Sonatest Sitescan 250 User manual

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Sitescan 250
User’s Guide

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Sitescan 250 User’s Guide
Page i
Copyright © 2006 Sonatest Limited
All rights reserved. No part of this publication may be reproduced, stored in a retrieval
system or transmitted in any form or by any means, electronic, mechanical, photocopying,
recording or otherwise, without the prior written permission of Sonatest Limited.
Sonatest Limited Sonatest Inc.
Dickens Road 12775 Cogburn
Milton Keynes San Antonio
MK12 5QQ Texas
England 78249
Phone: [phone] USA
Fax: [phone] Phone: [phone]
e-mail: [email protected] Fax: [phone]
Web: www.sonatest.com e-mail: [email protected]
Document Number: 147308

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Sitescan 250 User’s Guide ~ Contents
Page ii
Contents
1 How to Use This User’s Guide ..........................................................................................1
1.1 Typographical Conventions ..................................................................................1
2 Disclaimers and Notices....................................................................................................2
2.1 Specific Warnings ..................................................................................................2
2.2 General Warnings..................................................................................................2
2.3 Operator Training..................................................................................................2
2.4 Testing Limitations................................................................................................3
2.5 Critical Operating Factors .....................................................................................3
2.5.1
Calibration of the Sound Velocity ....................................................................3
2.5.2
Transducer (Probe) Zero Procedure................................................................3
2.5.3
Flaw Detection Calibration...............................................................................3
2.5.4
Effects of Temperature on Calibration.............................................................4
2.5.5
Transducer Condition ......................................................................................4
2.5.6
Use of Couplant................................................................................................4
2.6 Disclaimer of Liability............................................................................................5
2.7 Electromagnetic Compatibility..............................................................................5
3 Quick Start.........................................................................................................................6
3.1 Front Panel and Optional Keyboard Controls ......................................................6
3.2 Flaw Detection.....................................................................................................12
3.3 Thickness Gauging ..............................................................................................14
3.4 Sitescan 250 Memory...........................................................................................16
3.4.1
Reset to factory defaults: ................................................................................16
3.4.2
Clearing the Memory......................................................................................16
4 Detailed Menu Description.............................................................................................18
4.1 Menu Tree ...........................................................................................................18
4.2 Main Menu...........................................................................................................20
4.2.1 Main Menu Selection......................................................................................20
4.3 CAL Menu ............................................................................................................21
4.3.1
Calibration Menu............................................................................................21
4.3.2
Amplifier Menu...............................................................................................21
4.3.3
GATE1 & GATE2 Menus.................................................................................22
4.3.4
A-CAL Menu ....................................................................................................23
4.4 MEAS Menu..........................................................................................................24
4.4.1
Measurement Menu........................................................................................24
4.4.2
CSC (Curved Surface Correction) ..................................................................26
4.4.3
PROBE Menu ..................................................................................................26
4.4.4
Distance Amplitude Correction (DAC) Menu................................................27
4.4.5
DGS/AVG.........................................................................................................28
4.4.6
TCG Time Corrected Gain Menu ...................................................................29

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Sitescan 250 User’s Guide ~ Contents
Page iii
4.4.7
AWS Menu.......................................................................................................30
4.4.8
API Menu.........................................................................................................31
4.5 UTIL Menu...........................................................................................................32
4.5.1
UTIL Menu......................................................................................................32
4.5.2
VIDEO Menu...................................................................................................32
4.5.3
MISC Menu.....................................................................................................33
4.5.4
AGC (Automatic Gain Control) ......................................................................34
4.5.5
PRINT Menu....................................................................................................35
4.5.6
P_O/P Proportional Output Control Menu....................................................36
4.5.7 CLOCK Menu..................................................................................................36
4.6 MEMORY Menu ...................................................................................................37
4.6.1
PANEL Memory Menu.....................................................................................37
4.6.2
A-LOG Memory Menu.....................................................................................38
4.6.3
REF Menu........................................................................................................39
4.6.4
T-LOG Menu Numeric Mode..........................................................................39
4.6.5
T-LOG Menu Sequential Mode.......................................................................40
4.6.6
T-LOG Menu Delete Mode .............................................................................40
4.7 Storage & Recall of Calibration Setups................................................................41
4.7.1
To store a panel set: .......................................................................................41
4.7.2
To recall a panel set:.......................................................................................41
4.7.3
To delete a panel set: .....................................................................................41
4.7.4
Adding NOTES to PANEL and A-LOG sets......................................................41
4.7.5
Edit Notes Summary.......................................................................................43
4.7.5.1
Using the Front Panel Keypad..............................................................43
4.7.5.2
Using the Optional Keyboard...............................................................43
5 Flaw Testing ....................................................................................................................45
5.1 Basic Flaw Testing ...............................................................................................45
5.2 Flaw Testing Calibration......................................................................................46
5.3 DAC Operation ....................................................................................................50
5.4 TCG Operation ....................................................................................................53
5.5 Weld Inspection Using Trigonometry Mode .......................................................55
5.6 Weld Inspection Using the AWS Menu................................................................57
5.7 Evaluation of Pipe Imperfections using API 5UE ................................................59
5.8 DGS/AVG Operation ............................................................................................62
5.8.1
Theory.............................................................................................................62
5.8.2
DGS/AVG Frequency, NFL and ERS................................................................63
5.8.3
DGS/AVG dVK, Delay......................................................................................64
5.8.4
DGS/AVG T-Loss, Ref dB and Mat dB.............................................................65
5.8.5
DGS/AVG ~ TBVEL, REF TYPE and REFSIZE.................................................66
5.8.6
DGS/AVG Calibration......................................................................................67
5.8.6.1
Adjustment............................................................................................68

