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DIO 1000
Ultrasonic Flaw Detector
Operation Manual
This manual may not be copied in whole or in any portion by any means without the
express written consent of STARMANS electronics, Ltd. The material in this manual
is for informational purposes and is subject to change without notice.
In no event will STARMANS electronics, Ltd. be liable for direct, indirect, special,
incidental or consequential damages resulting from any defect in this documentation,
even if advised of the possibility of such damages.
Drawings and pictures in this manual contain confidential information and are
supplied by STARMANS electronics, Ltd., the owner of such information. In
accepting a drawing, the user agrees that it is for the users sole use. It will not be
reproduced or distributed to others and that the drawings or the information
contained herein will not be used in any manner detrimental to STARMANS
electronics, Ltd.
This statement covers new instruments, electro/mechanical devices, probes, transducers and supplies
manufactured and sold by STARMANS electronics, Ltd. (hereinafter referred to as STARMANS) to an
end user in consideration of the purchase price paid.
INSPECTION
Upon receipt of the instrument, it should be examined immediately for any evidence of hidden or
external damage. Damage should be promptly reported to the carrier making delivery, as the carrier is
normally liable for such damage. All documentation, waybills and packing materials should be retained
in order to establish claims. Please, advise STARMANS at the nearest Service Center after notifying
the carrier of shipping damage so that we may assist in damage claims and supply replacement
equipment, if necessary.
LIMITED WARRANTY
STARMANS warrants its instruments to be free from defects in materials and workmanship for a
period of 24 months from the date of shipment, under conditions of normal use and service.
Batteries and other expendable items are excluded from this warranty.
Specifically excluded from this warranty is equipment that becomes defective due to:
a) normal wear,
b) damage resulting from accident, misuse, abuse or negligence, and
c) attempts to modify, repair or perform internal adjustments by parties other than authorized
STARMANS service personnel.
STARMANS reserves the right to charge on a time and material basis for repairs that are necessitated
by a, b and c above. Seals may be applied in critical locations on the equipment to protect the integrity
of factory calibration and QA acceptance. The tamper-proof design of these seals renders them
fragile, so care should be taken not to break or remove these, as this will void the warranty.
If any of above items should prove defective within the warranty period, STARMANS will, at its option,
repair or replace them without charge, FOB the nearest STARMANS Service Center. Our policy is to
accept only prepaid shipments to our authorized service centers.
STARMANS makes no other warranty of any kind whatsoever and are no implied warranties of
merchantability or fitness for a particular purpose. STARMANS shall not be liable for any failure of the
equipment or equipment operators to discover defects in components being tested with such
equipment or for any consequential damages arising from the purchase or use of the equipment. In no
event shall damages for breach of warranty exceed the purchase price paid to STARMANS
hereunder.
STARMANS reserves the right to modify or change the specifications of its products without notice
and without incurring any responsibility for modifying previously manufactured products.
CALIBRATION INTERVALS
As the manufacturer, STARMANS electronics, Ltd. recommends that our electronic equipment be
calibrated at the end of its one year warranty period and every 12 months thereafter.
!
WARNING:
According to EN 55022 standard, the ultrasonic flaw
detector DIO 1000 meets requirements for class A only!
Contents
1. DIO 1000 Introduction ...................................................................................... 10
1.1 General Description ................................................................................................10
1.2 Unpacking ..............................................................................................................11
1.3 Operating Environment ...........................................................................................11
1.4 Power Requirements ..............................................................................................11
1.5 Language Setting ...................................................................................................11
1.6 Default Settings ......................................................................................................11
1.7 Top Panel Connectors ............................................................................................12
2. Specifications ................................................................................................... 13
2.1 Connectors and Communication Ports....................................................................14
Esc
3.2 Escape Key ....................................................................................................16
3.11 Lock................................................................................................................23
7. Applications ...................................................................................................... 65
7.1 Automatic Thickness Measurement ........................................................................65
7.2 Automatic Calibration of Probe Delay and Sound Velocity ......................................66
7.3 Distance-Amplitude Correction Function (DAC) ......................................................69
7.3.1 General ........................................................................................................................... 69
7.3.2 DAC Interpolation Modes (DAC INTERP.) ..................................................................... 69
7.3.3 DAC Modes (DAC MODE) ............................................................................................. 69
7.3.4 Setting of The Reference (Basic) DAC Curve (DAC TYPE 1) ....................................... 70
7.3.5 Setting of Auxiliary DAC Curves (DAC TYPE 2 to DAC TYPE 5) .................................. 71
7.3.6 JIS-DAC .......................................................................................................................... 72
7.3.7 TCG Modes (Time Corrected Gain) ............................................................................... 73
The DIO 1000 has a large number of standard features, high contrast, high resolution
translucent color LCD display (1024768 pixels) and the capability to store and recall
dozens instrument set-up programs, thousands A-scans, including distance
amplitude correction (DAC) and a low noise receiver with selectable RF and detected
displays.
The expanded top panel has seven connectors including two LEMOs for probes
connection (plus one wide connector for PA probe DIO 1000-PA only) and five
special connectors for synchronization, alarm and analog outputs, encoder (IRC)
connection, USB and power connector.
Notwithstanding of its of its digital signal processing, the DIO 1000 retains the high
repetition rate capability and superior waveform display.
Version 5.01 July 2012 / SW Version: 2012.06.12 DIO 1000 Introduction
1.2 Unpacking
All cartons should be opened and inspected upon receipt. The cartons and contents
should be inspected for any signs of damage that may have occurred during
shipment. If damage is noted, contact the carrier and retain the damaged shipping
materials until an inspection can be performed by a representative of the carrier. With
the exception of external accessories, all DIO 1000 options are installed before the
unit is shipped. Check the contents of the carton or cartons against the purchase
order to ensure that all accessories ordered have been received.
The DIO 1000 is designed as a portable instrument, and as such requires no special
site preparation before operation. When operated, the instrument should be firmly
supported on its tilt handle to prevent damage due to a fall. The unit should be
protected as much as possible from water or chemical splashes, rapid temperature
changes, or areas near large electrical equipment that may interfere with the
operation of the internal circuitry.
The battery charger (power unit) is provided with the DIO 1000, which allows the
instrument to be operated from the Li-Ion battery or from AC line power in the range
of 100-240 Volts at a line frequency of 50 to 60 Hz.
