ZBL Science & Technology ZBL-R800 User manual

ZBL-R800
Multifunctional Rebar Detector
ZBL-R630A
Rebar Scanner
ZBL-C310A
Rebar Rust Detector
Operation Manual
Beijing ZBL Science & Technology Co.，Ltd.

Operation manual of ZBL-R800, ZBL-R630, ZBL-C310A
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Contents
Conventions in This Manual.........................................................3
Chapter 1 General introduction.................... 4
1.1 Brief introduction....................................................................4
1.2 Major functions and characteristics ........................................4
1.2.1 Major functions.........................................................4
1.2.2 Major characteristics................................................5
1.3 Major technical indexes..........................................................5
1.4 Attentions................................................................................5
1.5 Maintenance............................................................................6
1.6 Responsibilities.......................................................................8
Chapter 2 Instrument description .................. 9
2.1 Components ............................................................................9
2.1.1 Host............................................................................9
2.1.2 Sensor and electrode ............................................11
2.1.3 Fittings .....................................................................12
2.2 Testing principles..................................................................13
Chapter 3 Software of ZBL-R800 multifunctional rebar
detector....................................... 16
3.1 Brief introduction of the software.........................................16
3.1.1 Starting-up interface and Main menu..................16
3.1.2 Keyboard operation ...............................................17
3.2 Data Output...........................................................................17
3.2.1 USB transmission...................................................18
3.2.2 GPRS transmission ...............................................19
3.3 System setting.......................................................................20
3.4 Introductions of rebar test.....................................................21
3.4.1 General-scan..........................................................22
3.4.2 Grid-scan.................................................................31
3.4.2.3 Measurement steps............................................35
3.4.3 Profile-scan.............................................................42
3.4.4 Data display............................................................44
3.4.5 Rebar data deletion................................................47

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3.4.6 On-site test..............................................................48
3.5 Introduction of rust test.........................................................55
3.5.1 Main menu of rust test...........................................55
3.5.2 Introduction of main menu....................................56
Chapter 4 Guide of quick operation ............... 62
4.1 Rebar test ..............................................................................62
4.1.1 On-site preparation................................................62
4.1.2 To connect sensor to host.....................................62
4.1.3 Starting test.............................................................63
4.1.4 Data transmission ..................................................63
4.1.5 Data analysis and process....................................63
4.1.6 Data deletion...........................................................64
4.2 Rust test ................................................................................64
4.2.1 Preparation before test..........................................64
4.2.2 Starting rust test .....................................................67
4.2.3 Data check..............................................................68
4.2.4 Data transmission ..................................................68
4.2.5 Data analysis ..........................................................69
4.2.6 Data deletion...........................................................69
4.3 Attention for field detection..................................................69
4.3.1 General principles of rebar test............................69
4.3.2 Attention for rust test..............................................70

Operation manual of ZBL-R800, ZBL-R630, ZBL-C310A
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Conventions in This Manual
1. Word with gray background and black box is a button on the
interface, e.g. OK.
2. The keys on the instrument panel are represented by 【】，e.g.
【SAVE】.
3. Word with white background and black box represent software
menu command in Windows, and “→”is a separator between different
menu levels. e.g. File→Open means the command of selecting
“Open” under the “File” menu.
4. Word with gray background but without box indicates the name
of the control (choice box, input box, etc.) of the popup window on
the screen, such as the input box of File Name in the open-file
window.
5. The sign means special attention is needed here.
6. Besides the descriptions in the manual, some prompt messages
may show automatically in the use of the software. Please operate
accordingly.
7. The software interfaces and photos in manual are only for
reference. There will be changes with software upgrade and
improvement of products. No further notice is provided.
Attention: This manual is the one for ZBL-R800
Multifunctional Rebar Detector. The operation manual of
ZBL-R630A Rebar Scanner can be seen in the section of
rebar test. ZBL-C310A Rebar Rust Detector can be seen in
the section of rust test.

Operation manual of ZBL-R800, ZBL-R630, ZBL-C310A
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Chapter 1 General introduction
1.1 Brief introduction
ZBL-R630A tests the thickness of concrete cover, rebar diameter,
location and space.
ZBL-C310A tests the degree of rebar corrosion and distribution.
ZBL-R800 Multifunctional Rebar Detector –a portable, integrative
and multifunctional one combines the functions of both ZBL-R630A
scanner for rebar test and ZBL-C310A detector for rebar rust test.
1.2 Major functions and characteristics
1.2.1 Major functions
1. Double function of rebar and rust test.
2. Identify rebar location, direction and distribution.
3. Test the thickness of concrete cover.
4. Test rebar diameter.
5. Qualify the thickness of concrete cover automatically.
6. Single-electrode testing of concrete rebar corrosion.
7. Double-electrode testing of concrete rebar corrosion.
8. Divide rebar corrosion in maximal 10 gray shades or color
graphs.
9. Test data storage, check and transmission.
10. Analyze professionally with Test Data Processing Software.