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Sitescan 250 User’s Guide ~ Contents
Page iv
5.8.7 Measurement..................................................................................................70
5.9 A-LOG, A-Scan Storage.........................................................................................71
5.9.1
To Store An A-Scan: ........................................................................................71
5.9.2
To Recall an A-Scan: .......................................................................................72
5.9.3
To Delete a Stored A-Scan..............................................................................73
5.9.4
REF, Reference Waveform Comparisons........................................................73
5.9.5
To Recall an A-Scan as a Reference Waveform:..............................................73
5.9.6
Peak Echo & Hold Dynamics..........................................................................74
6 Thickness Gauging ..........................................................................................................76
6.1 Basic Thickness Gauging .....................................................................................76
6.2 A-Cal.....................................................................................................................79
6.3 TCG for Reliable Gauging....................................................................................80
6.4 T-LOG Thickness Storage (Numeric) ..................................................................81
6.5 T-LOG Thickness Storage (Sequential & Download)..........................................82
6.6 T-Log Editing and Printing ..................................................................................84
6.6.1
To delete a single location: ............................................................................84
6.6.2
To delete all Locations in a single Block:.......................................................84
6.6.3
To delete all Blocks and all Locations:...........................................................84
6.6.4
To print thickness logs ...................................................................................85
7 Power Supply ..................................................................................................................86
7.1 Lithium-Ion Battery Pack.....................................................................................86
7.1.1 Battery Cautions .............................................................................................86
7.2 Battery Charging..................................................................................................88
7.2.1
Charging Caution ...........................................................................................88
8 Interface Connections.....................................................................................................90
8.1 RS232...................................................................................................................91
8.2 Composite Video .................................................................................................92
8.3 Proportional Outputs..........................................................................................92
8.4 Synchronisation Outputs.....................................................................................92
9 Features of the Sitescan 250 ...........................................................................................93
9.1 Functional Testing Methods................................................................................93
10 Specifications...................................................................................................................94
11 Warranty ..........................................................................................................................98
12 Index ...............................................................................................................................99

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Sitescan 250 User’s Guide ~ How to Use This User’s Guide
Page 1
1 How to Use This User’s Guide
This user’s guide has been designed so that a person with a good knowledge of the basics o
ultrasonic non-destructive testing may understand the operation and use of the features
offered by the Sitescan 250. The user is advised, however, of the important nature of
ultrasonic non-destructive testing and is referred to Section 2 for important information on
the proper use of this technology.
Section1: How to Use This User’s Guideis this section.
Section2: Disclaimers and Noticescontains important information that must be understood
by users of the Sitescan 250
Section3: Quick Startprovides a user familiar with ultrasonic testing a means to operate the
instrument’s basic functions and to quickly achieve familiarity without having to
understand all of its features in detail.
Section: 4:Detailed Menu Descriptionis an in-depth description of the menu items found in
the Sitescan 250 with brief descriptions of each item.
Section 5:Flaw Testinggives guidelines on performing flaw testing with examples of how
to calibrate the Sitescan 250 and how to set up the unit for DAC, TCG, DGS/AV
and how to use the A-Scan storage facilities.
Section 6:Thickness Gauginggives guidelines on performing thickness measurements
including the calibration of the Sitescan 250, using TCG and how to use the
thickness measurement memory functions.
Section7: Power Supply describes important aspects of using and caring for the battery
power supply so as to get maximum battery duration time and life.
Section8: Interface Connectionsis for users who desire to operate the Sitescan 250 with
ancillary equipment.
Section9: Features of the Sitescan 250is a quick reference listing the pertinent
characteristics of the instrument and the various functional testing methods that
may be used with the instrument.
The function keys are shown throughout this manual as shown in Section3.1, Front Panel
and Optional Keyboard Controls.
1.1 Typographical Conventions
When describing front panel buttons the text is
éêáåíÉÇ=áå=íÜáë=Ñçåí .
When describing settings in the Sitescan 250 the text is.
printed in this font

