REGULA 7515M User manual
EDDY-CURRENT MAGNETOGRAPHING DEVICE
REGULA 7515M
Operating Manual
2019
MAGNETO-OPTICAL DEVICES
For nondestructive investigation of metal surfaces
Certied Quality
Management System
CONTENTS
INTRODUCTION ...................................4
1. DESCRIPTION AND OPERATION ......................5
1.1. Device function ..............................5
1.2. Technical specications .........................5
1.3. Delivery set.................................6
1.4. Structure and Operation of the Device ..............6
1.5. Means of measurement, tools and accessories........ 12
1.6. Marking .................................. 16
1.7. Packaging ................................. 16
2. INTENDED USE ................................. 17
2.1. Operating restrictions ......................... 17
2.2. Preparation for use........................... 18
2.3. Device use ................................ 18
3. MAINTENANCE ................................. 27
3.1. General instructions .......................... 27
3.2. Safety measures ............................ 28
3.3. Serviceability test ........................... 28
4. ROUTINE REPAIRS............................... 29
4.1. Safety Measures ............................ 29
4.2. General Instructions .......................... 29
4.3. Instructions on Repairs ........................ 29
5. STORAGE ..................................... 31
6. TRANSPORTATION ............................... 31
7. RECYCLING ................................... 31
8. ACCEPTANCE CERTIFICATE......................... 32
9. SALE CERTIFICATE .............................. 33
4
INTRODUCTION
The present Operating Manual (OM) is the main operational document
for the eddy-current magnetographing device (hereinafter referred
to aas the “device” or “ECMD”) Regula 7515M used as add-in module
of magneto-optical devices (MODs) for identication and detection of
falsication of vehicle identication numbers (VIN) Regula 7505M.
The OM contains the information on the device and its design,
principle of operation and technical characteristics. It also provides
instructions on the correct and safe use of the device (intended
use, technical maintenance, simple routine repairs, storage and
transportation) and on its technical condition evaluation when making
a deсision regarding its repairs.
The document is elaborated under the requiments of
the international standarts.
5
DESCRIPTION AND OPERATION
Device function
The device of eddy-current magnetographing is designed for
examining the surface of items made of conductive materials and
increasing the sensitivity of magnetographing process (magnetic
copying) in the supercial layers of ferromagnetic items. The device is
viewed as an add-in module of Regula 7505M intended for magneto-
optical visualization of VINs when carrying out forensic examinations.
The device enables examination of markings on data carriers
made of aluminum alloys (silumin bodies of the blocks of cylinders
and reducers, manufactory’s aluminum plates, duraluminium bodies)
and extends the functionality of the equipment when examining weak
signals in the supercial layers of ferromagnetic items, e.g. – residual
(accumulated) tension.
Technical specications
Basic technical specications of the device:
Table 1
Scanner supply voltage, V 24
Current in scanner conductor (peak value), A 90-110
Magnetic eld tension on scanner conductor sur-
face (peak value), kA/m 30-35
Nonatness of examined surface, mm, max 0.5
Scan rate, max, mm/s 50
Effective width of copying, mm, max 20
Time of continuous work (without recharge), min,
minimum
40 (≈120 copies)
Capacity of controller accumulator (ACC) (set of 2
nickel-metal-hybrid ACC of 6F22 (9 V)), min 170 mAh
Charge time of ACC (charge current, max 24mA) ≈8 hour
Design life of the device, years, min 5
Design life of ACC, charge cycles, min 500
Overall dimensions of scanners, mm 28×30×35
Controller overall dimensions, mm 160×100×30
Overall dimensions of charging unit, mm 100×80×30
Device weight, g, max 900
Climatic conditions for operation
and storage
in accordance with
technical requirements
for magneto-optical
devices Regula 7505
1
1.1
1.2
6
Delivery set
Device delivery set (Fig. 1):
Table 2
Controller (1) pos. 1
AL-scanner (1) pos. 2
Fe-scanner (1) pos. 3
ACC (2)
Charging unit of controller ACC (1) pos. 4
Test-object №1 (Al) (1) pos. 5
Test-object № 2 (Fe) (1) pos. 6
Magnetizing attachment of Fe-scanner (1) pos. 7
Inductors for scanners (SPCS*) (5) pos. 8
Device Operating Manual (OM)(1)
* – Spare Parts and Components Set
Structure and Operation of the Device
The device consists of 2 basic structural elements (Fig. 2):
the controller and the scanner. Scanners are specialized according
to the type of the examined material. Thus, Al-scanner is intended
for electro-conductive non-ferromagnetic materials and Fe-scanner
for ferromagnetic materials. Two ACC are the power supply source
of the device controller. These batteries are charged by a subsidiary
charging unit. Device function control is carried out in the composition
of Regula 7505M using test-objects №1 and №2.