The default settings of the instrument may be restored any time simply by depressing
? key, then SETUPS DEFAULT and confirm YES .
All special functions will be set OFF and the instrument will operate in the BASIC
mode. Then select the TR MODE (see 4.1.4. TR MODE Transmitter/Receiver
Mode), unlock the HW_SET (see 4.1. Basic Menu) and check initial settings.
Seven external connectors are provided on the DIO 1000 top panel (refer to
Figures 2a, 2b).
PA probe
2. Specifications
Pulser
Type Square wave
Pulse Amplitude Selectable from 75 to 275 Volts in 5 V steps
Pulse Width 15 to 5000 ns
Pulse Repetition Rate 10 Hz to 20 kHz
Pulser Excitation Spike (1 pulse) or Burst (1 to 10 pulses)
Modes SINGLE (Pulse Echo), DUAL (Dual or Through
Transmit), EMAT
Receiver
Bandwidth 0.5 to 30 MHz (at -3 dB)
Frequency Filters Broadband, Narrowband, or Custom Selectable
Low and High Pass Filters 1.0 MHz, 2.0 MHz,
2.25 MHz, 4.0 MHz, 5.0 MHz, 10.0 MHz
Damping Selection values: 42, 51, 180 or 1000 Ohms
Gain Control Range 0 to 111.0 dB
Gain Control Steps Selectable 0.1, 0.5, 1.0 and 6.0 dB
Display RF, Half-wave+, Half-wave-, Full-wave
Reject 0 to 80 % full screen height in 1 % steps
Time Base
Test Range 1.9 mm to 14353.0 mm at 200 Hz PRF in steel (for
cL = 5990 m/s), max. 298901 mm at 10 Hz PRF
Probe Delay Range -10.00 s to 4800.00 s
Display Delay Range -8.50 s to 4774.69 s
(-25 mm to 14300 mm at cL = 5990 m/s)
Material Velocity 1 to 19999 m/s
Angle Beam Control Fixed settings of 0, 30, 45, 60, 70, 80,
or variable from 0 to 90 in 0.1 increments
Gates
Four independent gates controllable over entire sweep range
- Floating gate,
- Interface gate,
- Measuring gate relative, absolute, amplitude, time
- Back-wall echo attenuator
Threshold Variable 2.0 to 97.8 % of full screen
Trigger Logic Positive or Negative
Gate Synchronization Initial Pulse or selected interface
Analog Output
Note: We strongly recommend to use original cables from STARMANS for all
connectors.
T Transmitter (Pulser).
R Receiver.
ANALOG OUT (for details see 6. Functions of Analog Output):
TTLout
- TTLout: - synchronization pulses output with positive GND AOUT2
logic; can be used for generator RxD AOUT1
General
Dimensions 22418837 mm
Display Color TFT 9930 mm (1024768 pixels)
65535 colors
Weight 0.74 Kg without battery
+ 0.54 kg battery for 8 hours operation
Operating Temperature -10 C to 50 C
Storage Temperature -40 C to 70 C
Power 100-240 VAC, 50 to 60 Hz, 50 VA max. for battery
charging and operation
Battery Built-in rechargeable Li-Ion battery pack,
3.6 V, 16 Ah
3. Keyboard Description
Control Keys for Values Changing
Power
Escape Key ON/OFF
Immediate
Execution
Keys
Display Freeze Save Quick Save Help
ON/OFF Setup / Picture Picture
Display Load Zoom Lock
Brightness Setup / Picture
The POWER button switches instrument power ON and OFF. Immediately after
power is turned ON, an initialization routine is started. During the start-up routine, the
instruments microprocessor measures and corrects circuit offsets. Also, the
microprocessor verifies that all circuits are operating properly.
After the Check and then press Lock for pulser enable.. message had been
displayed, make sure that the appropriate probe (transducer) is connected properly
and depress the key in order to activate pulser.
NOTE: Long depressing the button will switch OFF the instrument, without
saving last settings conditions.
Esc
3.2 Escape Key
Within the Basic MENU, after Esc key had been depressed, the instrument may be
switched OFF with or without saving the actual settings. SAVE & EXIT & OFF message
will be displayed at the display bottom. Depress the appropriate yellow Execution Key:
- YES the instrument will be switched OFF with saving last settings conditions;
- CANCEL return to the previous operation mode.
Within any other menu, Esc key will turn back into the Basic MENU see 4.1.
These keys provide execution of the menu item displayed just above them.
Default display brightness value is 50 %. This setting is not saved in the last status.
If any key had not been depressed during 2 minutes, then display brightness
decreases automatically, in order to save battery.
This power saving mode is indicated by text *for PWS OFF in the status window.
First depressing of any key within power saving mode will only restore the initial
brightness, but will have no other effect no action. Only next depressing of any
key will take effect.
In order to deactivate the power saving mode, depress the key. This
deactivates the power saving mode until the instrument switched OFF.
When the battery voltage decreased under the critical level (approx. 5 % of estimated
capacity), the brightness will go down indefinitely, to avoid sudden shut-down of the
instrument, e.g. caused by settings with higher energy consumption.
NOTES: The actual setup number (setup position) is displayed above the
SET_XXx, if t had been saved previously.
Depressing yellow keys below the STORE SETUP ? will trigger ERASE
SETUP ? , enabling erase any of 6 setups.
key enables quick save picture (frozen or live see 3.4). A picture with
appropriate data will be saved to the preset group. The picture file name (as well as
appropriate data files) is generated automatically and always includes a prefix (if any
had been specified in advance) and timestamp, i.e. Pxx_PREFIX_timestamp.*
see 3.6.2. Save Picture (Screenshot).
3.9 Zoom
3.11 Lock
After the instrument power ON or Transmitter Mode change, the pulser is OFF, in
order to prevent accidental probe damage with built-in preamplifier. Make sure that
the probe is connected properly, then enable the pulser by short depressing of the
key.
Long depressing (longer than 3 sec) the key will lock/unlock the instrument
*LOCKED* indication will appear in the lower right corner.
Instrument settings cannot be changed in the *LOCKED* mode, as all side keys (for
parameters settings) are inactive.
Only keys of context items (which dont affect operation) in the bottom row of the
display are active:
Some function keys remain active also: (Freeze), (Save for pictures only
see 3.6.2. Save Picture (Screenshot)), (Load for setups and pictures see
3.7.1. Load Setup and 3.7.2. Load Picture), (Quick Save Picture see 3.8.
Quick Save Picture(Screenshot)) ? (Help for help pictures only) and (Lock
for unlock the instrument).
