OKOndt GROUP Eddycon C User manual

Eddy current flaw detector
Eddycon C
Operating manual
ЕС.14327992.03.13 OM
Produced by LLC ”ULTRACON-SERVICE”

2
TABLE OF CONTENTS
P.
INTRODUCTION.......................................................................................................................................3
1 PURPOSE ...........................................................................................................................................10
2 MAIN SPECIFICATIONS...............................................................................................................11
3 DESIGN OF THE FLAW DETECTOR........................................................................................12
3.1 Instrument appearance.........................................................................................................12
3.2 Structural scheme....................................................................................................................13
3.3 Appearance of the flaw detector screen.........................................................................14
3.4 Menu structure .........................................................................................................................18
3.5 "TEST" menu..............................................................................................................................19
3.6 GUIDELINES FOR OVERLOAD PROCESSING................................................................28
3.7 "CONDUCTIVITY" mode ........................................................................................................29
3.8 "GENERAL SETTINGS" menu ..............................................................................................33
3.9 VIEW..............................................................................................................................................34
3.10 "ARCHIVE"menu .....................................................................................................................36
3.11 "RESULTS"menu .....................................................................................................................36
3.12 "SETTINGS"menu ...................................................................................................................37
3.13 Set up of "CALIBRATION"menu........................................................................................38
3.14 Communication with PC........................................................................................................41
3.14.1 Running the program...........................................................................................................41
3.14.2 Program description ............................................................................................................41
3.14.3 Working with the program................................................................................................47
4 LABELING AND SEALING ...........................................................................................................49
5 COMPOSITION AND DELIVERY SET ......................................................................................50
6 SAFETY MEASURES ......................................................................................................................51
7 SETTING-UP PROCEDURES.......................................................................................................51
8 INSTRUCTIONS FOR USE............................................................................................................51
8.1 SINGLE COIL PROBE...............................................................................................................51
8.2 REFLECTION, DIFFERENTIAL PROBE ............................................................................52
8.3 ROTATION PROBE...................................................................................................................53
9 MAINTENANCE...............................................................................................................................55
10 TYPICAL FAILURES AND TROUBLESHOOTING................................................................56
11 TRANSPORTATION AND STORAGE.......................................................................................57
12 ACCEPTANCE CERTIFICATE.....................................................................................................58
APPENDIX A ...........................................................................................................................................59
APPENDIX B ...........................................................................................................................................60

3
INTRODUCTION
User manual of «Eddycon C» portable eddy current flaw detector
(hereinafter referred to as "Flaw detector"), is intended for the study of
operation principles of the flaw detector and its operating instructions, and
includes the information on application, specifications, operating principle
and structure, operating instruction, and also other information allowing a
full-scale implementation of flaw detector technical capabilities.
The following graphic symbols and designations of controls, plug-type
connections and indicators are used in the flaw detector.
Front panel of the «Eddycon C»:
Figure 1 –«Eddycon C» eddy current flaw detector. Front panel
Automatic flaw alarm by the first and second frequencies,
respectively, and by the mix of the 1st and 2nd frequencies, as well as
overloading alarm square. If ALARM triggers during testing, the signal
amplitude and phase are automatically measured and the signal is evaluated
by the calibration curve.

4
- Function keys.
Respectively:
"F1 NULL"–Balancing, "F2 DISP MODE"–different types of full-screen
mode, "F3 ERASE"–erase and centering –in "TEST"menu;
"F1 Load", "F2 Create/ Save","F3 Delete"–in "RESULTS"/"SETTINGS"
submenu;
"F1 An"(An - amplitude noise) –in "VIEW"menu;
"F1 Add", "F2 Del", "F3 STD"–in "CALIBRATION"menu.
-automatically puts a displayed signal from lift-off (or from any
interference) in horizontal position;
-in the mode of name editing –selects a digit/letter
-changes the parameter variation step;
-in the mode of name editing –selects a digit/letter
-increases the selected parameter;
-in the mode of name editing –selects a digit/letter
-changes the frequency;
-in the mode of name editing –selects a digit/letter
-moves up through the menu;
-in the mode of name editing –selects a digit/letter
-decreases the selected parameter;
-in the mode of name editing –selects a digit/letter
-cancels the selection;
-in the mode of name editing –selects a digit/letter;
-pressing the key results in displaying the firmware version
in"SETTINGS"menu
-moves down through the menu;
-in the mode of name editing –selects a digit/letter
-confirms the selection;
-in the mode of name editing –selects a digit/letter;
-pressing the key in "TEST"menu results in saving of current setup
as a default one (if the current item is above the ALARM item)
-quick access to "TEST"menu