Magnetographing with the use of the device consists in the successive
execution of a number of operations. Demagnetize, place and x
the magnetic tape on the examined surface beforehand. Connect
the scanner corresponding to the examined material type to the device
controller. Switch on power supply of the device controller and move
the scanner is moved along the examined surface.
The device controller creates and sends voltage impulses with set
parameters to the scanner. Pulse current, which ows in the scanner
conductor, creates around the scanner the alternating magnetic
eld, which induces eddy currents in the conductive material of
the object. The eddy currents trajectories and connected with them
magnetic stray elds reect the lines of electric resistance specied
by the form, sizes and positioning of defects in the examined item.
The obtained magnetogs of the object (VIN) stray elds are visualized
by Regula 7505M under its OM. The obtained images are processed
and analyzed for the following expert appraisal.
1.3
1.4
7
External view of the device
Figure 1
Figure 2
Structural scheme of the device as a component of regula 7505M
Device Scanner Charging Unit of
Controller ACC
(converter
≈220V/=24V)
Device
Controller
Stray eld’s record (magnetogram)
Object (VIN)
Surface
Magneto-optical
device (MOD)
Regula 7505M
8
External view of the device controller with the basic controls
of indication and commutation is shown in Fig. 3:
Figure 3
1 – controller body;
2 – сonnection socket for scanners;
3 – сontrol button;
4 – state indicators of the controller and ACC charge;
5 – ACC cells;
6 – connection socket for the network power unit.
а) top view b) bottom view
External view of the device controller
2
6
5
3
1
4
The device controller (Fig. 3) is produced in a metal body (pos. 1).
The controller side slab has a socket for connecting the scanner
(pos. 2), and ACC charging device (pos. 6).Its bottom panel provides
access to the ACC compartment. The control button (pos. 3) and state
indicators of the controller and ACC charge (pos. 4) are located on
the front panel of the controller body.
9
During the operation the device controller creates and sends
voltage impulses with set parameters to the scanner. These parameters
correspond to the type of the connected scanner and the selected
operating mode. Moreover, the controller carries out self-diagnostic,
controls ACC charge and provides its additional charge (if the ACC
charging device is connected).
After the scanner socket (pos. 2) is connected and power supply
of the controller device is activated with the button (pos. 3),
the indicators may have the following states:
Only the green indicator glows – controller state and ACC
charge are normal; the scanner is activated – it receives
voltage impulses necessary for magnetographing;
The green indicator glows and the red indicator blinks
impulsively – ACC charge is needed;
The green indicator blinks impulsively – the current
operating mode. The indicator blinks one time when
switching on the controller and changing its operating
modes. The numbers of ashes correspond to the power
level of Fe-scanner (see paragraph 2.3 for the power levels);
None of LEDs glows – ACCs are absent or are fully
discharged, the device controller malfunction;
The controller switches off automatically one minute after
its activation to save energy and protect the scanner from
overheating.
To save energy and protect the scanner from overheating, the
controller is switched off automatically in a minute after activation.
When the ACC charging device is connected to the controller device
(socket – pos. 6) and its power supply is connected to the mains
220V, the yellow indicator (pos. 4) may glow. The glowing means
the presence of external power supply (=24V) at the controller
input, which provides additional ACC charge of the ACC including
the ACC charge during the device operation process.
The access to ACC for their charge and replacement is carried
out by unscrewing 4 screws and removing the cover of the ACC cells
(pos. 5).
External view of AL-scanner is given in Fig. 4.
The Al-scanner is intended for examination of non-ferromagnetic
materials. The scanner is shown in Fig. 4. It is designed in a plastic
body (pos. 1). The eddy-current inductor (pos. 2) is inserted into
the groove in the lower part of the scanner and xed with screws
(pos. 3) on the pads.
10
The system of conductor tension is designed in the form of a dielectric
cushion (pos. 4). An arrow (pos. 5) with a symbol indicating the type of
examined material shows the direction of magnetic tape demagnetization
(preliminary) and examined object scanning. The scanner is connected
to the controller via the cable (pos. 6) connector.
During operation the ECMD forms and sends voltage impulses with
specied parameters to the scanner inductor. To carry out magnetic
copying, x a demagnetized magnetic tape on the examined surface.