NOTE: Short depressing the key will switch OFF/ON high voltage and pulser.
It is recommended to switch the pulser OFF during probe exchange as well
as for battery saving during interruptions.
4. Menu Description
Note: The active menu item is always highlighted with green background of the
menu item text.
RF radio-frequency (alternating);
4.1.3 GATE ^
Adjustment of the gate vertical position actual
gate number (activated in the GATES menu see 4.4) is indicated in parentheses next
to the gate vertical position value.
Info about actual transmitter/receiver mode is displayed just beneath the TR MODE.
In order to activate the pulser after TR MODE had been changed, depress the key.
4.1.7 GAIN
Adjustment of the input gain value 0.0 dB
to 111.0 dB. See also NOTES in 4.2.6.
4.1.8 STEP G
Selection of the gain change step value:
- 0.1 dB;
- 0.5 dB;
- 1.0 dB;
- 6.0 dB.
4.1.9 FILTER
Selection of frequency band filters (these
frequency values are valid for SF instrument
only):
- OFF,
- 1.0 MHz,
- 2.0 MHz,
- 2.25-2.5 MHz,
- 4.0 MHz,
- 5.0 MHz,
- 10.0 MHz.
4.1.10 VOLTAGE
Adjustment of the pulser voltage value 75 to 275 Volts.
4.1.11 VELOCITY
Adjustment of the sound velocity value in the tested material 1 m/s to 19999 m/s.
For convenient setting, there are predefined sound velocities in most frequently used
materials. During setting the velocity value, value stops at predefined velocities.
The table containing predefined sound velocities is defined in the
dio1000\lang\help\matvel_def.txt file, which can be easily edited and loaded for USB
device as other HELP files see 10.6. Management of User Help.
This file can be displayed during browsing. If this file not found, the table is filled with
default values (as in older SW versions).
4.1.12 RANGE
Adjustment of the time base (sweep) range 1.9 mm to 298901.0 mm for
longitudinal wave in steel (cL = 5990 m/s) (at PRF of 10 Hz) two bottom keys on
the right side.
The maximum RANGE value is automatically limited depending on the PRF (Pulse
Repetition Frequency) value set in HW_SET menu see 4.2. In order to allow higher
RANGE value, the PRF value shall be lowered accordingly see 4.2.8. PRF.
There are automatic PRF modes available for 200, 100, 50, 20 Hz (indicated by
AUTO next to the PRF value), i.e. maximum possible PRF value is decreased
automatically, when the RANGE value is increased and vice versa, if the RANGE
value is shortened, then the PRF value increases up to the preset value.
For the RANGE values < 35.0 mm, the waveform is expanded digitally this is
indicated with asterisk symbol (*RANGE: ##.#mm).
4.2.1 BANDWIDTH
Switches the bandwidth range: 0.5 - 6 MHz,
3.5 - 6 MHz, 0.5 - 12 MHz, 3.5 - 12 MHz,
0.5 - 25 MHz, 3.5 - 25 MHz, 0.5 50 MHz,
3.5 50 MHz, 0.5 - 100 MHz, 3.5 - 100 MHz,
0.5 200 MHz, 3.5 200 MHz.
Note: Bandwidth is a combination of analog
pass band and FIR filters.
4.2.2 AVERAGING
Switches the averaging function of digital signal processing the resulting displayed
signal amplitude is equal to the average amplitude of 2, 4, 8, 16, 32 or 64
consecutive signals.
Note: Averaging function is applied to limited A-Scan range (intended mainly for
EMAT). At the RANGE over approx. 250 mm (for longitudinal wave in steel),
the rest of the signal is not averaged this is indicated by changing the
RANGE indicator colour to red.
4.2.3 DETECTOR
Switches the detector modes:
- FULL W (rectified full-wave);
- NEG HW (rectified negative half-wave);
- POS HW (rectified positive half-wave).
4.2.4 TR MODE
Switches the Transmitter/Receiver modes for details see 4.1.4:
- SINGLE (for single element probe);
- DUAL (for dual element probe T/R);
- DUAL+ExtAmp (for special dual element probe with built-in preamplifier);
- EMAT (for special EMAT probe with Electro-Magnetic Acoustic Transducer).
4.2.5 P.WIDTH
Adjustment of the pulse width, in relation to the pulse frequency (P.FREQ).
4.2.6 ATT
Selection of the pre-attenuator:
- AUTO;
- 0 dB;
- -20 dB;
- -40 dB.
NOTES: With pre-attenuator set to AUTO, some discontinuity of the GAIN may occur
at 20 dB and 40 dB, therefore, linearity is not guaranteed.
The same GAIN value with different ATT values may show different noise
level.
The best signal-to-noise ratio will be achieved with ATT set to AUTO,
i.e. the best combination of gain and attenuator
Selection ATT value other than AUTO will change available GAIN range as
follows:
- AUTO GAIN range 0 111 dB;
- 0 dB GAIN range 0 71 dB;
- -20 dB GAIN range 20 91 dB;
- -40 dB GAIN range 40 111 dB.
4.2.7 DAMP
Adjustment of the receiver damping (impedance):
- 42 Ohms;
- 51 Ohms;
- 180 Ohms;
- 1000 Ohms.
4.2.8 PRF
Adjustment of the Pulse Repetition Frequency in steps: 10, 20, 50, 100, 200, 500,
1000, 2000, 2500, 4000, 5000, 6000, 7000, 8000, 9000, 10000, 11000, 12000,
13000, 14000, 15000, 16000, 17000, 18000, 19000, 20000 Hz.
Maximum PRF is limited depending on the actual time base RANGE.
Therefore, if the next higher PRF value is too high for the actual RANGE value,
then >--<<?? appears instead of the PRF value. Nevertheless, if the right side button
had been depressed once more, then the PRF increases to the next higher value,
and at the same time, the RANGE value automatically decreases accordingly.
There are automatic PRF modes available for 200, 100, 50, 20 Hz (indicated by
AUTO next to the PRF value), i.e. maximum possible PRF value is decreased
automatically, when the RANGE value is increased and vice versa, if the RANGE
value is shortened, then the PRF value increases up to the preset value.
4.2.9 SPIKE/BURST
Selection of the pulser mode:
SPIKE low energy, single pulse;
BURST high energy, single pulse or series of pulses, max. 10.
