Panametrics NDT MAGNA-MIKE 8500 User manual

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USER’S MANUAL
MAGNA-MIKE 8500
Hall Effect Thickness Gage
Part No. 910-198E
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In accordance with European Directive 2002/96/EC on Waste
Electrical and Electronic Equipment, this symbol indicates that
the product must not be disposed of as unsorted municipal
waste, but should be collected separately. Refer to your local
Olympus distributor for return and/or collection systems avail-
able in your country.
Copyright 2005 by Olympus NDT.
All rights reserved.
No part ofthis manual may be reproduced or transmitted in any form or by
any means, electronic or mechanical, including photocopying, recording,
or by any information storage and retrieval system, without the written
permission of Olympus NDT, except where permitted by law. For
information, contact us at pana@Olympus NDT.com.
Other product names mentioned in this document may be trademarks of
their respective companies, and are mentioned for identification purposes
only.
Printed in the United States of America.
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8/19/03 910-198E
Model 8500 3
WARRANTY
Olympus NDTTM guarantees the Model 8500 to be free from defects in
materials and workmanship for a period of two years from date of
shipment. The warranty only covers equipment that has been used in a
proper manner as described in this instruction manual and has not been
subjected to excessive abuse, attempted unauthorized repair, or
modification. DURING THIS WARRANTY PERIOD, Olympus
NDT’ LIABILITY IS STRICLTY LIMITED TO REPAIR OR
REPLACEMENT OF A DEFECTIVE UNIT AT ITS DISCRETION.
Olympus NDT does not warrant the Model 8500 to be suitable for
intended use, and assumes no responsibility for unsuitability for
intended use. Olympus NDT accepts no liability for consequential or
incidental damages including damage to property and/or personal
injury.
Olympus NDT warranties the probe, probe cable, and battery for a
period of 90 days. This warranty applies only to defects in
workmanship that render the probe inoperative. Normal wear and tear
on the probe tip or any defects caused by misapplication or abuse is not
covered. Olympus NDT reserves the right to judge whether the probe
shall be covered under warranty.
The customer will pay shipping expense to the Olympus NDT plant
for warranty repair; Olympus NDT will pay for the return of the
repairedequipment. (For instruments not under warranty, the customer
will pay shipping expenses both ways.)
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910-198E 3/19/03
4 Model 8500
Olympus NDT reserves the right to modify all products without
incurring the responsibility for modifying previously manufactured
products. Olympus NDT does not assume any liability for the results
of particular installations, as these circumstances are not within our
control.
THE WARRANTIES SET FORTH HEREIN ARE EXCLUSIVE
AND ARE IN LIEU OF ALL OTHER WARRANTIES WHETHER
STATUTORY, EXPRESS OR IMPLIED (INCLUDING
WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE, AND WARRANTIES ARISING FROM
COURSE OF DEALING OR USAGE OR TRADE).
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8/19/03 910-198E
Model 8500 i
TABLE OF CONTENTS
1 GENERAL INFORMATION
2 CALIBRATION
2.1 Choosing a Ball........................................... 2-1
2.2 When to Calibrate ....................................... 2-2
2.3 Ball Calibration............................................ 2-3
2.4 Multi-Point Calibration................................. 2-5
3 MEASUREMENTS
3.1 Maintaining Accuracy.................................. 3-4
3.2 QCAL .......................................................... 3-5
3.3 Periodic Verification .................................... 3-6
3.4 Traceability.................................................. 3-7
4 MIN MEASUREMENTS
4.1 Save/Send Parameters............................... 4-3
5 SETUP
5.1 Measurement .............................................. 5-2
5.1.1 Units.................................................... 5-3
5.1.2 Resolution........................................... 5-3
5.1.3 Max Capture....................................... 5-4
5.1.4 Min Capture........................................ 5-4
5.1.5 Primary Data....................................... 5-6
5.1.6 Max/Min Clear..................................... 5-7
5.1.7 Max/Min Delay.................................... 5-7
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910-198E 8/19/03
ii Model 8500
5.1.8 Display Rate ....................................... 5-8
5.2 General Setup............................................. 5-8
5.2.1 Beeper ................................................ 5-9
5.2.2 Inactive Time ...................................... 5-9