And then move the scanner in the direction indicated by the arrow
(pos. 5) along the examined area.
When carrying out magnetic copying of a relief surface, the elastic
pressing cushion (pos. 4) deforms the inductor (pos. 2) in accordance
with the current surface relief.
1 – body;
2 – inductor;
3 – screws for xing the inductor;
4 – elastic pressing cushion;
5 – arrow (with a symbol indicating
the type of examined materials) which
shows the direction of scanning;
6 – cable for connecting the scanner
to the controller.
External view of Al-scanner
Figure 4
2
1
6
5
3
4
11
The Fe-scanner is intended for examination of ferromagnetic
materials. Its construction (Fig. 5) is similar to the construction of
the dynamic Al-scanner: elements pos. 1–6 (see the description of
Fig. 4).
The specic feature of this type of the scanner is a magnetic
excitation system (Fig. 5 pos. 7, pos. 7) which includes a source of
permanent magnetic eld adjustable by the ywheel (pos. 9) and
magnetic cores with polar tips (pos. 8).
To excite magnetic stray elds of the defects located in
the subsurface layers of a ferromagnetic object, during magnetic
copying polar tips (pos. 9) of the magnetic excitation system should
make tight contact with magnetic tape and the examined surface.
1 – body;
2 – inductor;
3 – screws for xing
the inductor;
4 – elastic pressing
cushion;
5 – arrow (with a symbol
indicating the type of
examined materials) which
shows the direction of
scanning;
6 – cable for connecting
the scanner to the controller;
7- magnetizing
attachment (18 mm);
8 – polar tips;
9 – ywheel adjusting
the level of magnetization.
External view of Fe-scanner
Figure 5
7
8
1
6
59
3
2
4
12
1.5
ATTENTION!
НЕ СНИМАЙТЕ НАСАДКУ-НАМАГНИЧИВАТЕЛЬ!
IF THERE IS NO EXTERNAL SOURCE OF MAGNETIZATION
FOR THE EXAMINED OBJECT, THE USE OF AN ATTACHMENT
(POS. 7 OR 8) IS OBLIGATORY.
Means of measurement, tools and accessories
Magneto-optical device Regula 7505M (used in composition
with ECMD) belongs to the category of displaying(not measuring)
devices. Therefore, means of operation control of Regula 7505M and
ECMD as its component are produced as test-objects, simulating
widespread modied changes of VINs (pouring by polymers, pressing
in fragments, and removal of the metal supercial layer). The control
order of device serviceability with the use of the test-objects is
described in detail in paragraph 2.1.3. of Regula 7505M OM and 3.3
of the given OM.
Characteristics of the test-object of the device:
Test-object №1 (Al) (Fig. 6) is the imitator of Category “A” control
object (the data carrier of the vehicle body). It is executed in the form
of a plate made of a sheet of aluminum alloy 1 mm thick. The initial
number 20165 is applied by machining process (cold pressing).
The initial number was made in the following way: manual stamping
using “№10 type” markers kit and hammer on a massive anvil.
The depth of digits relief makes about 0.3-0.4 mm.
Three digits of the initial number were modied as follows: “0” for
“9”, “6” for “9” and “5” for “7”. Thus, the altered number appears as
“29197” (the altered digits are underlined).
Digit “0” in the initial number was altered manually using
cold calking of the element (bulkhead) of digit “9” with the help
of a bench tool and then stamping of the new digit “9” over
the remaining contour of digit “0”.
Digit “6” in the initial number was altered in the following way:
dismantling (cutting-out) of the initial number fragment bearing digit
“6” with the help of a blanking tool, swap (180° rotation), pressing
in of the cut-out fragment with digit “6” (thus digit “6” is transformed
into digit “9”).
Digit “5” in the initial number was altered manually using
the process of pouring of the digit relief by polymer (epoxy spackling);
stamping of the new digit “7” over soft spackling.
After the digits of the initial number were modied, the following
operations were executed on the test-object: scraping; spackling;
13
Figure 6
Function control of the device with the use of Al-scanner
а) surface image of test-object No1
b) magneto-optical visualization of magnetogram of test-object No1
priming; two-layer tinting with aerosol motor enamel using cold
drying using technology corresponding to repairs coating.
Test-object №2 (Fe) (Fig. 7) is the imitator of Category “A”
control object (the data carrier of the vehicle body). It is executed in
the form of a plate made of a sheet of tool steel 2 mm thick “20165”.
The initial number is applied by machining process of pressing (cold
pressing). The initial number was made in the following way: manual
stamping using “№10 type” markers kit and hammer on a massive
anvil. The depth of digits relief makes about 0.3-0.4 mm.