4.2.10 P.FREQ
Adjustment of the pulse main frequency: 0.10 to 33.33 MHz.
With DGS set ON (see SETTING CURVES DGS, 7.4), DGS key will
be displayed instead of DAC key.
DAC+TCG and TCG modes may be activated only after reference DAC
curve had been established see 7.3.4.
DAC+TCG and TCG modes may be activated only with TCG ENABLE
see 4.8. CURVES Sub-Menu (SETTING) and 4.8.2.
The DAC key activates amplitude correction functions as follows (see 7.3.7):
- depressed once, the DAC button (green background) indicates active Distance-
Amplitude-Correction mode;
- depressed twice, the DAC+TCG button (green background) indicates active
Distance-Amplitude-Correction + Time-Corrected-Gain mode;
- depressed triple, the TCG button (green background) indicates active Time-
Corrected-Gain mode.
4.3.3 GATE ^
Adjustment of the gate vertical position actual gate number (activated in
the GATES menu see 4.4) is indicated in parentheses next to the gate vertical
position value.
4.3.6 GAIN
Adjustment of the input gain value 0.0 dB to 111.0 dB. See also NOTES in 4.2.6.
4.3.7 STEP G
Changes the gain step value 0.1 dB, 0.5 dB, 1.0 dB and 6.0 dB steps.
4.4.3 GATE ^
Adjustment of the gate vertical position actual gate number is indicated in parentheses
next to the gate vertical position value.
4.4.4 GATE
Switches the actual gate number makes it accessible for adjustments. Actual gate
number is displayed with appropriate gate colour.
4.4.5 GATE #
Switches actual gate ON/OFF and its modes as follows:
GATE 2 measures always against Gate 1 see 5.2 for details options are:
OFF inactive not displayed;
THICKNESS AUTO 1P-1P A-P 1st peak to 1st peak see 5.2.2 for details;
THICKNESS 1P-1P P-P 1st peak to 1st peak see 5.2.3 for details;
THICKNESS F-F F-F flank to flank see 5.2.4 for details;
THICKNESS P-P M-M peak to peak see 5.2.5 for details.
GATE 3 measures position and peak echo amplitude see 5.3 for details options
are:
OFF inactive not displayed;
ON 3 (positive logic) without any alarm;
ON + 3 + (positive logic) with acoustic alarm;
ON - 3 - (negative logic) with acoustic alarm;
AUTOFREEZE AF automatic freezing of actual picture (screenshot).
4.4.6 GAIN
Adjustment of the input gain value 0.0 dB to 111.0 dB. See also NOTES in 4.2.6.
4.4.7 STEP G
Changes the gain step value 0.1 dB, 0.5 dB, 1.0 dB and 6.0 dB steps.
4.4.8 REJECT
Adjustment of the reject level all signals below this level will be neither displayed
nor evaluated.
4.4.9 THICKNESS
- Adjustment of minimum thickness value for automated thickness measurement
using Gate 2 this value must be lower than any really expected thickness to be
measured.
- Adjustment of nominal thickness line in the B-scan thickness measuring mode.
4.4.10 VELOCITY
Adjustment of the sound velocity value in the tested material 1 m/s to 19999 m/s.
For details see 4.1.11. VELOCITY.
4.5.1.3 GATE ^
Adjustment of the gate vertical position actual gate number (activated in GATES
menu see 4.4) is indicated in parentheses next to the gate vertical position value.
4.5.1.4 TR MODE
Switches the transmitter/receiver modes see 4.1.4 for details.
4.5.1.6 GAIN
Adjustment of the input gain value 0.0 dB to 111.0 dB. See also NOTES in 4.2.6.
4.5.1.9 THICKNESS
- Adjustment of minimum thickness value for automated thickness measurement using
Gate 2 this value must be lower than any really expected thickness to be measured.
- Adjustment of nominal thickness line in the B-scan thickness measuring mode.
4.5.1.10 VELOCITY
Adjustment of the sound velocity value in the tested material 1 m/s to 19999 m/s.
For details see 4.1.11. VELOCITY.
NOTE: For better visibility in any mode, menu descriptions may be hidden by
depressing the MENU key.
If an incremental encoder (IRC) had been connected to the instrument, then BSCAN
deployment depends on incoming pulses rate IRC_RATE.
IRC_RATE value (in SETTING DISPLAY sub-menu see 4.7.6 in 4.7. DISPLAY
Sub-Menu (SETTING)) determines number of pulses per one scan line in the graph.
Negative IRC_RATE value enables reverse co-ordinates to match probe movement
direction with BSCAN orientation on the screen.
In order to use B-Scan for thickness measuring, the following conditions need to be
fulfilled see also 7.1. Automatic Thickness Measurement:
5) Set the materil thickness and probe angle for the bottom reflection at chosen
probe distance
6) In order to enable correct basic measurings, set the correct VELOCITY for used
ultrasonic wave.
9) If there is any discontinuity in the weld axis, then another echo appears between
two echoes, Gate1 start point should be set to the lateral echo (which is
constant for given distance between probes), and the end point should be set to
the evaluated echo. Approximate reflector depth D=xx will be calculated based
on the time difference between lateral and discontinuity echoes and the distance
between probes 2S; the D value is displayed blue next to the gate, S is only for
information regarding the distance from probes to the weld axis.
Each time after BSCAN had been activated, measured thickness values are recorded
to the memory in a temporary file.
In order to save actually measured data, depress the Display Freeze key and save
the picture see 3.6.2. Data of the last measured scan will be saved to the file with
the same name, as actual picture (Pnn.dddddd, but with .txt extension). The data
file length is limited to 500 kB.
Each line of the data file (.txt) contains measured value in mm (2 decimal positions)
or inches (3 decimal positions), depending on actual settings:
XXX.XX <cr><lf>
If incremental encoder (IRC) had been connected, then each line of the data file (.txt)
contains actual co-ordinate as well:
NNNN; XXX.XX <cr><lf>
The data file format enables simple import to MS Excel etc. Dot (not comma) is used
as a decimal separator.
For saving data to USB memory stick see 10.3. Save Pictures (Screenshots) And
Data To USB Memory Stick.
4.6.4 DIAMETER
Adjustment of actual surface curvature diameter of the test surface, when INSIDE
or OUTSIDE option is active.