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Sitescan 250 User’s Guide ~ Disclaimers and Notices
Page 3
More specific information about operator training, qualification, certification and test
specifications can be obtained from technical societies, industry groups and government
agencies.
2.4 Testing Limitations
In ultrasonic testing, information is obtained only from within the confines of the sound
beam as it propagates into the test material. Operators must exercise great caution when
making inferences about the nature of the test material outside the limits of the sound
beam. The condition of materials can vary significantly and the results can be erratic if
operators don’t exercise good judgment.
2.5 Critical Operating Factors
The following procedures must be observed by all users of this ultrasonic flaw detector in
order to obtain proper and accurate results.
2.5.1 Calibration of the Sound Velocity
An ultrasonic flaw detector operates on the principle of measuring the time of flight of a
burst of high frequency sound through the test piece as well as evaluating the amplitude of
reflected or transmitted echoes. The sound velocity of the test piece multiplies this time in
order to obtain an accurate distance or thickness reading. Since the actual sound velocity in
materials can vary from the published values, the best result is obtained when the
instrument is calibrated on a reference block made from the same material as the test piece.
This block should be flat, smooth and as thick as the maximum thickness expected of the
test piece.
Users should also be aware that the sound velocity might not be constant throughout the
test piece due to effects such as heat-treating. This must be taken into consideration when
evaluating the results of ultrasonic thickness testing. The calibration should always be
checked after testing to minimize errors.
2.5.2 Transducer (Probe) Zero Procedure
The transducer calibration procedures must be performed as described in this manual. The
calibration block must be clean, in good condition and free of noticeable wear. Failure to
perform the transducer zero and calibration procedure will cause inaccurate thickness
readings.
2.5.3 Flaw Detection Calibration
When performing flaw detection, it is important to note that the amplitude of indications is
not only related to the size of the discontinuity; the depth of a discontinuity below the test
piece surface will also have an effect on the amplitude due to characteristics of the sound
beam spread and near field zone of the transducer. In addition, the characteristics of the
discontinuity such as orientation and classification can alter the expected amplitude

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Sitescan 250 User’s Guide ~ Disclaimers and Notices
Page 4
response. For these reasons, calibration should be performed on test blocks made of the
same material as the test piece with artificial discontinuities within the range of size and
depth in the material to be detected. The user is again cautioned to refer to reference
books which are beyond the scope of this manual.
2.5.4 Effects of Temperature on Calibration
The sound velocity in test pieces and the transducer wear face changes with temperature
variations. All calibrations should be performed on site with test blocks at or near the same
temperature as that expected on the test piece, to minimize errors.
2.5.5 Transducer Condition
The transducer used for testing must be in good condition, without noticeable wear of the
front surface. The specified range of the transducer must encompass the complete range of
the thickness to be tested and/or the types of discontinuities to be investigated. The
temperature of the material to be tested must be within the transducer’s specified
temperature range.
2.5.6 Use of Couplant
Operators must be familiar with the use of ultrasonic couplant. Testing skills must be
developed so that couplant is used and applied in a consistent manner to eliminate
variations in couplant thickness which can cause errors and inaccurate readings. Calibration
and actual testing should be performed under similar coupling conditions, using a
minimum amount of couplant and applying consistent pressure to the transducer.