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1.2.2 Major characteristics
1. Store data in U-disk.
2. While GPRS module is equipped on the detector, the data
can be transmitted with GPRS, which is convenient and fast.
3. Place brief introduction of functions and operation manual
inside, handy for check.
4. Draw contour map of corrosion potential
5. Soft backlight.
1.3 Major technical indexes
Figure 1.1 Major technical indexes
Item Index
Measurement range of cover(rebar
diameterΦ6mm-Φ50mm)
First range: 3mm～98mm
Second range:3mm～196mm
Detection range of corrosion
voltage
-1000mv～+1000mv
Detection precision of corrosion
voltage
0.1mv
Power supply mode lithium battery Inside (charge with
standard configured charger)
Working time 38 hours
Weight 0.9kg
Volume 212mm×134mm×50mm
Display 160*128, LCD
USB port Transmit with U-disk, with capacity <=2G
is suggested.
1.4 Attentions
1. For a better usage, please read operation manual carefully

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before using the instrument.
2. Requirements for working environment:
Environmental temperature: 0℃～40℃；
Relative humidity :< 90%RH;
Long time sunlight perpendicular incidence is avoided.
Anti-corrosion: when used under damp, dusty and full of
corrosive gas conditions, protective measures are
necessary.
3. Requirements for storage environment:
Environmental temperature:-20℃～+60℃.
Relative humidity: < 90%RH;
Out of use, please place instrument into package, store in a
ventilated, cool and dry place, Long time sunlight
perpendicular incidence is avoided.
If long time out of use, please charge and start up for a
check regularly.
4. Avoid water.
5. Avoid usage under strong magnetic field, such as the nearby of
large electromagnet or transformer.
6. Shock-proof: During the process of usage or handling, avoid
severe vibration or shock.
1.5 Maintenance
1. Power supply: instrument charges with inside specific
chargeable lithium battery, after full charge, it can work last for
nearly 26 hours. When used, please pay attention to left of
electricity. If lack of electricity, close instrument quickly and
charge in time. Or it can lead to lost of testing data as a result of
sudden blackout even damage to instrument. Avoid using other
batteries or power supplies.

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2. Charge:
When charged, plug the power supply into AC220±10%V
socket and plug charger into the instrument’s power
supply .when the charge indicator is red, it is charging to the
inside battery. When turning to yellow, it is completed. At that
time, unplug the charger in time lest overcharge affects the
battery service life.
Attention: To guarantee full charge, please charge
6-8 hours consecutively, at the same time, avoid charge
under the environment of over 60℃.
Long time out of use, charged battery will discharge and lead to
decrease of electricity. Recharge before usage. While charged, a
common phenomenon is instrument and charger will be heated
in some extent. Good ventilation is necessary for heat
dissipation.
Attention: Avoid charge with other power adapters, or
it will cause damage to instrument.
3. Rechargeable battery: when battery is near the end of service
life after frequent charges and discharges, if the battery works
abnormally (cannot charge with electricity, cannot charge full or
short time is used after full charge), it is probable that
rechargeable battery has been damaged or reaches its end. At
that time, please contact with our company, change a new one.
Avoid short circuit of battery or approaching high source
temperature.
4. Every time when used, proper cleaning for host and sensors etc
is necessary against water or dirty into plug in or instrument, or
it will lead to low performance even damage of instrument.
Attention: Avoid placing instrument and fittings in
water or cleaning with wet cloth.
Avoid scrubbing instrument and fittings with organic solvent.

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Please wipe host and socket with clean and soft dry cloth.
1.6 Responsibilities
The instrument is sophisticated testing equipment. When user has one
of the following actions or the other man-made destruction, the
company does not undertake related responsibilities:
1. Violate the above requirements for working and storage
environment;
2. Improper operation;
3. Open case arbitrarily or dissemble any components without
permission;
4. Man-made or accident-caused severe damage to instrument.