4.6.6 GAIN
Adjustment of the input gain value 0.0 dB to 111.0 dB. See also NOTES in 4.2.6.
4.6.7 ANGLE
Adjustment of the angle value for angle beam probe OFF, 1.0 to 89.0.
4.6.8 X-VALUE
Adjustment of the x-point of the angle probe 0.0 mm to 100.0 mm (this button is
active only if the ANGLE is different from zero).
4.6.9 THICKNESS
Adjustment of thickness value (distance D to the opposite reflecting surface) for
proper calculations of S (sound path) and P (projection distance) values with angle
beam probe.
4.6.10 VELOCITY
Adjustment of the sound velocity value in the tested material 1 m/s to 19999 m/s.
For details see 4.1.11. VELOCITY.
4.7.1 LANGUAGE
Setting of interface language using
appropriate left or right button:
- 0 = English,
- 1 = Japan,
- 2 = Czech,
- 3 = Russian,
- 4 = Turkish,
- 5 = Chinese,
- 6 = German.
4.7.2 UNITS
Setting of measuring units for time base and all calculated values mm / inches /
microseconds (s). Available settings are as follows:
- mm & s push once the left (yellow) button;
- mm initial (default) setting;
- inch push once the right (grey) button;
- inch & s push twice right (grey) button.
NOTES: With the s option activated, the following data will be calculated and
displayed in microseconds: S-axis (sound path), positions of all gates,
positions of measured echoes, distance between echoes (measured
thickness), attenuation correction in dB/s. All other values remain
unchanged, e.g. for angle probe, P (projection distance) and D (depth) in
mm (inches), thickness diagram and the BSCAN mapping min/max.
When A.CALIB had been activated, the microsecond units will be
automatically switched off.
The time base settings in s a saved in setups separately, as well as units
mm/inch; setups saved with older SW versions (using Velocity 2000 m/s)
will be loaded with units set to s automatically.
4.7.3 FILL
Setting of the envelope background colour:
- OFF;
- ON [1] filled envelope (with transparent light-green background);
- ON [2] filled envelope (with yellow background).
4.7.4 GRID
Setting of vertical grid display:
- OFF;
- DYNAMIC positions of vertical lines change depending on the time base range;
- FIXED there are 10 fixed vertical lines through the full screen width.
4.7.6 IRC
Switching ON / OFF the incremental sensor (encoder) function.
With IRC ON and encoder connected to the MULTI connector (see 1.7 and 2.1), a
diagnostic squares will appear, showing actual state of A/B and C inputs as well as
IRC=xx status for simple calibration:
- run with encoder some length (e.g. 1 m),
- read the IRC value, i.e. number of pulses,
- set the IRC RES value (in increments/meter) as IRC_value/length.
NOTE: The appropriate encoder (IRC) type shall be set in the Help menu ?
see 3.10 MULTI MODE as follows:
- IRC A & C for encoder without direction resolution;
- IRC A,B & C for encoder with direction resolution.
Input C is used for encoder resetting (to zero), if the encored is equipped with
additional switch.
4.7.10 ENVELOPE
Switching ON / OFF the envelope. Applying the envelope to the processed signal
(the red indicator *ENV* appears below the A-Scan window).
NOTE: This function is the same as that one set in the Basic menu by cyclic
depressing RF/FW* key see 4.1. Basic Menu.
4.8.1 DGS
Switching ON / OFF the DGS function see
7.4. DGS Function.
4.8.2 TCG
Switching ENABLE / DISABLE the TCG (Time Corrected Gain) mode see 7.3.7.
TCG Modes (Time Corrected Gain)
4.9.6 GAIN
Adjustment of the input gain value 0.0 dB to 111.0 dB. See also NOTES in 4.2.6.
4.9.7 ANGLE
Adjustment of the angle value for angle beam probe OFF, 1.0 to 89.0.
4.9.8 X-VALUE
Adjustment of the x-point of the angle probe 0.0 mm to 100.0 mm (this button is
active only if the ANGLE is different from zero).
5. Functions of Gates
Default conditions are:
- GATE 2, 3, 4 OFF;
- GATE 1 ON;
- ANGLE OFF;
- DAC OFF.
5.1 GATE 1
- (3) D=XXmm calculated depth of the indication (maximum echo peak within
the GATE 1, marked with blue cross );
- (4) maximum echo peak (marked with blue cross ) relative amplitude against
the GATE 1 [dB] (not active in RF display mode);
- (5) maximum echo peak (marked with blue cross ) absolute height within the
GATE 1 [% FSH];
- (6) P projection distance from the probe X-point to the maximum echo peak
(marked with blue cross ) within the GATE 1.
- ON+AUX: analog output may be switched ON. There is a signal on the AOUT1
output (LEMO Analog Out), with voltage corresponding to relative echo position
within GATE 1 (see also 6. Functions of Analog Output):
minU = GATE1_BEGIN;
maxU = GATE1_END.
5.2 GATE 2
IMPORTANT: ANGLE and DAC functions shall be OFF for proper thickness
measurement!!!
- THICKNESS AUTO 1P-1P 1st peak to 1st peak see 5.2.2 for details;
- THICKNESS 1P-1P 1st peak to 1st peak see 5.2.3 for details;
- With proper GATE 1 position, width and minimum thickness setting, you can get
automatic thickness gauge, operating within wide range, which doesnt require any
operators intervention.
- If measured values are very unstable and their variation exceeds certain limit, then
minimum measured value will be displayed, because highly probably there is
some unwanted echo within the gate, which interferes with measuring.
5.3 GATE 3
- AUTOFREEZE any signal within GATE 3 level, which exceeds the gate level
for 1 sec. or more, will cause automatic freezing of actual picture (screenshot),
indicated by the red indicator *FROZEN*. The picture then may be saved see
3.6.2. This function is used with SPOT WELD mode (optional).
Actual GAIN correction (GATE 3 XX.X dB) is displayed at the center of the right
section of the display (instead the REJECT value) in the GATES menu with GATE 3
switched on (ON, ON + or ON -).
Notes: If required gain correction within GATE 3 cannot be executed due to actual
setting of the attenuator and basic GAIN, a figure of the gain correction is
displayed in red colour.
Info about actual gain correction is displayed with small text directly under
GATE 3 ON.