5.2.3 Language.......................................... 5-10
5.2.4 Radix................................................. 5-10
5.2.5 Backlight Timeout............................. 5-11
5.2.6 Backlight........................................... 5-11
5.2.7 Display Contrast ............................... 5-11
5.3 Communication Setup............................... 5-12
5.4 Calibration Setup....................................... 5-14
5.5 Diagnostics Setup ..................................... 5-15
5.5.1 Keypad Test...................................... 5-16
5.5.2 Video Test......................................... 5-16
5.5.3 Hardware Test.................................. 5-17
5.6 Resets....................................................... 5-18
5.6.1 Measurement Reset ......................... 5-20
5.6.2 Communication Reset ...................... 5-20
5.6.3 Dbase Reset..................................... 5-21
5.6.4 Master Reset .................................... 5-21
5.7 Clock ......................................................... 5-21
5.8 Differential................................................. 5-22
5.9 Alarm......................................................... 5-24
5.10 Optional Items......................................... 5-26
6 DATALOGGER
6.1 Creating Data Files ..................................... 6-1
6.2 Saving Data................................................. 6-7
6.3 File Options Menu....................................... 6-8
6.3.1 Open................................................... 6-8
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8/19/03 910-198E
Model 8500 iii
6.3.2 Create................................................. 6-9
6.3.3 Copy ................................................. 6-10
6.3.4 Delete ............................................... 6-11
6.3.5 Send ................................................. 6-12
6.3.6 File Edit-Rename.............................. 6-12
6.3.7 Reports (On Screen)......................... 6-13
6.4 ID# Review/Edit......................................... 6-16
6.5 Inserting or Appending
ID# Locations into a File............................ 6-18
6.5.1 Inserting or Appending ID# Locations into
Incremental Files............................... 6-19
6.5.2 Inserting or Appending ID# Location into
Sequential or Sequential with Custom
Point Files.......................................... 6-19
6.6 Erasing Data ............................................. 6-21
8 TECHNICAL SPECIFICATIONS
7 COMMUNICATIONS,
RS-232 DATA TRANSFER
7.1 Single Send Data Transfer.......................... 8-2
7.2 Range Data Transfer................................... 8-2
7.3 File Data Transfer ....................................... 8-3
7.4 Serial Communication Setup....................... 8-5
7.5 Data Output Formats................................... 8-7
7.6 Database Reset .......................................... 8-7
9 MAINTENANCE AND TROUBLESHOOTING
9.1 Probe........................................................... 9-1
9.2 Battery......................................................... 9-2
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910-198E 8/19/03
iv Model 8500
9.3 Error Messages........................................... 9-3
9.4 Diagnostics.................................................. 9-6
9.5 ROM Upgrades ........................................... 9-6
9.6 Repair and Technical Assistance................ 9-7
APPENDIX I - RS-232 INTERFACE
APPENDIX II - I/O FORMATS
APPENDIX III - REMOTE COMMANDS VIA RS-232
APPENDIX IV - CALIBRATION VERIFICATION FORM
APPENDIX V - PROBES, FIXTURES, AND TARGETS
FOR SPECIAL APPLICATIONS
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8/19/03 910-198E
Model 8500 Page 1-1
1 GENERAL INFORMATION
Panametrics-NDTTM’ Magna-Mike 8500 is a small, lightweight
thickness gage designed to make measurements of nonferrous
materials such as plastics, glass, composites, aluminum, and titanium.
Accuracy is generally not affected by material shape or internal
properties.
The Magna-Mike 8500 is based on the Hall Effect Principle. Wall
thickness is measured by placing a small steel target ball on one side of
test material and the magnetic probe on the opposite side. The probe’s
Hall Effect sensor measures the distance between the probe tip and the
ball, instantly displaying a thickness reading.
As the sample thickness changes, thefield strength in the probe tip also
changes from a minimum when the ball is far away, to a maximum
when the ball rests, centered on the tip. These field strengths however,
are different for each size target ball and vary from probe to probe. The
control unit, therefore, employs a numerical look-up table to translate
these changes in field strength into thickness values.