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Chapter 2 Instrument description
2.1 Components
ZBL-R800 consists of host, rebar sensor, copper sulfate electrode,
double electrode handle, rebar signal wire, rust signal wire, U-disk
and charger.
ZBL-630A consists of host, rebar sensor, rebar signal wire, U-disk and
charger.
ZBL-C310A consists of host, copper sulfate electrode, double
electrode handle, rust signal wire, U-disk and charger.
2.1.1 Host
Following is the illustration of the host of R800 multifunctional rebar
detector, only for reference.
(A) Detector

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(B) Side plate
Figure2.1 Outward appearance of host
2.1.1.1 Keyboard
Keyboard is on the panel of host, function of each key is as follows.
Figure2.1 Table of functional key
Key name Function description
【MENU】To go back to upper menu in the operating menu
【BACK】To go back to previous menu
【a、b、
_、`】
Up, down, left, right direction, shift to the target menus and
options, parameter change, increase or decrease etc.
【SAVE】To save the test data, time, number and parameter, etc.
【ENTER】Parameter choice and determination, or change of testing
direction.
【 】 Power key, opening and closing of instrument
2.1.1.2 Display screen
Display screen is installed on instrument panel to present operating
interface, test data and exchange information etc.
2.1.1.3 Charging port
To charge instrument with battery charger attached with the
instrument, 6~8 hours is suggested in order to have a full charge.
2.1.1.4 USB port
Port for connection with U-disk is on the left side of instrument baffle.
Plug specific U-disk into USB port, testing data will be transmitted to
Charging port
USB port Rebar sensor
p
ort
Rust
electrode
port

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U-disk through Data Output and then analyze the data in U-disk with
computer software.
2.1.1.5 Sensor port
It is used for connecting with sensor signal wire.
2.1.1.6 Nameplate
On the back of instrument and sensor, nameplate consists of company
name, manufacture date, instrument serial number etc.
2.1.2 Sensor and electrode
2.1.2.1 Rebar sensor
With an integrative design, rebar sensor as shown in fig.2-2 can scan
rebar and record displacement of sensor in real time accurately. While
going forward, sensor scans rebar and backward, scrubs it.
Figure2.2 Rebar sensor
Sensor is directive. When sensor axis parallels with the direction of
rebar, it is most sensitive, conversely, when sensor axis is
perpendicular to the direction of rebar, the signal is weakest. Therefore,
while measuring, sensor axis should be parallel with the direction of
rebar and scans in the vertical direction.

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2.1.2.2 Copper sulfate electrode
Copper sulfate electrode as shown in fig.2-3 has following features:
stable electrode potential, under standard conditions, potential to
calomel electrode is 70±3mV satisfying with theoretical results and
potential difference below ±1mV. Electrode is difficult for polarization.
If copper sulfate crystal dissolves completely, the internal resistance of
electrode is below 3kΩ. Electrode has a long service life. If there is no
damage to cavity, it can be used for a long time once irrigated and
follow-up irrigation is allowed.
Figure 2.3 Copper sulfate electrode
2.1.3 Fittings
2.1.3.1 Power supply charger
Entry plug connects with 100~240V AC power supply and exit plug
into charging plug of host for charging of inside lithium battery.
2.1.3.2 Double-electrode handle
When testing rebar rust with double-electrode, two copper sulfate
electrodes should be installed on the handle (as shown in fig.2.4)
which is used with stable space 20cm.

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Figure 2.4 Double-electrode handle
2.1.3.3 Signal wire
Instrument signal wire consists of rebar sensor signal wire and rust
electrode signal wire. Ports of these two signal wire are on the left of
baffle. Please install according to chapter 4.
2.1.3.4 U-disk
It is used to copy the testing data which saved in the detector into
computer for further analysis.
2.1.3.5 Other fittings
Please see the packing list.
2.2 Testing principles
1. Magnetic testing principle of rebar
The sensor emits magnetic field to part of tested structure, at the same
time, receives induced magnetic field produced by iron-like medium
(rebar) in the scope of magnetic field and then converting to electrical
signals. The host analyzes digitalized signal timely and shows with
various ways such as graphs, data and sound etc to identify rebar
location, cover thickness and diameter precisely, such as figure 2.5.

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Figure 2.5 Magnetic testing principle of rebar
2. Single-electrode and double-electrode method of rust test
Single–electrode method (as shown in fig.2.6) applies testing principle
of half-cell self-potential method, the rebar under ionic environment
can be seen as an electrode, after corrosion, electrode potential
changed, therefore, potential reflects corrosion directly. As it is
well-known, battery consists of cathode and anode. Since rebar
electrode has only half feature of the battery, therefore it is called
half-cell.
Figure 2.6 Single-electrode method
Double-electrode method (as shown in fig.2.7) also applies
self-potential method. The difference only lies in that single-electrode
method applies to outside exposed structure of rebar end, while
double-electrode method applies to non-outside structure.