5.4 GATE 4
Undefined
ON any 4.1V
(used internally for ver.C)
ON+A/TTL any Gate1 eco logic TTL output 0V / 4.7V no echo / echo
ON+AUX OFF Gate1 echo amplitude 0V to 4.1V 0 % - 100 % screen
ON+AUX Thickness Gate1-Gate2 Thickness 0V to 4.1V 0 to BSCAN_MAX
Positive pulse on
cycle start, 10 s
Firmware since Jan 2012 Sync pulses with PRF freq. 0V / 4.7V duration, falling
edge matches TX
pulse
Analog output of measured thickness is enabled, when the GATE 1 is switched to the
ON+AUX mode, and GATE 2 is switched to any thickness measuring mode.
Signal with voltage corresponding to thickness measured in each cycle is present on
AOUT2 output (LEMO Analog Output see 1.7 and 2.1) as follows:
- minU=0mm;
- maxU=[BSCAN MAX]mm value BSCAN MAX, which had been set in BSCAN
menu see 4.5;
7. Applications
In the SETTING menu, depress the A.CALIB key in order to activate auto-calibration
mode. The beginning of time base will be moved to the initial pulse, and range
and gate will be adapted accordingly automatically.
If operator doesnt want to change any range and gate settings automatically, then
button may be used for switch directly to the Settings menu.
Notes: The example below describes Auto-calibration procedure with the Test Block
No.1 (EN 12223) and 45 angle probe.
This Auto-calibration procedure is applicable using any other sample with
known thickness (sound path), e.g. Test Block No.2 (EN 27963), and/or any
other probe (e.g. dual or single element straight probe) as well.
Position of echo flank within GATE1 will be used for Auto-calibration,
therefore it is advisable to adjust the echo height just above the GATE1
during measuring both S1 and S2 echoes, in order to minimize difference
between echo flank and echo peak readings.
7.3.1 General
A DAC curve may be set depending on application requirements in different modes
see also 4.8. CURVES Sub-Menu (SETTING):
Notes: Cross mark, indicating the echo peak against DAC, is red, when over the
curve, or pink, when its position is known (within the GATE 1 range).
In the DAC mode, echo dB value and position are related to the curve, not to
the horizontal gate.
DAC curve may be constructed using up to 20 points, which may be set in
any order they will be automatically arranged in the ascending order.
- FIXED - the DAC curve will not change its position, when the GAIN
value changes;
- NORMAL - the DAC curve moves accordingly to the GAIN value change,
i.e. trigger level is constant.
5. Repeat steps 3 and 4 for the rest auxiliary DAC curves and dB differences.
7.3.6 JIS-DAC
JIS-DAC mode (Japanese standard) is
similar to common DAC mode.
The difference compared to DAC is that 5 (five) auxiliary curves will be set
automatically with fixed predefined offsets:
L-LINE -12 dB (light blue);
M-LINE -6 dB (magenta);
H-LINE 0 dB (pink dashed basic curve);
U-LINE +6 dB (red);
U-LINE +12 dB (orange);
U-LINE +18 dB (yellow).
In the Status Window, an indication within the GATE 1 range is assigned to one of
seven zones (I to VII), in addition to relative dB value:
Zone I below L-LINE;
Zone II between L-LINE and M-LINE;
Zone III between M-LINE and H-LINE;
Zone IV between H-LINE and U-LINE;
Zone V between U-LINE and U-LINE;
Zone VI between U-LINE and U-LINE;
Zone VII above U-LINE.
The TCG mode shall be enabled (TCG ENABLE) in the CURVES submenu see
4.8.2. See also 4.3 for activation of DAC modes.
In order to use DAC+TCG or TCG mode, the reference (basic) DAC curve
(DAC TYPE 1) shall be set in advance see 7.3.4. Setting of The Reference
(Basic) DAC Curve (DAC TYPE 1).
In order to use the DGS function, the following conditions must be fulfilled:
all appropriate probe parameters shall be set in the PROBE sib-menu see
4.9. PROBE Sub-Menu (SETTING);
attenuation in the reference block shall be known (measured);
attenuation in the object under test shall be known (measured).
11. To return to the reference DGS curve, depress the REF ECHO <-- button.
Notes: API 5UE mode shall be OFF see 4.8. CURVES Sub-Menu (SETTING).
11. Depress --- ADD button to record the reference point. The reference
evaluation curve appears at the echo peak level, with AWS REF indicator
just above the "DEL ---".
12. The measured value is displayed in the Status Window as AWS d=
13. If CLASS DISP is ENABLE and AWS value had been measured and is valid,
then corresponding classification A, B, C, D is calculated and displayed as
yellow-black next to the result.
Notes: GATE 4 has its own velocity, which can be set in range from 1 m/s up to
20000 m/s.
3. With active FREEZE MAX mode, move probe over a calibration notch in the
reference block and get envelope shape. Bring GATE 4 over the echo and
adjust VELOCITY value (pink for GATE 4) to get calibrated size of the
reference notch.
The value is displayed in Status Window as API fx= xx.xx [mm or inch]. In order to
display value of the notch under the test, echo from the notch shall cross the GATE 4
level GATE 4 level shall be adjusted accordingly.
The width of peak at half level of echo amplitude measured with GATE 4 is used for
calculation, velocity multiplied by amplitude/100% FSR (Full Screen Range), so if
echo peak is 100% of screen, then coef = 1.
API 5UE function works in combination with all other modes, except RF mode. When
AWS function is activated, value is displayed on the same position in Status Window
as API value, but when FREEZE MAX is activated, API 5UE has preference.
The curved surface metric is very useful function for inspection with angle probe on
curved surface of object to be inspected. This function may be activated from within
the SETTING menu see 4.6.
Some parameters of angle probe shall be set in the SETTING menu prior to use this
function: ANGLE and X-VALUE. Then actual geometrical parameters of the object to
be inspected shall be set as well: CURVED SURF. INSIDE (concave) or
OUTSIDE (convex); DIAMETER and THICKNESS. The skip lengths are calculated
automatically and displayed as white zigzag line in the upper part of the screen.
The symbols /\/\ next to the sound path value S in the Status Window indicate, in
which half skip is flaw located.
If a relation of outside diameter D and thickness T is D <= 2*T, then material will be
considered as full and the cutting reflex is assumed. In such case, the symbol (O)
under the DIAMETER value is changed to O; in addition, SKIP XX.X mm is changed
to SKIP (\) XX.X mm.
If the combination of sizes is nonsense, then projection distance axis ~Pmm], P and
D values are not displayed, with pink SKIP error message under the CURVED
SURF.