5
-quick access to "SETTINGS"menu
-quick access to "VIEW"menu
-quick access to "ARCHIVE"menu;
-confirms the saving of the entered name of the file or folder while
operating in "ARCHIVE"menu
-quick access to "CALIBRATION"menu
-automatically sets the parameters of single coil (parametric) ECP
with switched on Single input;
-sets the number of rounds while operating with eddy current
rotary scanner
-switches On/Off the instrument
Rear panel of the flaw detector:
1 –Ethernet port for connecting a communication cable to PC;
2 –USB port for updating the flaw detector software and recording the testing
results on the external Flash-Card
Figure 2 –«Eddycon C» eddy current flaw detector. Rear panel
2
1

6
Table 1 –Description of connector for the instrument connection to
the PC Ethernet port
Contact
Description
Ethernet
ERA.0S.304.CLL
(front view)
1
Data of transmitter «+»
2
Data of transmitter «–»
3
Data of receiver «+»
4
Data of receiver «–»
Table 2 –Description of connector for the instrument connection to
the PC USB port
Contact
Signal
USB type A
(front view)
1
+5 V
2
Data –
3
Data +
4
Common
Left side panel of the flaw detector:
1 - LEMO jack for headphones with microphone connection;
2 - Charger connector;
3 - Switching On/Off the instrument.
Figure 3 –«Eddycon C» eddy current flaw detector. Left side panel
1
2
3

7
Table 3 –Description of LEMO jack for headphones with microphone
connection
Cont.
Signal
EGG.0B.304.CLL
(front view)
1
Input signal from the microphone
2
Right audio output
3
Common
4
Left audio output
Table 4 –Description of charger connector
Cont.
Signal
EGG.1B.304.CLL
(front view)
1
Charging device –
2
Not used
3
Charging device +
4
Sync signal output

8
Right side panel of the flaw detector:
2
1 - Single (parametric) eddy current probe (ECP) connector;
2 - Connector for eddy current probe (ECP) and eddy current rotary scanner;
3 - Encoder (Enc) connector
Figure 4 –Eddycon C eddy current flaw detector. Right side panel
Table 5 –Description of single (parametric) eddy current probe
(ECP) connector
Cont.
Signal
Lemo ERA.00.250CLL
1
Parametric ECP
2
Common for parametric ECP
2
3
1

9
Table 6 –Description of encoder (Enc) connector
Cont.
Signal
Lemo EGG.1B.308CLL
(front view)
1
Positive signal input "A"
2
Power "+5V"
3
Negative signal input "Z"
4
Positive signal input "Z"
5
Negative signal input "B"
6
Positive signal input "B"
7
Negative signal input "A"
8
Common
Table 7 –Description of connector for eddy current probe (ECP)
and eddy current rotary scanner
Cont.
Description
EGG.2B.316.CLL
(front view)
1
Common
2
Positive amplifier input
3
Bridge generator output
4
Generator signal output
5
Single-wire interface
6
Signal input to control the rotation speed of the
rotary scanner (four pulses per revolution)
Common
7
Rotary scanner power
8
Common of rotary scanner
9
Signal input to control the rotation speed of the
rotary scanner (one pulse per revolution)
10
Bridge generator output
11
Negative amplifier input
12
External balancing input
13
External cleaning input
14
Alarm output
15
Power «+12V »
16
Not connected