All digits of the initial number were removed by removing
the metal supercial layer of the test-object to the depth of 0.5
mm. The supercial layer was removed from the initial marking by
machining process of cutting (milling and polishing).
As a result of the mentioned processing of the test-object surface,
the initial marking can not be observed by visual-optical methods (as
the relief is removed). However, internal residual tension, produced
as a result of deformation of the metal when executing the initial
marking, remains in the supercial layer of the test-object metal.
14
Figure 7
Function control
Take out the test-objects of the device and make their
magnetic copy as described in paragraph 2.3;
Perform magnetic copy stitching in the PC as described
in paragraph 2.2.1.3 of Regula 7505M OM;
Compare the results of the obtained magnetic copies
stitching with the control images, shown in Figure 6 and
Figure 7. If comparison results are positive, the device
operation can be considered as normal. Comparison
criteria the results of the obtained magnetic copy stitching
with the control images for Al-scanner are as follows:
–compare the processing quality of the alteration
features of the initial number digits (the contours
traces of the initial marking digits on the 2th and 6th
digit position and fragments pressing-in contours on
the 4th digit position as well as the traces of machining
process on the 4th and 6th digit position shall be visible)
–compare the processing quality of the digits
of the secondary number (the contours of all digits
shall be visible)
Function control of the device with the use of Fe-scanner
а) surface image of test-object No2
b) magneto-optical visualization of magnetogram of test-object No2
15
Comparison criteria of the results of the obtained
magnetic copy stitching with the control images for Fe-
scanner are as follows:
–compare the processing quality of the digits contours
of the remoted initial number (the contours outlines of
all digits shall be visible)
in case of malfunction during any of the operation control
stages see paragraphs 3 and 4.
16
Marking
The device marking is executed in the form of a label on the back
side of the device controller and provides information as follows:
manufacturer’s name or trade mark;
symbolic notation of the device;
manufacturer’s serial number of the device;
date of manufacturing (year and month);
rated voltage, V;
rated current, A;
TC marking;
national mark of conformity (certication);
Device seals are applied with destructive labels on
the device controller body. Sealing violation deprives the User
of warranty maintenance.
Packaging
The case with the hardware of the device and the SPCS (Spare
Parts and Components Set) are packed in cardboard packaging.
The device is transported and stored in special transportation
packaging (wooden or cardboard) of the delivery set.
1.6
1.7
17
INTENDED USE
Operating restrictions
IT IS STRONGLY PROHIBITED TO:
–Disconnect the scanner socket if the controller is
activated. I.e. it is prohibited to disconnect the scanner
if the green indicator of the controller is switched on.
–use other charging units different from the stipulated
ones
–use faulty network sockets and power supplies for
ACC charge
–turn on the device with apparent damages of protective
isolation and conductors
–turn on the device when protective shrouds are removed
The User should observe the following operating restrictions when
operating the device:
Сlimatic operational conditions as described in paragraph
1.1.1 of Regula 7505M User’s Guide. Do not use the device
under the rain out-of-doors or out of a vehicle. In case
water or condensate appear on the body of the device
elements, stop the device operation and proceed with it
only after drying;
the device should not be exposed to impacts and strong
vibration when operating and transporting it;
observe quality norms for power supplies, under
paragraph 1.1.2.4 of Regula 7505M User’s Guide;
all commutations of the device components connected
with opening and closing of electric sockets shall be
carried out with deactivated power supply of the device.
NON-OBSERVANCE OF DEVICE OPERATING RESTRICTIONS
CAUSES THE LOSS OF THE MANUFACTURER’S WARRANTY.
Limitations of use:
it is possible to examine only electro-conductive materials
when the scanner type is chosen correctly;
do not operate the device with damaged (through breaks
with sharp edges, heavily crushed), and dirty magnetic
tapes with bent edges (see paragraphs 2.2.2.2 and 3.2.2
of Regula 7505M User’s Guide. Failure to observe these
requirements may result in discrepancies during stitching
and jamming of magnetic tapes in the device;
2
2.1
18
when using the device on the surfaces with nonatness
more than 0.1 mm on the basic area of 18x20mm or
roughness more than Rz 80µm, the quality of the magnetic
copy is not guaranteed due to signicant contact losses
recharge ACC according to 3.1 at least once in 2 months
Preparation for use
Activation order:
Choose the scanner corresponding to the type of
the examined material: Fe- scanner for ferromagnetic
materials (steel, cast iron); Al-scanner for non-ferromagnetic
electro-conductive materials (nonferrous metals and their
alloys)
Connect the chosen scanner (Fig. 1, pos. 2 or pos. 3)
to the controller socket (Fig. 1, pos. 1)
Turn on the device controller using the button (Fig. 3,
pos. 3) and make sure that ACC are charged enough
according to the state of indicators (Fig. 3, pos. 4) as
described in paragraph 1.4. If it is necessary, charge ACC
under paragraph 3.1
Press shortly the button (Fig. 3, pos. 3) to turn off
the device controller and carry out the operations
necessary to start magnetographing under paragraph 2.3
Turn on Regula 7505M under paragraph 2.2 of Regula
7505M User’s Guide.