Only after the calibration procedure is performed, and only if the
calibrated state of the instrument is maintained as directed in Section 2
of this manual, will the thickness values obtained from the Magna-
Mike 8500 be accurate and meaningful.
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910-198E 8/19/03
Page 1-2 Model 8500
Note: The probe contains a strong magnet. Damage to the probe
can change its magnetic properties. To ensure accurate
operation of the Magna-Mike 8500, DO NOT: (1) drop the
probe as it may cause damage; (2) use the probe near iron or
steel as it may cause false readings; (3) apply force to the
tip—the most fragile part of the probe (damage to the tip is
not repairable); or (4) bring the probe near diskettes or tape
cassettes as it may cause data loss in these items.
For best results, store the probe upright in the stand, away
from large steel objects.
The contents of your new Magna-Mike 8500 package include the
following items in addition to this manual:
• Magna-Mike 8500
• WIN8500 Interface Program #85IP-EX
• Charger/Adapter with Power Cord
• Magnetic Probe
•ProbeCable
•ProbeStand
• Gage Stand #85GS
• Quick Reference Card
• Foot Switch (optional)
• Data Output Cable 8509F or 8525F (9 or 25-pin RS-232)
• Accessory Container with:
- Three (3) Containers of Target Balls
- Three (3) Calibration Reference Fixtures (blue labels)
- Three (3) Target Ball Alignment Fixtures (red labels)
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8/19/03 910-198E
Model 8500 Page 1-3
Charger Input Probe Connector
RS-232 Port Foot Switch Connector
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910-198E 8/19/03
Page 1-4 Model 8500
Thismanualisdesignedtohelpusersgetstartedbyplacingtheessential
operatinginformationinthefirstfewsections;whereas theDatalogger,
maintenance, and troubleshooting information are found in the latter
sections. At first, it may be helpful to use this manual in conjunction
with the Magna-Mike 8500.
Charger
Input
Foot Switch
Connector
Keypad
Datalogger
Dialog Box
Secondary
(Bottom)
Display
Primary (Top)
Display
RS-232 Port Probe Connector
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8/19/03 910-198E
Model 8500 Page 1-5
Refer to the illustrations above to identify the different gage features,
especially the Primary and Secondary Display.
• The top portion of the display shows Datalogger information
including filenames, ID numbers, and stored thickness values
for your reference while making measurements.
• The middle portion of the screen is split into two (2) sections.
The Primary display, located in the main area of the screen,
shows current thickness measurements. The Secondary Display
is located beneath the Primary Display and shows minimum,
maximum, and differential measurements.
• The bottom portion of the screen displays the dialog box that
contains helpful information for calibrating, operating, and
diagnosing the gage. Instructions, status conditions, and error
messages are also displayed in the dialogue box. The far right
section of this portion continuously shows flags that describe
the battery condition and operating mode.
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910-198E 8/19/03
Page 1-6 Model 8500
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8/19/03 910-198E
Model 8500 Page 2-1
2 CALIBRATION
Olympus NDTTM recommends monthly calibration (with regular
verification) of the Magna-Mike 8500 to ensure consistency and
accuracy of thickness readings. This chapter outlines how to choose a
target ball, when to calibrate, and how to calibrate.
2.1 Choosing a Ball
The Magna-Mike 8500 comes with three (3) different sized target balls.
Ingeneral, usethelargesttargetball thatwillmove freelyintheconcave
areas that need to be measured. Consider the following criteria when
choosing a ball:
• Minimum curvature of the material
• Maximum thickness measurement
• Accuracy needed for measurement
Once the criteria have been established, review the descriptions below
and Table 2-1 to choose an appropriate target ball.
Target Ball Descriptions
3/16" (4.76mm) diameter target ball
Useful for applications that require high accuracy, or where material is
thicker than the range offered by other target balls. However, the
ability to measure intricate corners is limited, and soft materials are
more likely to be compressed using this target ball.
1/8" (3.2mm) diameter target ball
Serves all standard applications, such as plastic blow molding, simple
shapes, and wall thicknesses up to 0.180" (4.6mm).
