TI-007 manual - Reliability Direct, Inc.
Contents
1. press and hold down the ALRM key 2 Press ON OFF key to power up the unit 3 Release the ALRM key BEEP ON or BEEP OFF will be displayed enabling or disabling the beeper 4 Repeat steps 1 through 3 to toggle between BEEP ON or BEEP OFF Alarm Mode 1 Press ON OFF key to power up the TI 007 2 Press the ALRM key ALAr OFF or ALAr followed by a thickness value and flashing IN or MM symbol will be displayed indicating the alarm mode is enabled 3 Repeat step 2 to toggle between ALAr OFF or ALAr value and flashing IN MM symbol On 4 Assuming ALAr value flashing IN is displayed use the UP and DOWN arrow keys to scroll to the desired Lo alarm value 5 Press the SEND key to select the Lo value entered The Hi value will now be displayed Repeat step 4 select the Hi alarm value 6 The TI 007 is now ready to perform measurements using the Alarm feature Differential Mode In the Quality Control environment it is sometimes necessary to know the difference between a nominal target thickness value and an actual thickness value This feature is also included in the TI 007 With the Differential Mode enabled the TI 007 will display the positive or negative difference from an entered nominal value The following steps out line the procedure for setting up this feature Differential Mode 1 Press ON OFF key to power up the TI 007 2 Press the DIFF key DIFF OFF or DIFF followed by a thickness value and flashing IN2. 1 Make sure the TI 007 is ON 2 Press the CAL key to enter calibration mode If the IN or MM symbol is flashing press the CAL key again so that the IN us or M s symbols are flashing 3 Use the UP and DOWN arrow keys to adjust the displayed velocity up or down until it matches the sound velocity of the material to be measured 4 Press the CAL key once more to exit the calibration mode The TI 007 is now ready to perform measurements NOTE At any time during the calibration procedure IN MM IN us or M s flashing in the display pressing the SCAN key will restore the tool to the factory default sound velocity for steel 0 233 IN us To achieve the most accurate measurements possible it is generally advisable to always calibrate the TI 007 to a sample piece of known thickness Material composition and thus its sound velocity sometimes varies from lot to lot and from manufacturer to manufacturer Calibration to a sample of known thickness will ensure that the tool is set as closely as possible to the sound velocity of the material to be measured 3 0 TI 007 MODES Scan Mode While the TI 007 excels at making single point measurements it is sometimes desirable to examine a larger region searching for the thinnest point The TI 007 includes a feature called Scan Mode which allows it to do just that In normal operation the TI 007 performs and displays four measurements every second which is quite adequate f
3. While it may seem that using a lower frequency transducer might be better in every instance low frequencies are less directional than high frequencies Geometry of the Transducer The physical constraints of the measuring environment sometimes determine a transduc er s suitability for a given job Some transducers may simply be too large to be used in tightly confined areas Also the surface area available for contacting with the transducer may be limited requiring the use of a transducer with a small cone tipped delay line Measuring on a curved surface may require the use of a transducer with a matching curved wearface Temperature of the Material When it is necessary to measure on surfaces that are exceedingly hot special delay lines may be neccessary Additionally care must be taken when performing a Calibration to Known Thickness with a high temperature application See Appendix B for more information on measuring materials with a high temperatures Selection of the proper transducer is often a matter of tradeoffs between various characteristics It may be necessary to experiment with a variety of transducers in order to find one that works well for a given job ELKECTROMATIC can provide assistance in choosing a transducer and offers a broad selection of transducers for evaluation in specialized applications 10 large ranges The 007 provides two simple methods for setting the sound velocity described in the fo