Connect the EMAT probe to the instrument. Pay attention to the proper connections
of probe cables. The cable from the probe receiver shall not be connected to the
output connector of DIO 1000 otherwise built-in preamplifier in the probe will
be damaged.
1. Turn TR MODE to the BASIC MODE depress right (dark) button and confirm
YES, if the instrument had been set to ENHANCED MODE.
Other parameters settings depend on probe type, material to be tested etc. and may
be set in HW_SET menu for experienced operators only.
Dio1000 can be synchronized with another Dio1000 instrument (or generator) via
MULTI and ANALOG OUT outputs using the following connection diagram:
C A IRC B IRC B C A
B B
IRC A IRC A
Settings of Dio1000:
HW_SET/ Puse repetition rate (PRF [Hz]) value for Master device must be
lower than for Slave device for setting see 4.2. HW_SET Menu >
4.2.8. PRF.
TTL OUT is used as output of SYNC pulses for both devices positive pulse
4.7V on cycle start, 10 s duration, falling edge matches TX pulse. These
pulses are present on TTL OUT always, independently on MULTI MODE
setting, as SYNC for generator or oscilloscope use GND and TTL OUT for
connection.
AOUT2 was used in firmware until Jan 2012 for SYNC pulses.
NOTE: In order to correct function of S-Scan (Sector scan) the BSCAN MODE
must not be set to THICKNESS in SETTING > DISPLAY menu.
8.2.1 PA WEDGE
The angle of refraction of the plexiglas
wedge attached to the PA probe.
With instrument in the basic PA mode (default), the main functions of standard
ultrasonic flaw detector may be applied, such as DAC, TCG and their combinations.
Descriptions of values in the Status Window
see 5.1.2, 5.1.3, 5.1.4.
Auxiliary lines 1*T and 2*T will be displayed
BW echo
on the S-scan, if they fit within actual time
base range. T=THICKNESS value
in SETTING menu see 4.6.9.
The group of RX channels may be moved within all 16 channels by yellow and grey
Control Keys next to the PA MODE on the display, e.g. for APERTURE 5
Chan 12..16 RX then Chan 11..15 RX etc.
All 16 elements are transmitting phased and
focused wave in this mode, but receiving is
limited to the number of elements, specified
by the APERTURE value.
It may be needed to correct the THICKNESS value as well, for displaying the correct
weld geometry. This parameter is the same as can be seen in the SETTING menu.
All co-ordinates are related to the weld thickness T (T = 1) and shall be expressed
as numbers with decimal point.
Weld configuration diagram can be chosen from the file by depressing the WELD
X of N [Name] (see 8.6.1), where X is sequential number, N is total number of
weld configurations within the file, and [Name] is the name of the weld
configuration diagram within the file.
Since definition file is a text file and is saved in the dio1000\help folder, it can be
easily transferred between the USB device and instrument; also it can be
displayed during viewing the help.
Example 1
Butt V-weld, thickness T = 20 mm
Groove Angle = 60
Groove Bevel = 30
Weld Gap = 2 mm (10 % of T, i.e. 5 % on both sides of the weld axis)
Depth of Groove = 100 %
X1; Y1 X1; Y1
-0.627 -0.05 0 0.05 0.627
-1 1
30 -X +X
20 (T)
1
X2; Y2 2 X2; Y2
Y
Example 2
Butt X-weld, thickness T = 60 mm
Groove Angle on the top = 30
Groove Angle on the bottom = 60
Groove Bevel = 15
Weld Gap = 3 mm (5 % of T, i.e. 2.5 % on both sides of the weld axis)
Depth of Groove = 50 mm, i.e. 83 %
-0.123 -0.025 0 0.025 0.123
X1; Y1 X1; Y1 -0.247 0.247
-1 1
-X +X
15
50
60 (T)
X2; Y2
X2; Y2
0.83
1
3 Y
X3; Y3 X3; Y3
30
Example 3
Fillet weld, thickness T = 15 mm
Groove Angle = 45
Groove Bevel = 45
Weld Gap = 1 mm (6.7 % of T)
Depth of Groove = 13 mm = 87 %
-0.067
-0.937
X1; Y1 X1; Y1
-1 1
0
45
-X +X
1
15
0.87
1
X2; Y2 X2; Y2
X3; Y3 Y
Depress the ? key for access to the special mode (see 3.10) and then
depress SETUPS key for access to MANAGEMENT OF CONFIGURATION FILES
(SETUPS) table.
The actual group number is highlighted on the display in the bottom left corner,
e.g. GROUP 0 .
The actual group number may be selected using Control keys (yellow and grey) next
to the green GROUP .
Saved setups are highlighted (with yellow background) and may have names and/or
descriptions (if had been saved with names and/or descriptions).
NOTE: In order to return to the basic mode, the Esc key may be used instead of
the QUIT key.
NOTES: Any USB function may be cancelled during searching for the disc by
depressing the Esc key.
If there is no dio1000 folder on the USB device (flash memory), then all
appropriate folders will be created automatically.
For proper function of USB device (flash memory), it shall be properly
disconnected from the PC (using appropriate system function), otherwise it
may be recognized by the instrument as Read Only.
- connect the USB memory stick to the USB port of the instrument;
- depress the ? key switch to special help mode;
- depress SETUPS key;
- depress STP->USB key send setups to the USB port, which will be saved in
dio1000\setups\ folder.
Setup files shall be saved from the computer to the USB memory stick in
dio1000\setups\ folder in advance.
- connect the USB memory stick to the USB port of the instrument;
- depress the ? key switch to special help mode;
- depress SETUPS key;
- depress STP<-USB key setups from the USB memory stick will be loaded to the
instrument.
In order to upload pictures, which had been saved in the instrument (see 3.6.2), to
the USB memory stick,
- connect the USB memory stick to the USB port of the instrument;
- activate picture listing mode (see 3.7.2) by depressing the Display Freeze key;
- select the desired memory group (PIC_01 to PIC_09) by depressing the
appropriate Execution Key (yellow) memory group number changes by 1 after
each depressing;
- depress the key the last picture from the list within actual group (in
alphabetical order) will be displayed on the screen;
NOTE: Pictures from the chosen picture group will be saved to USB memory stick
in dio1000/pictures/XX-XXX folder (XX-XXX is the instrument serial No.)
including all appropriate setups and data files.