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910-198E 8/19/03
Page 2-2 Model 8500
1/16" (1.6mm) diameter target ball
Useful for applications that involve intricate contours. While the small
size is efficient for measuring difficult shapes, it is less accurate than
the 1/8" ball and has a restricted thickness range.
Use only Panametrics-NDT’ target balls with the Magna-Mike 8500as
other seemingly identical balls may cause inaccurate measurements.
2.2 When to Calibrate
Perform a Ball Calibration:
• Daily or at the start of a work session
• If changing to a different target ball size
Table 2-1: Target Ball Measurements and Accuracy
Target Ball
Diameter Maximum Thickness Range Measurement Accuracy* Minimum Surface Radius
3/16"
(4.76mm) 0.250" (6.35mm) 1% 3/32" (2.38mm)
1/8"
(3.18mm) 0.180" (4.57mm) 2% 1/16" (1.59mm)
1/16"
(1.59mm) 0.090" (2.29mm) 3% 1/32" (0.79mm)
Note: * Reflects accuracy after Multi-Point Calibration.
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8/19/03 910-198E
Model 8500 Page 2-3
Perform a Multi-Point Calibration:
• At least once per month
• If superior accuracy is desired
• If the probe is replaced, dropped, or contacts strong
magnetic material
• If the probe tip is worn from abrasive material
Note: If the unit hasjust been turned on, or theprobe just connected,
allow the gage to warm-up for at least five (5) minutes with
the probe connected before performing either a Ball Calibra-
tion or Multi-Point Calibration.
2.3 Ball Calibration
Ball Calibration matches each target ball being used to an internal
lookup table from the unit’s memory. Ball calibration also measures
the two extremes of the ball’s possible locations (Ball On and Ball Off)
and assigns these endpoints to the lookup table. If no table exists for
the ball, then the unit automatically creates a default table from which
subsequent measurements are displayed. The table is preserved in the
unit’s memory, even if powered off, until overwritten by a new
calibration or deliberately erased by a Measurement or Master Reset.
1. With the probe sitting in the probe stand, press the [CAL] key.
The gage display instructions will read "Ball Off".
2. Remove any target ball from proximity to the probe tip by lifting
the ball straight up, and press [CAL]. The display will read
“Wait” while the gage measures the field strength at the probe
tip, and will then change to “Ball On”.
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910-198E 8/19/03
Page 2-4 Model 8500
3. Select the target ball that you will be using in subsequentmeasure-
ments, along with the RedLabelledAlignmentFixturefor thatball
size. The fixture centers the target ball on the probe tip. Place the
ball on top of the fixture. Place the fixture over the tip of the probe
and slide it down until it stops, as shown in Figure 2-1.
Note: Place the target ball into the red labelled fixture before plac-
ing the fixture onto the probe. Dropping the ball repeatedly
into the fixture as it rests on the probe may pit the tip of the
probe causing small measurement inaccuracies.
Figure 2-1: Alignment of Target Ball in Fixture on Probe
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8/19/03 910-198E
Model 8500 Page 2-5
4. Once the ball is centered on the probe tip, press [MEAS]. A brief
“Wait” message will appear while the gage measures the field
strength again, and then automatically returns to Measure Mode
with a zero thickness reading. The unit will now display thick-
ness values according to the most recently created table for that
ball.
2.4 Multi-Point Calibration
Multi-Point Calibration produces customized lookup tables to obtain
superior accuracy. To activate the Multi-Point Calibration feature, turn
on the Multi-Point Cal option located in the Calibration Setup Menu.
1. Press [SETUP] to enter the Setup Menu screen.
2. Use the []and []keys to select Calibration. Press [ENTER].
3. Use the []and []keys to select Multi-Point Cal.
4. Use the [ ]or []key to turn Multi-Point Cal “ON”.
5. Press the [MEAS] key to return to the Measure screen.
To begin Multi-Point Calibration:
1. Press [CAL]. The gage display will read “Ball Off”.
2. Remove any ball from the probe.
3. Press [CAL]. The display will read “Wait”, then “Ball On”.
4. Place the target ball into the Red Labelled Alignment Fixture, and
position fixture onto the probe.
5. Press [CAL]. “Wait” and then “Point #1” will appear on the gage
display.
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