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Sitescan 250 User’s Guide ~ Disclaimers and Notices
Page 5
2.6 Disclaimer of Liability
All statements, technical information and recommendations contained in this manual or any
other information supplied by Sonatest Limited in connection with the use, features and
qualifications of the Sitescan 250 are based on tests believed to be reliable, but the accuracy
or completeness thereof is not guaranteed. Before using the product you should determine
its suitability for your intended use based on your knowledge of ultrasonic testing and the
characteristics of materials. You bear all risk in connection with the use of the product.
You are reminded that all warranties as to merchantability and fitness for purpose are
excluded from the contract under which the product and this manual have been supplied to
you. The Seller’s only obligation in this respect is to replace such quantity of the product
proved to be defective.
Neither the seller nor the manufacturer shall be liable either in contract or in tort for any
direct or indirect loss or damage (whether for loss of profit or otherwise), costs, expenses o
other claims for consequential or indirect compensation whatsoever (and whether caused
by the negligence of the company, its employees or agents or otherwise).
2.7 Electromagnetic Compatibility
This product conforms to the following European Directives:
Directive 2002/95/EC on the Restriction of the Use of certain Hazardous Substances in
Electrical and Electronic Equipment (RoHS)
Directive 2002/96/EC on Waste Electrical and Electronic Equipment (WEEE)
Low Voltage Directive (LVD) 73/23/EEC
CE Marking Directive 93/68/EEC
EMC Directive 89/336/EEC. However, in order to ensure the equipment meets the
requirements, the following should be read:
WARNING! This is a “CLASS A” product. In a domestic environment, this product
may cause radio interference. In which case the user may be required to
take adequate measures.
Note: This product should not be connected to cables greater than three (3)
meters in length. If this is necessary, the installation may require further
EMC testing to ensure conformity.
The Sitescan 250 also complies with EN 12668-1, Non-destructive testing and verification
ultrasonic examination equipment – Part 1: Instruments. For any questions relating to the
proper use of this product, please contact the manufacturer at the number indicated on
page i.

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Sitescan 250 User’s Guide ~ Quick Start
Page 7
This button operates in connection with the plain grey buttons next to the
parameter boxes to decrease the value or step the selection in the reverse
direction. In the case of transducer
ZERO or Delay , it moves the signals to
the left. This is a repeat button with acceleration to facilitate quick scrolling
of the value. Corresponds to down arrow (
 ) when using a keyboard.
This button changes the size of the steps that are used to adjust the
parameters; there are two sizes: small and large that are dependant on the
parameter that is being changed. The button toggles between the two sizes
and the current state is indicated by
for small and by  for the larger
step in the parameter box that is being adjusted. Corresponds to the letter “I”
when using the keyboard.
This button operates in conjunction with the memory menus to accept a store
or to accept a recall of a memory already in storage. In the print mode,
lh=
acts as the print button. Corresponds to “Enter” or the return key.
Press this button once to select freeze mode for the A-Scan display. This is a
useful feature for holding an echo for evaluation. When in this mode, a box is
highlighted showing
FREEZE below the graticule.
Pressing the button a second time selects peak mode, which holds and
updates all echoes on the display during inspection. This feature allows an
envelope or echo dynamic pattern to be drawn on the screen with the "live"
signal shown within, which is useful for angle beam inspection to locate the
peak signal. When in this mode, a box is highlighted showing
PEAK below
the graticule as sown below:
Pressing the key again invokes the Hold mode that captures the current A-

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Sitescan 250 User’s Guide ~ Quick Start
Page 8
Scan in white allowing a comparison to be made with the live A-Scan that is
shown in green. When this mode is selected a box is highlighted showing
HOLDas shown below:
If key lock is enabled from within the
UTIL menu, pressing the button a
fourth time selects
KEYLOCKmode, preventing accidental changing of
parameters
Pressing the button a fifth time returns the A-Scan display to normal mode.
This is a momentary button with no repeat action. Corresponds to the letter
“F” when using the keyboard.
This button selects the help menu which overlays the display. The help menu
explains how the Sitescan 250 operates with a choice of three options:
Using the Sitescan 250
Description of the active menu
Calibration procedure.
Pressing the
ebim button again at any point in the help screens returns the
display to normal mode. The Help Screen also displays the Instrument serial
number & software version. Corresponds to “F5” when using a keyboard.

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Sitescan 250 User’s Guide ~ Quick Start
Page 9
The full screen button is used to toggle between showing the A-Scan on the
full display and showing it with the menus and parameter boxes as shown
below:
Full display is useful for maximising the size of the A-Scan while performing
inspections. While in full screen mode the user can still change the gain in
the normal way and use the
cobbwbLmb^h button; all other buttons are
disabled. If split screen is enabled from the
UTIL menu this button is used
to display the A-Scan in the upper half of the display and parameters in the
lower half as shown below:
In this mode the main parameters are shown in a grid that the user navigates
by using the grey buttons next to the
&arrows to scroll up or down and
the and buttons to move form left to right. Once the required
parameter has been selected it can be changed in the normal way by pressing
the , and buttons.