4. of material however will require the use of different transducers Choosing the correct transducer for a job is critical to being able to easily perform accurate and reliable measurements The following paragraphs highlight the important properties of transducers which should be considered when selecting a transducer for a specific job Generally speaking the best transducer for a job is one that sends sufficient ultrasonic energy into the material being measured such that a strong stable echo is received by the TI 007 Several factors affect the strength of ultrasound as it travels These are outlined below Initial Signal Strength The stronger a signal is to begin with the stronger its return echo will be Initial signal strength is largely a factor of the size of the ultrasound emitter in the transducer A large emitting area will send more energy into the material being measured than a small emitting area Thus a so called 1 4 inch transducer will emit a stronger signal than 1 8 inch transducer Absorption and Scattering As ultrasound travels through any material it is partly absorbed If the material through which the sound travels has any grain structure the sound waves will experience scatter ing Both of these effects reduce the strength of the waves and thus the TI 007 s ability to detect the returning echo Higher frequency ultrasound is absorbed and scattered more than ultrasound of a lower frequency
5. removed from the surface the display will hold the last measurement made 5 IMPORTANT 5 0 Occasionally a small film of couplant will be drawn out between the transducer and the surface as the transducer is removed When this happens the TI 007 may perform a mea surement through this couplant film resulting in a measurement that is larger or smaller than it should be This phenomenon is obvious when one thickness value is observed while the transducer is in place and another is observed after the transducer is removed Condition and Preparation of Surfaces In any ultrasonic measurement scenario the shape and roughness of the test surface are of paramount importance Rough uneven surfaces may limit the penetration of ultrasound through the material and result in unstable and therefore unreliable measurements The surface being measured should be clean and free of any small particulate matter rust or scale The presence of such obstructions will prevent the transducer from seating properly against the surface Often a wire brush or scraper will be helpful in cleaning surfaces In more extreme cases rotary sanders or grinding wheels may be used though care must be taken to prevent surface gouging which will inhibit proper transducer coupling Extremely rough surfaces such as the pebble like finish of some cast iron will prove most difficult to measure These kinds of surfaces act on the sound beam like frosted glass on light
6. the display and its various symbols The Keypad This key is used to turn the TI 007 on and off When theTI 007 is turned ON it will first perform a brief display test by illuminating all of the segments in the display After one second the tool will display the internal software version number After displaying the version number the display will show 0 0000 or 0 000 if using metric units indicating the tool is ready for use The TI 007 is turned OFF by pressing the ON OFF key The tool has a special memory that retains all of its settings even when the power is off The tool also features an auto powerdown mode designed to conserve battery life If the tool is idle for 5 minutes it will turn itself off The CAL key is used to enter and exit the TI 007 s calibration mode This CAL mode is used to adjust the sound velocity value that the TI 007 will use when calculating thickness The tool will either calculate the sound velocity from a sample of the material being measured or allow a known velocity value to be entered directly Refer to page 7 for an explanation of the two CAL functions available The IN MM key is used to switch back and forth between English and metric units This key may be used at any time whether the tool is displaying a thickness IN or MM or a velocity value IN us or M s this key is used to increase numeric values on the display An auto repeat function is built in so that when th
7. ING WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED INCLUDING BUT NOT LIMITED TO THE WARRANTY OF MERCHANTABILITY AND FITNESS FOR ANY PARTICULAR PURPOSE OR APPLICATION ELECTROMATIC SHALL NOT BE RESPONSIBLE NOR LIABLE FOR ANY CONSEQUENTIAL DAMAGE OF ANY KIND OR NATURE RESULTING FROM THE USE OF SUPPLIED EQUIPMENT WHETHER SUCH DAMAGE OCCURS OR IS DISCOVERED BEFORE UPON OR AFTER REPLACEMENT OR REPAIR AND WHETHER OR NOT SUCH DAMAGE IS CAUSED BY MANUFAC TURER S OR SUPPLIER S NEGLIGENCE WITHIN ONE YEAR FROM INVOICE DATE Some State jurisdictions or States do not allow the exclusion or limitation of incidental or consequential damages so the above limitation may not apply to you The duration of any implied warranty including without limitation fitness for any particular purpose and merchantability with respect to this product is limited to the duration of the foregoing warranty Some states do not allow limitations on how long an implied warranty lasts but not withstanding this warranty in the absence of such limitations shall extend for one year from the date of invoice ELECTROMACTIC Equipment Co Inc 600 Oakland Ave Cedarhurst NY 11516 USA Tel 1 800 645 4330 Tel 516 295 4300 Fax 516 295 4399 14 2 0 OPERATION The TI 007 interacts with the operator through the membrane keypad and the LCD display The functions of the various keys on the keypad are detailed below followed by an explanation of