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1PURPOSE
1.1 The flaw detector is intended for manual and mechanized testing by
eddy current method for the presence of surface and subsurface defects, such
as material discontinuity (cracks, laps, cissings, fine cracks etc.), for
conductivity and thickness measuring.
1.2 The flaw detector can be applied for the testing of products during
their manufacture and operation by NDT services and laboratories of
enterprises that provide the products quality control.
1.3 The parameters of testing objects, which limit the flaw detector
application area, are specified in regulatory documents for a specific type of
testing products and materials.
1.4 The flaw detector provides the possibility of connecting and
operating ECP of the following types:
- differential ECP;
- differential ECP, connected by the bridge circuit;
- differential transformer ECP with center-point earth;
- differential transformer ECP;
- single (parametric) ECP;
- single transformer ECP.
1.5 Operating and ambient temperature range is from minus 20 °С to
plus 45 °С.
1.6 The level of the flaw detector protection from solid bodies and water
penetration is IР 64.
1.7 The flaw detector is intended for operation in industrial enterprises
environment and refers to A level equipment, 1 group equipment according to
CISPR 11.

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2MAIN SPECIFICATIONS
2.1 Range of operating frequencies adjustment –from 10 Hz to 16 МHz.
2.2 Setup of the max. sampling frequency/digitizing rate –
10 kHz/10000 samples per second (max).
2.3 Setup of the range of adjustment of ECP excitation signal voltage
(double amplitude) –from 0.5 to 6.0 V.
2.4 Preamplifier adjustment –from minus 6 to plus 40 dB with a step of
0,1; 1; 10 dB.
2.5 Gain adjustment –from 0 to 30 dB with a step of 0,1, 1 and 10 dB.
2.6 When displaying the signal in a complex plane it is possible to have
the following variants: а) the complex plane center is situated in the center of
display area; b) the complex plane center is situated in the left upper corner;
c) the complex plane center is situated in the right upper corner; d) the
complex plane center is situated in the left bottom corner; e) the complex
plane center is situated in the right bottom corner; f) all frequencies and
mixtures are displayed on the same page (when operating in dual-frequency
mode); g) manual adjustment of the positioning of the center of the complex
plane.
2.7 There is automatic LED and sound flaw alarm (ALARM) in the flaw
detector.
2.8 In processing of the testing results the flaw detector provides the
following options:
−changing of ECP signal phase (the range of signal turn –from 0° to
360° with a step of 0.1°; 1°; 10°);
−filtering of ECP signal (there are 5 types of filters: Averaging,
Differential, Low-pass, High-pass, Bandpass);
−formation of a mix of two frequencies (for combining an operator can
select one of 4 algorithms: summation, subtraction, summation with
horizontal inversion, summation with vertical inversion).
2.9 Time of continuous operation of the flaw detector from fully charged
storage battery –no less than 8 hours.
2.10 Average mean time between failures –no less than 40000 hours.
2.11 Defined no-failure operating time –4000 hours.
2.12 Total average service life –10 years. The criterion of marginal
state of the flaw detector is economical inexpediency of restoration of its
performance by repair.
2.13 The flaw detector is powered from the in-built storage battery
with rated voltage of 12 V.
2.14 Weight of the flaw detector with a storage battery (without ECP
set, cables and casing) –no more than 0.9 kg.
2.15 Overall dimensions of the flaw detector –no more than
230 mm 135 mm 98 mm.

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3DESIGN OF THE FLAW DETECTOR
3.1 Instrument appearance
Instrument appearance is shown in Figure 5.
Figure 5 –«Eddycon C» eddy current flaw detector
Display screen
Keypad

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3.2 Structural scheme
Structural scheme of the flaw detector
Figure 6 –Structural scheme of the flaw detector
Structurally, the flaw detector consists of:
a) casing and cover plate with the membrane keypad, indicators of
ALARM and overloading, Mini-USB port for connection to PC, USB port for
external flash-card connection, charger connector, headphones and
microphone;
b) connector, ECP connector;
c) TFT display;
d) processor and memory boards;
e) analog board;
f) battery.