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Sitescan 250 User’s Guide ~ Quick Start
Page 10
Press to select the dB step value of amplifier gain as 0.1, 0.5, 1, 2, 6, 10, 14, or
20dB. The selected value is indicated at the top right-hand corner of the gain
box, which is always located at the bottom right side of the screen. This is a
momentary button with no repeat. Corresponds to the letter “X” when using
a keyboard.
Press to increment or decrement the gain value indicated in the gain box.
This is always located at the bottom right side of the screen. This is a repeat
button with acceleration to facilitate quick changing of the value.
Corresponds to “Page Up” and “Page Down” when using a keyboard.
Selects either reference or gain settings within the gain box. When reference
is selected, the increment and decrement buttons will change both the
reference and gain values together. This is a momentary button with no
repeat. Corresponds to the letter “R” when using a keyboard.
This button toggles between single and double element transducers. The
user should switch the unit off or stop the pulser by pressing the
cobbwbLmb^h key before changing transducers. Corresponds to the letter
“S” when using a keyboard.
BNC or LEMO 1 connector is the transmitter and receiver socket used for
single transducers or as the transmitter only, for twin or dual transducer
operation.
BNC or LEMO 1 connector is the receiver socket used for twin or dual
transducer operation.
A socket to connect various USB devices such as a printer, keyboard or the
user’s PC.
A socket used to connect the battery charger for recharging the battery pack.
A red dot is provided on both the socket and plug to facilitate alignment.
Refer toPower Supply for information on power supplies and charging of the
battery pack.

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Changes between Normal
& Full screen views
Changes between
Normal, Freeze & Peak
display of A-Scan
Displays context
specific help
On/Off Switch
Increase gain
Decrease gain
Switch between
Reference & Gain
C
adjus
Used as acceptance of memory
functions and when drawing
various measurement curves
4 “Soft” keys
Move menu
selection Left
USB Connector
Charge Connector

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Sitescan 250 User’s Guide ~ Quick Start
Page 12
3.2 Flaw Detection
Perform the following steps to establish a basic flaw detection mode for the Sitescan 250.
Units shown are in inches. For metric units, select
METRIC UNITS from theUTIL menu
and use the corresponding values for the parameters.
1. Select a suitable transducer, preferably a 5MHz, half inch diameter narrow band.
2. When making a quick adjustment on a menu parameter, press the button until the
double arrow appears next to the parameter name. This establishes the fast scroll using
the and buttons.
3. In theCAL menu, set the following parameters:
• ZERO to 0.000
• VEL should be set the specimen material velocity.
• RANGEto125 or other suitable value to cover the test range of interest.
• DELAY to 0.000
• GAIN to 50.0
4. In the
AMP menu, set the following parameters:
• DETECT to FULL
• PRF to 150Hz
5. In theGATE1 menu, set the following parameters:
• STATE to ON +VE
• START to 10.0
• WIDTH to 50 or other suitable value to cover the test range of interest.
• LEVEL to 50.0
6. In theGATE2 menu, set theSTATE to OFF
7. In the
MEAS menu, set the following parameters:
• MODE to DEPTH
• TRIGGER to FLANK
• HUDto OFF
• T-MIN to OFF
The Sitescan 250 is now configured for basic flaw detection. Using an appropriate
calibration block, adjust the
GAIN parameter to establish the correct sensitivity. Adjust

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Sitescan 250 User’s Guide ~Quick Start
Page 13
other parameters as necessary to optimize the calibration. For more in-depth features of the
Sitescan 250, seeFlaw Testingon page45.

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Sitescan 250 User’s Guide ~ Quick Start
Page 14
3.3 Thickness Gauging
Perform the following steps to establish a basic thickness-gauging mode for the Sitescan
250. Units shown are in metric. For inch units, select
INCHES from theUTIL menu and
use the corresponding values for the parameters.
1. Select a suitable transducer, preferably a broadband, 5MHz, with a 10mm diameter.
2. Select an appropriate calibration block with at least three known thickness sections
covering the range to be inspected and made from the same material as the test piece.
3. When making a quick adjustment on a menu parameter, press the button until the
double arrow appears next to the parameter name. This establishes the fast scroll using
the and buttons.
4. In theCAL menu, set the following parameters:
• ZERO can be left alone
• VEL should be set the specimen material velocity.
• RANGEto 125 or other suitable value to cover the test range of interest.
• DELAY to 0.000
• GAIN to 50.0
5. In the
AMP menu, set the following parameters:
• DETECT to +VE HW
• PRF to 150Hz
6. In theGATE1 menu, set the following parameters:
• STATE to +VE
• START to 10
• WIDTH to 50 or other suitable value to cover the test range of interest.
• LEVEL to 25.0
7. In the
MEAS menu, set the following parameters:
• MODE to DEPTH
• TRIGGER to FLANK
• HUDto ON
• T-MIN to OFF