8. NOTES 16 OI UT003 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 TABLE OF CONTENTS dete 2 Operation 3 2 1 The Keypad 2 2 The Display 2 3 Transducer 2 4 Making Measurements 2 5 Condition and Preparation of Surfaces 2 6 Selecting Measurement Mode 2 7 Calibration TE007 Modes eg a ee 8 3 1 Scan Mode 3 2 Alarm Mode 3 3 Diff Mode 3 4 5 232 Port Transducer Selection 10 Appendix A Product 11 Appendix B Application Notes 12 Appendix Sound Velocities of Common Materials 13 Warranty Information 14 1 0 INTRODUCTION NOTES The Electromatic Model TI 007 is a precision Ultrasonic Micrometer Based on the same operating principles as sonar the TI 007 is capable of measuring the thickness of various materials with accuracy as high as 0 0001 inches or 0 001 millimeters The principle advantage of ultrasonic measurement over traditional methods is that ultrasonic measurements can be performed with access to only one side of the material being measured This manual is presented in three sections The first section covers operation of the TI 007 and explains the keypad controls and display The sec
9. ackages generally have the ability to capture the screen data to a common text file This text file containing the measurements can then be imported into any common spreadsheet program i e Excel Quattro Pro Lotus123 for further reporting requirements CHECK LINE BY ELECTROMATIC 007 ULTRASONIC MICROMETER CHECK LINE ELECTROMATIC 600 Oakland Ave Cedarhurst NY 11516 U S A TEL 516 295 4300 FAX 516 295 4399
10. d on pressing the ALRM key will toggle the alarm mode to the on off positions and allow the user to enter a nominal thickness value Refer to page 8 for details on how to use the alarm feature The DIFF key is used to enable or disable the Differential mode and allow the DIFF user to enter a nominal value as a comparison against actual thickness measure ments Refer to page 9 for a complete explanation of this feature The SEND key is used to send the currently displayed thickness measurement 5 to an external storage device via the TI 007 s RS232 port Refer to page 9 for an explanation of how to use this feature The Display The numeric portion of the display consists of four complete digits preceded by a leading 1 and is used to display numeric values as well as occasional simple words to indicate the status of various settings When the TI 007 is displaying thickness measurements the display will hold the last value measured until a new measurement is made Additionally when the battery voltage is low the entire display will begin to flash When this occurs the batteries should be replaced These eight vertical bars form the Stability Indicator When the TI 007 is idle only the left most bar and the underline will be on While the gauge is taking a mea surement six or seven of the bars should be on If fewer than five bars are on the TI 007 is having difficulty achieving a stable measurement and the thickness val
11. e key is held down numeric values will increment at an increasing rate When the TI 007 is in measurement mode this key is used to select between three different modes of measurement echo echo interface echo or auto Refer to page 6 for an explanation of the calibration procedure and to review the various measurement modes The SCAN key switches the SCAN measurement mode on and off Refer to SCAN page 8 for an explanation of the SCAN measurement mode 2 The DOWN arrow key has two functions When the TI 007 is in the CAL arrow key has two functions When the 007 is in calibration mode mode this key is used to decrease numeric values on the display An auto repeat function is built in so that when the key is held down numeric values will decrement at an increasing rate When the TI 007 is not in calibration mode the DOWN arrow key switches the display backlight between three available settings OFF will be dis played when the backlight is switched off AUTO will be displayed when the backlight is set to automatic mode and ON will be displayed when the backlight is set to stay on In the AUTO setting the backlight will illuminate while the TI 007 is making a measurement and turn off after several seconds to conserve battery life The ALRM key has two functions By holding down the ALRM key when ALRM powering up the TI 007 the audible beeper will be turned on or off accordingly After the unit has been turne
