "Delay" specifies the time delay
relative to the start of scanning of the
probe pulse.
Setting range from 0 to 1000 µs.
RECTIFY
Selecting the type of visualization of the
signal. Can take two values: the POS
HW and RADIO.
POWER
Setting the level of the generator
excitation. It can take values 100V, 150
V, 200 V.
F.FILT
Selecting the central operating
frequency of receiver path (selection of
frequency range receiver path). It can
take values from 1 MHz to 10 MHz.
FILTER
Turn on / off frequency filter.
REJECT
Parameter allows to set the minimum
level of the signals displayed on the
screen.
Gates
GAIN
Setting of gain of received path from 0
to 115 dB at 0.1, 1 dB.
GATE
Selecting gate. Takes the values: A or

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B.
START
Coordinate of the beginning of the
selected gate. It can take values from 0
to the maximum value of scanning.
WIDTH
The width of the selected control gate
along the beam. It can take values from
0 to the maximum value of scanning.
The total value of the start and the width
of the gate can not exceed the value of
the maximum scanning.
LEVEL
The threshold level of the selected
control gate. Is given in % of the screen
height, can take values from 0 to 100%
of the screen height.
PARAM.1
Allows to select the measured value in
the first block. **
PARAM.1
Allows to select the measured value in
the first block. **
PARAM.1
Allows to select the measured value in
the first block. **
Functions
GAIN
Setting of gain of received path from 0
to 115 dB at 0.1, 1 dB.
DGS
Turn on / off DGS
TVG
Turn on / off TVG
REJECT
Parameter allows to set the minimum
level of the signals displayed on the
screen.
PEAK
Turn on / off fixing the maximum
amplitude of the echo.
B-Scan
Turn on / off display of a scanning-type
B-scan.
AVG.
Number of echoes which are averaged

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result.
Probe
DUAL
Set the type of the connected ultrasonic
transducer. Has two meanings: the
combined and separate (dual).
DELAY
Setting a delay in the prism of
transducer.
ANGLE
The angle of entry of the ultrasonic
vibrations to the connected transducer.
X.VAL
Allows to specify an arrow of transducer
(set from 0 to 90 mm).
FREQ
Setting the operating frequency of the
ultrasonic transducer. Has a range from
1 MHz to 10 MHz.
PULSE
Setting the duration of the transducer
pulse.
TVG
GAIN
Setting of gain of received path from 0
to 126 dB, in steps of 0.5, 5 dB.
RANGE
The duration of scanning - depth
sounding along the beam.
Adjustment range from 1 to 1000 µs.
Flaw detector processed only signals
that are under scanning.
DELAY
The "Delay" specifies the time delay
relative to the start of scanning of the
probe pulse.
Setting range from 0 to 1000 µs.
TVG
Turn on / off TVG.
CLEAR
Allows to reset the TVG.
POINT
Select point TVG and display the total
number of points. The maximum
number of points TVG - 15.
POS.
Displays coordinates of the position of

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the current point of TVG. The distance
between two neighboring points is not
less than 3 microseconds.
+dВ
Gain of the current point TVG. The total
value of all the points of the TVG not
more 40 dB, accuracy of setting 0.1 dB.
DGS
GAIN
Setting of gain of received path from 0
to 126 dB, in steps of 0.5, 5 dB.
DGS
Turn on / off DGS.
POINT
Select Point TVG and display the total
number of points. The maximum
number of points TVG - 15.
POS.
Displays coordinates of the position of
the current point of TVG. The distance
between two neighboring points is not
less than 3 microseconds.
dВ
Gain of the current point DGS. The total
value of all the points of the DGS not
more 40 dB, accuracy of setting 0.1 dB.
А LEVEL
Allows to set the level / amplitude of the
reference signal.
mm2
Allows to set the value of the equivalent
area of the reflector.
AFS
START
Coordinate of the beginning of the
selected gate. It can take values from 0
to the maximum value of scanning.
WIDTH
The width of the selected control gate
along the beam. It can take values from
0 to the maximum value of scanning.
The total value of the start and the width
of the gate can not exceed the value of
the maximum scanning.

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GATE
Selecting gate. Takes the values: A or
B.
MEAS.
A method for determining the time of
arrival of the signal in the tested gate:
"by the peak" - on the state of the
maximum signal in the control gate;
"by the flank" - on the first crossing of
the signal with the threshold in the
control gate.
MODE
Determines the mode of operation of
the gate:
MORE - echo level is crossed gate;
LESS - echo signal is below the gate.
CONTR.
Setting the control area. The maximum
value of 20 dB, but can not exceed the
value of the search gate.
SEARCH
Setting the level of the search area. The
maximum value is 20 dB.
ALARM
Turn on / off sound.
Block 1
PARAM.1
Allows to select the measured values in
the first of three blocks. **
PARAM.2
Allows to select the measured values in
the first of three blocks. **
PARAM.3
Allows to select the measured values in
the first of three blocks. **
Block 2
PARAM.1
Allows to select the measured values in
the second of three blocks. **
PARAM.2
Allows to select the measured values in
the second of three blocks. **
PARAM.3
Allows to select the measured values in
the second of three blocks. **
Block 3
PARAM.1
Allows to select the measured values in