Device use
Magnetic copying of the examined object consists of the following
steps:
Prepare the examined surface as described
in paragraph 2.2.2.3 of Regula 7505M User’s Guide
Prepare (demagnetize) the magnetic carrier as described
in paragraph 2.2.2.3 of Regula 7505M User’s Guide;
Execute a magnetic copy execution.
ATTENTION!
THE DEMAGNETIZATION PROCESSES OF THE MAGNETIC
CARRIER AND MAGNETOGRAPHING MUST BE CARRIED
OUT IN THE SAME DIRECTION (SEE FIG. 8). OTHERWISE
THE MAGNETIC RECORDING WILL BE WEAK, AND IN CASE
OF WEAK SIGNALS IT CANNOT BE EXECUTED AT ALL.
2.2
2.3
19
In order to prevent errors of the direction coordination, a visual
noticeable tag should be placed on the magnetic tape surface, e.g.
as is shown in Fig. 8 to make a “start” point by a felt-tip pen at
the beginning of the magnetic tape.
The magnetic carrier should be demagnetized as described in paragraph
2.2.2.3 of Regula 7505M User’s Guide. The demagnetizer must be moved
from left to right relative to the “start” point (see Fig. 8a).
The demagnetized magnetic tape is placed on the examined
surface without overturns, i.e. so that the “start” point is always at
the left edge.
When carrying out magnetographing the demagnetizer is also
moved from left to right relative to the “start” point (see Fig. 8b).
And the scanner body must be placed in the way that the direction of
the arrow with the symbol indicating the type of examined materials
and the direction of the preliminary demagnetization are the same,
i.e. from left to right.
Note:
If the device and Regula model 7505 are not delivered together,
the demagnetizer may exchange the polarity. In this case when
carrying out scanning, turn over the tape before placing it on
the object (“start” point to the right edge).
Magnetic copy:
Put the magnetic tape on the prepared number area
of a vehicle and x its end on the examined surface by
a magnetic clamp, adhesive tape or manually (try to avoid
skewness and shifts relative to the examined number);
Fix the other end of the magnetic tape stripe in the same
way (if one end of the magnetic tape stripe is xed rmly,
the other end may be left loose). The operator may
choose any way of the magnetic tape xation;
Place the body of the device scanner so that the relief tag
(Fig. 5, pos. 5) in the form of an arrow is directed forward
in the scanning direction (Fig. 8b). Put the scanner on
the xed stripe of the magnetic tape, make sure they
have a tight contact with the examined surface.
Switch on the power supply of the device controller with
the button (Fig. 3, pos. 3), make sure the green LED
glows (Fig. 3, pos. 4). If necessary, hold down the button
to choose the required power mode (for Fe-scanner only).
The number of ashes is in proportion to the set power
level of Fe-scanner;
Move the scanner slightly pressing it to the surface from
the beginning of the examined fragment to the end.
The speed of scanning should not exceed 50 mm/s.
20
Figure 8
Coordination of the processes of demagnetization
and magnetographing by the direction
а) demagnetization, demagnetizer moves from left to right
b) magnetographing, scanner moves from left to right
1 – direction for demagnetizer
movement;
2 – position of the demagnet-
izer button (on top).
1 – pressing force;
2 – direction for scanning
(scanner movement).
Otherwise the magnetizing signal will be recorded to
the tape in the form of vertical black and white lines. To
obtain a good-quality copy, the operator should control
the contact between the scanner and the examined
surface visually and manually. If the conditions of
magnetic copying are not observed (displacement of
magnetic tape, no contact between the examined surface
and the scanner or the scanner moved aside), repeat all
operations starting from magnetic tape demagnetization;
Press shortly the button (Fig. 3, pos. 3) to switch off
power supply of the device controller (Fig. 3, pos. 3);
make sure the green LED is switched off (Fig. 3, pos. 4);
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