12. e of the material being measured This is accomplished with the use of a coupling fluid commonly called couplant This fluid serves to couple or transfer the ultrasonic sound waves from the transducer into the material and back again Before attempting to make a measurement a small amount of couplant should be applied to the surface of the material being measured Typically a single droplet of couplant is sufficient After applying couplant press the transducer wearface down firmly against the area to be measured The Stability Indicator should have six or seven bars darkened and a number should appear in the display If the TI 007 has been set to the correct sound velocity see page 6 the number in the display will indicate the actual thickness of the material directly beneath the transducer If the Stability Indicator has fewer than five bars darkened or the numbers on the display seem erratic first check to make sure that there is an adequate film of couplant beneath the transducer and that the transducer is seated flat against the material If the condition per sists it may be necessary to select a different transducer size or frequency for the materi al being measured See page 10 for information on Transducer selection While the transducer is in contact with the material that is being measured the TI 007 will perform four measurements every second updating its display as it does so When the transducer is
13. e transducer is the business end of the Transducer TI 007 It transmits and receives ultrasonic sound waves that the TI 007 uses to calculate the thickness of thematerial being measured The transducer connects to the TI 007 via the attached cable and one coaxial connector Delay Line add small amount of coupling fluid here The transducer must be used correctly in order for the TI 007 to produce accurate reliable measurements Below is a short description of the transducer followed by instructions for its use The photo above shows a typical single element delay line transducer This delay line is fastened to the transducer with a retainer ring A drop of couplant is applied between the delay line and transducer body The transducer body contains one crystal element that is responsible for conducting ultrasonic sound into and back from the material being mea sured When the transducer is placed against the material being measured it is the area directly beneath the delay line that is being measured When measuring press against the top of the transducer with the thumb or index finger to hold the transducer in place Moderate pressure is sufficient as it is only necessary to keep the transducer stationary and the delay line seated flat against the surface of the material being measured Making Measurements In order for the transducer to do its job there must be no air gaps between the wear face and the surfac
14. ent inherent sound velocities For example the velocity of sound through steel is about 0 233 inches per microsecond versus that of aluminum which is about 0 248 inches per microsecond If the tool is not set to the correct sound velocity all of the measurements the tool makes will be erroneous by some fixed percentage The one point calibration is the simplest and most commonly used calibration procedure optimizing linearity over 6 APPENDIX PRODUCT SPECIFICATIONS Weight Size Operating Case Keypad Power Source Display Measuring Range Resolution Accuracy Sound Velocity Range 10 ounces with batteries 2 5W x 4 5 H x 1 24 D inches 63 5W x 114 3 H x 31 5 Dmm 20 to 120 F 30 to 50 C Extruded aluminum body nickel plated aluminum end caps Sealed membrane resistant to water and petroleum products Two AA size 1 5 volt alkaline or 1 2 volt NiCad cells 150 hours typical operating time on alkaline 100 hours on NiCad Liquid Crystal Display 4 5 digits 0 500 inch high numerals LED backlight 0 0060 to 1 0000 inches 0 15 to 25 40mm Steel 0 0001 inch 0 001 0 0001 inch 0 001 depends on material and conditions 0 0492 to 0 3937 in ms 1250 to 10000m s 11 4 0 TRANSDUCER SELECTION The TI 007 is inherently capable of performing measurements on a wide range of materials from various metals to glass and plastics Different types