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3.3 Appearance of the flaw detector screen
Appearance of the flaw detector screen is shown in Figure 7.
Figure 7 –Display appearance after switching On the flaw detector
Working filed in the testing mode is divided in 3 areas of signal reflection
and display area title:
Working field (display areas –complex plane, time charts);
Bottom horizontal field (data line);
Navigation menu:
oFREQ –test frequency;
oPRE AMP –preamplifier gain;
oGAIN –main gain;
oH GAIN –horizontal gain;
oV GAIN –vertical gain;
oDRIVE –probe drive level;
oPHASE –phase adjustment;
oFILTER –filter type;
oPOSITION –spot position;
oGRID –grid;
oAXIS –axis;
oALARM –short cut to ALARM Setting;
oSWEEP –number of points in a screen scan;
oPROBE –type of connector;
Bottom horizontal
field
Working field
Navigation menu

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oRPM –rounds per minute for the eddy current rotary scanner;
oROT PRESENT–type of connected rotary eddy current scanner.
The flaw detector displays two time charts of time dependence of signal
and eddy current signal which is displayed in a complex plane for the selected
frequency.
1
1 - Navigation menu; 2 - Time charts; 3 - ALARM frame; 4 - Eddy current
signal; 5 - Signal display area; 6 - Parameters of the measured signal (A –
amplitude in “Volts”, P –phase in “degrees”, D –equivalent depth of flaw in
“mm” or conductivity in “MSm/m”), T - current value of a receive circuit
parameters (“…/” – load of the input circuit before the balancing; “…/” non-
balance of the input circuit; “…” – the current value of the input circuit
expressed in % from the maximum possible), F- sampling frequency;
7 - Frequency number; 8 - Battery life indicator;
9 - Temporary memory indicator of the flaw detector; 10 - Digital overload
indicators for receiving circuit; 11 - digital trigger indicators of ALARM levels
for the first, second and mix of frequencies respectively (from left to right)
Figure 8 –The flaw detector interface
Note –Parameter "T: …/…/..." shows:
1) The value of a signal amplitude at the input of the receiving circuit
expressed in % from the maximum possible,
2) Input circuit is not balanced, after performing the balancing in %;
3) Current value of the load of the input circuit expressed in % from the
maximum possible.
8
9
10
11
1
7
6
5
4
2
3

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The most suitable option is one in which the two parameters do not
exceed, or exceed but not significantly the 50 %. Operation in mode, in
which one of the parameters exceeded the threshold of 90 % is
unacceptable and requires the adjustment of flaw detector parameters.
Lightning of a left overload indicator (pos. 10, Figure 8) - indicates that
unacceptably large amplitude signal came to the input of the receiving circuit.
The flaw detector electronic unit displays the signal in complex plane that
allows to foil defects by waveform analysis (Figure 9):
Figure 9 –Display of signal in the complex plane (XY)
Figure 10 –Mix of two frequencies (MIX)
The flaw detector has the mechanism of automatic flaw alarm (ALARM).
It is provided for the creation of up to 4 "frames" (threshold levels) of alarm
for each frequency and mix (examples of threshold levels see Figures 14, 15,
16, 17). These frames together with the signal form an event (for example, the
threshold level exceeding by the signal). An operator is able to adjust the
reaction to an event. Reaction to an event can be the following:
−LEDs illuminating on the instrument panel;
−or LEDs illuminating and sound alarm.