The complete display content (frozen picture) is saved in .png format to
the chosen picture group.
All setup parameters for each picture are saved in *.stp file, with A-scan in
digital form (*.dat file 1024 max. values for FW waveform and 2048
max.-min. pairs for RF waveform for research purposes or for import to
Excel).
Depending on the EXPORT setting ( csv , csv+html_1 , csv+html_2 ) in
? menu (see 3.10), setup parameters for each picture are saved also in
*.csv file (all parameters with values only) and *.htm file (all parameters with
values, including the screenshot two different formats).
If BSCAN had been activated, then last measured data are saved as well in
*.txt file.
Records (pictures) files shall be saved from the computer to the USB memory stick in
dio1000\pictures\ folder in advance.
- connect the USB memory stick to the USB port of the instrument;
- depress the ? key switch to special help mode;
- depress USB->Pxx key records from the USB memory stick will be loaded to the
instrument.
Complete folder (directory) dio1000 for upgrade, which is distributed via e-mail, is
packed in one ZIP file.
In order to download new firmware, it shall be saved from the computer (PC or
laptop) to the USB flash memory stick extracted to the root of the USB flash
memory stick, strictly retaining the original structure:
..\dio1000
[main files: dio; diomap; fpga; fpga.bin; fpgaomap; fpgapa*)]
\data
[data files] if any not necessary for firmware update
\lang
\help
[help file(s) in .png or .jpg picture format]
[interface language files language_str.txt]
\pictures not necessary for firmware update
[printscreen files .png, associated data and settings files .dat,.stp, .csv, .htm]
\setups not necessary for firmware update
[setup files .txt]
*)
for DIO1000-PA only
IMPORTANT NOTES:
Every time during the firmware update (even with new empty USB
memory stick with no firmware), all saved records (pictures with
settings etc.) will be saved to the USB memory stick in the
/dio1000/pictures folder (if there is enough space on the USB
memory stick) and at the same time all records will be erased in the
instrument.
The USB SDERVICE function may be used also to move All picture records
to the USB device at once. In this case, it is advisable to use empty USB
device with NO Dio1000 folder it will be created automatically. Otherwise,
the firmware will be always re-updated at each start of USB SERVICE.
Records from the USB memory stick may be downloaded back to the
instrument follow the procedure described in 10.4. Load Records From
USB Memory Stick.
The user may prepare his own specific help files using texts, pictures converted to
the .png or .jpg format and/or movies in the .avi or .vob format.
- yellow keys under the file name open the menu for actual file or folder backup
to the USB disc to the /dio1000/files folder;
- HLP<-USB load help file from the USB memory stick;
11. Index
A.CALIB ......................................................... 66 Curved Surface Metric .................................. 78
Acoustic alarm ............................................... 59 CURVES ....................................................... 52
Analog output ................................................ 59 CURVES Sub-Menu ..................................... 52
Functions of ............................................... 64 DAC ......................................................... 32, 69
Thickness measurement ........................... 64 Interpolation Modes ............................ 53, 69
ANGLE........................................................... 48 LINEAR .......................................... 53, 69
APERTURE ................................................... 86 LOG/LINEAR .................................. 53, 69
LOG/LOG ....................................... 53, 69
API 5UE ......................................................... 53
JIS-DAC .................................................... 72
API 5UE Mode ............................................... 77
JIS-DAC6 .................................................. 34
Applications ................................................... 65
Menu ......................................................... 32
Automatic calibration of probe delay and
Modes ................................................. 53, 69
sound velocity ....................................... 66
FIXED ............................................. 53, 69
Automatic thickness measurement ........... 65 NORMAL ........................................ 53, 69
DAC Function ............................................ 69 Setting of auxiliary curves ......................... 71
DGS Function ............................................ 74 Setting of the reference curve .................. 70
ATT ................................................................ 30 DAC Function ................................................ 69
ATT COMP .................................................... 53 DAC INTERP. ......................................... 53, 69
ATT OBJ ........................................................ 75 DAC MODE ............................................. 53, 69
ATT REF ........................................................ 74 DAC TYPE .................................................... 34
Attenuation compensation ............................. 53 DAC+TCG ............................................... 32, 73
AUTOCALIB .................................................. 66 DAMP ............................................................ 30
AUTOFREEZE .............................................. 62 Data Export ................................................... 96
AUTOGAIN .................................................... 22 DATE............................................................. 22
Automatic calibration Date and time setting .................................... 22
A.CALIB ..................................................... 66
Default Settings ............................................. 11
Automatic thickness measurement ............... 65
Default Setup ................................................ 94
AUX LINE OFFSET ....................................... 34
DELAY
AVERAGING ................................................. 29 DISPLAY DELAY ...................................... 27
Averaging function ......................................... 29 PROBE DELAY ........................................ 27
AWS Mode..................................................... 76 DELAY LEN .................................................. 55
AWS MODE ................................................... 53 DELAY VEL................................................... 55
BANDWIDTH ................................................. 29 DETECTOR
Basic Menu .................................................... 24 NEG HW ................................................... 29
BSCAN POS HW ................................................... 29
Data records .............................................. 45 DETECTOR .................................................. 29
Menu ......................................................... 38 FULL W ..................................................... 29
Modes ........................................................ 40 DGS .............................................................. 52
BSCAN MAX ................................................. 39 DGS Function................................................ 74
BSCAN MIN ................................................... 39 Diam eff ......................................................... 54
BSCAN MODE .............................................. 50 DIAMETER.................................................... 47
BURST........................................................... 31 Display .......................................................... 14
BW ........................................................... 52, 74 Brightness ................................................. 17
BW-K1 ..................................................... 52, 74 Freeze ....................................................... 16
Calibration DISPLAY DELAY .......................................... 27
Automatic calibration of probe delay ......... 66 DISPLAY Sub-Menu ..................................... 49
Automatic calibration of sound velocity ..... 66 Distance Gain Size ....................................... 74
Calibration intervals ..................................... 3 Distance-Amplitude Correction ..................... 69
CAMERA ....................................................... 22 DSR ......................................................... 52, 74
Configuration files EMAT Probes ................................................ 79
Management of configuration files ............ 94
ENV ............................................................... 51
Connectors .................................................... 12
Envelope ....................................................... 25
Connectors and Communication Ports .......... 14
ENVELOPE ................................................... 51
CURVED SURF. ...................................... 47, 78