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Figure 2.7 Double-electrode method
When tested with single-electrode method, a constant potential
reference electrode (copper sulfate electrode or agcl electrode) should
be placed on the surface of concrete to form battery with rebar, the we
can identify the potential distribution through testing the relative
electric potential difference between rebar and reference electrode.
Through summarizing statistical law between potential distribution
and rebar corrosion, corrosion can be indentified through potential
test.
Double-electrode method needs putting two electrodes which distance
is constant on the surface of concrete. Moving these two reference
electrodes on the surface of concretes, if the rebars under the two
electrodes are in the same state, there is no potential difference; if
different, such as one is in corrosion, the other is not, potential
difference can be measured and corrosion can be identified
successively.

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Chapter 3 Software of ZBL-R800
multifunctional rebar detector
3.1 Brief introduction of the software
ZBL-R800 multifunctional rebar detector has both the function of
rebar test and rust test. We can examine diameter of rebar and the
thickness of cover of concrete rebar which diameter is betweenφ6
andφ50, and examine and describe corrosive situation of rebar. We
will introduce rebar test and rust test respectively in the following
chapters.
3.1.1 Starting-up interface and Main menu
After switched on, the first interface is the starting-up interface as
shown in figure3-1(A). It presents basic information of detector
consisting of name of manufacturer, model and name of detector,
version number and date etc. After nearly two seconds, starting-up
interface enters into the main menu as shown in figure3-1(B).
(A)Starting-up interface (B)Main menu
Figure3-1
The main menu has four options of Rebar Test, Rust Test, Data

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Output and Sys. Setup. The main menu interface displays with icons:
anti-color display represents present selected option, normally display
represents unselected one.
3.1.2 Keyboard operation
All the control operation are done through pressing keys in the
keyboard panel.
1) 【a、b、_、`】is used to select option. While selecting one option,
pressing the 【ENTER】to enter into corresponding submenu. At the
same time, 【a、b、_、`】can change parameter and switch options.
2) The LCD backlight of detector is closing as default after power is
on. The backlight can enhance the recognition of LCD, allowing users
to identify contents of display. After entering into main menu interface,
pressing 【`】to choose whether open or close backlight.
3)【ENTER】selects specific option.
4)【SAVE】stores data and parameter.
5)【BACK】goes back to previous interface, 【MENU】goes back
to main menu.
6)【】is power switch.
3.2 Data Output
Data output interface is as figure3-2, Data Output has two types- USB
transmission and GPRS transmission. USB transmits testing data into
U-disk, then into computer for analysis by software. GPRS transmits
testing information to server; users can login on server through client
software to establish task of transmission and receiving, check and
analysis of testing data.

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During the process of data transmission, rebar data and corrosion data
is transmitted respectively. User selects data for transmission manually;
storage file for rebar data is with the ext. name “.801” while rust data
is “.802”.
Figure 3-2 Data output option
3.2.1 USB transmission
(A)USB transmission option (B)USB transmission
Figure3-3 USB transmission
Plugging the U-disk attached with instrument into USB port of the left
side paddle, and then selecting “Data Output” in the option interface
as shown in figure 3-2, pressing 【a】,【b】for USB Trans., and then
press【ENTER】to enter “USB Options”interface as figure 3-3A.
Selecting Trans. Rebar Data or Trans. Rust Data below USB
transmission interface, and then pressing 【ENTER】, instrument will
start up U-disk power supply automatically. When transmission
completed and “please plug out U-disk” present, unplugging U-disk
from USB port of detector, and then pressing any key to go back to
USB transmission option interface. For usage of software analysis,

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please refer to <software operation manual>. Storage file for rebar
data is with the ext. name “.801” while rust data is “.802”. Detector
has tips for whether deleting data automatically after transmission.
Attention: please do not unplug the U-disk during
transmission lest errors are made during data transmission.
3.2.2 GPRS transmission
Selecting “Data Output” in the option interface as shown in figure 3-2,
pressing 【a】,【b】for GPRS Trans., and then pressing 【ENTER】
to GPRS options interface as figure3-4A. Selecting Trans. Rebar Data
or Trans. Rust Data below GPRS transmission interface, and then
pressing 【ENTER】,detector will start up the power supply of GPRS
module to connect with internet. During the connection, 【BACK】
key can cancel the connection and exit from the process. After
successful connection, selected data can be transmitted automatically.
During the process,【BACK】key can cancel data transmission and
exit from it.
After transmission, “successful transmission” and whether to backup
data or not will be provided such as figure 3-4(B), it shows successful
transmission of GPRS and it depends on user for the choice of data
backup, if【ENTER】is pressed, it will enter into data backup such as
figure 3-4(C). After backup, pressing any key will enter into data
deletion interface just as in figure 3-4(D). While after deletion, it will
go back to the GPRS transmission option interface of 3-4(A).if
pressing【b】in figure 3-4(B), data backup will not be done and data
deletion will be directly entered.