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"ALARM" menu setup
This menu allows setting of ALARM (automatic flaw alarm). There is a
possibility to setup ALARM for each frequency and mix. ALARM itself is the
response of flaw detector to the event occurring at crossing or non-crossing of
alarm frame (threshold level) by a signal. All in all one alarm frame can be
activated for each frequency.
Frame setup is carried out in special item of ALARM settings –“
ALARM” from "TEST" menu. To change the type of the alarm frame operator
should press or key on “ALARM” position (if the icon is
displayed, the frames are switched off). To enter in alarm frame setup
operator should press key.
Note. An operator is offered to set up the frame according to the
frequency, he plans to work with.
Automatic measurement of the signal amplitude and phase provides a
possibility to evaluate the defect size in analyzing the data. The measured
values of the voltage phase or amplitude are required for estimating the defect
size in conformity with the selected calibration curve. Such curve compares
the parameters of signal amplitude or phase with the defect parameters in
millimeters or percent from the wall thickness. The flaw detector interface
allows calibration curves plotting both by the phase and amplitude.
The flaw detector connectors for the eddy current probes connection
(see Figure 4) provide the possibility of ECP connection of various
constructions (see Figure 11):
differential ECP, connection by the bridge circuit;
single transformer ECP;
differential ECP, connection by the bridge circuit;
differential transformer ECP with center-point ground;
single (parametric) ECP;
differential transformer ECP.

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Figure 11 –Circuits of PROBE connection
3.4 Menu structure
Figure 12 –Menu structure
MENU
TEST
SETTINGS
VIEW
ARCHIVE
CALIBRATION
RESULTS
SETTINGS
ALARM

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Navigation of the menu map described below is performed with the help
of the following keys:
The instrument menu is divided in five inserts: "TEST", "SETTINGS",
"VIEW", "ARCHIVE", "CALIBRATION", the first and the fourth ones are also
divided in submenus.
3.5 "TEST" menu
"Test" menu is displayed immediately after switching On the instrument
(see Figure 13) and contains main settings an operator will need to set during
operation.
Figure 13 –"TEST" menu
In this menu, an operator can set (change) the settings of the selected
frequency, the values of operating frequency, gain and preamplifier, generator
voltage, initial phase of signal, filter type and its parameter, input type,
general scale and independently to axles, position of complex plane center as
well as set up ALARM and general flaw detector parameters.
Moving through the vertical menu of the electronic unit parameters is
carried out by , keys. In order to change the value of any parameter
one should use , keys. A step of parameter variations can be
changed by multiple pressing of key.

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Quick selection to "TEST", "SETTINGS", "VIEW", "ARCHIVE",
"CALIBRATION"inserts is carried out by pressing , , , ,
keys.
"Hot keys"which are operated by "F1", "F2", "F3"function keys are
situated on the keypad of the flaw detector:
−F1 (Balancing)
1
–to balance the signal, place it in the screen center
and clear the flaw detector screen;
−F2 (Full-screen mode) –the complex plane and time chart is
maximized to fill the entire screen.
−F3 (Centering) –to place the signal in the screen center and clear the
flaw detector screen;
“Balancing” –it is hardware compensation of input signal. It is carried
out by summation of input signal with reference signal of the same amplitude
but opposite in phase. Current procedure is conducted after preamplifier
according to radio signal (before signal detecting). Balancing algorithm is
iterative and takes some time. The procedure is necessary for ECP non-
balance voltage compensation. After the balancing of flaw detector the
centering is carried out automatically.
“Centering” –it is a displacement of present (complex) signal in user
selected position on the screen of the flaw detector. The algorithm is fully
performed by processor module. Current procedure is carried out according
to digital detecting signal and necessary for signal displacement elimination
caused by amplifier and digital filters.
Balancing should be applied in case if:
−ECP type was changed;
−One of following parameters was changed: ECP frequency, gain
coefficient, preamplification coefficient, ECP excitation voltage;
−Testing object was changed.
Centering should be used if the operator needs to set the signal in the
complex plane centre.
1" F, Hz"- operating frequency of probe
2
; varied in the range from 10
Hz to 16 МHz with a step of 1, 10, 100, 1000, 10000, 100000, 1000000,
10000000 Hz.
1
Balancing of the flaw detector is required after the ECP operating frequency was set or changed.
Also, the balancing should be carried out after the ECP replacement. If the flaw detector was once
balanced and its operating frequencies were not changed, it is possible to carry out centering.