15. llowing pages Calibration to a known thickness NOTE This procedure requires a sample piece of the specific material to be measured the exact thickness of which is known e g from having been measured by some other means 1 Make sure the TI 007 is ON 2 Apply couplant to the sample piece 3 Press the transducer against the sample piece making sure that the transducer sits flat against the surface of the sample The display should show some probably incorrect thickness value and the Stability Indicator should have nearly all its bars on 4 Having achieved a stable reading remove the transducer If the displayed thickness changes from the value shown while the transducer was coupled repeat step 3 5 Press the CAL key The IN or MM symbol should begin flashing 6 Use the UP and DOWN arrow keys to adjust the displayed thickness up or down until it matches the thickness of the sample piece 7 Press the CAL key again The IN us or M s symbols should begin flashing The TI 007 is now displaying the sound velocity value it has calculated based on the thickness value that was entered in step 6 8 Press the CAL key once more to exit the calibration mode The TI 007 is now ready to perform measurements Calibration to a known velocity NOTE This procedure requires that the operator know the sound velocity of the material to be measured A table of common materials and their sound velocities can be found in Appendix
16. may also be necessary to use a specially constructed high temperature delay line It is recommended that the probe be left in contact with the surface for as short a time as needed to acquire a stable measure ment While the transducer is in contact with a hot surface it will begin to heat up and through thermal expansion and other effects may begin to adversely affect the accuracy of measurements Measuring laminated materials Laminated materials are unique in that their density and therefore sound velocity may vary considerably from one piece to another Some laminated materials may even exhibit noticeable changes in sound velocity across a single surface The only way to reliably measure such materials is by performing a calibration procedure on a sample piece of known thickness Ideally this sample material should be a part of the same piece being measured or at least from the same lamination batch By calibrating to each test piece individually the effects of variation of sound velocity will be minimized An additional important consideration when measuring laminates is that any included air gaps or pockets will cause an early reflection of the ultrasound beam This effect will be noticed as a sudden decrease in thickness in an otherwise regular surface While this may impede accurate measurement of total material thickness it does provide the user with positive indication of air gaps in the laminate 12 The Transducer Th
17. ond section provides guidelines in selecting a transducer for a specific application The last section provides application notes and a table of sound velocity values for various materials Electromatic maintains a customer support resource in order to assist users with questions or difficulties not covered in this manual Customer support may be reached at any of the following Electromatic Equipment Company 600 Oakland Avenue Cedarhurst NY 11516 USA Telephone 516 295 4300 Facsimile 516 295 4399 Online www checkline com Email sales checkline com 15 8 0 WARRANTY ELECTROMATIC Equipment Co Inc ELECTROMATIC warrants to the original pur chaser that this product is of merchantable quality and confirms in kind and quality with the descriptions and specifications thereof Product failure or malfunction arising out of any defect in workmanship or material in the product existing at the time of delivery there of which manifests itself within one year from the sale of such product shall be remedied by repair or replacement of such product at ELECTROMATIC s option except where unauthorized repair disassembly tampering abuse or misapplications has taken place as determined by ELECTROMATIC returns for warranty or non warranty repairs and or replacement must be authorized by in advance with all repacking and shipping expenses to the address below to be borne by the purchaser THE FOREGO
18. or MM will be displayed 3 Repeat step 2 to toggle between DIFF OFF or DIFF value and flashing IN 4 Assuming DIFF value flashing IN is displayed use the UP and DOWN arrow keys to scroll to the desired nominal thickness value 5 Press the SEND key once again to select the nominal value entered 6 The TI 007 is now ready to perform measurements using the Differential feature RS232 Serial Port The TI 007 is equipped with RS232 serial port Using the accessory cable N 306 0010 the TI 007 has the ability to connect to a computer or external storage device The following section outlines the procedure for connecting the TI 007 to a computer and how to collect data using any standard communications program Connecting To a Computer 1 Connect the accessory cable part N 306 0010 to the 2 pin jack located on the bottom of the TI 007 and the 9 pin connector to a serial port on the computer 2 Start the communications software that will be used to collect the measurements i e Windows 95 98 HyperTerminal 3 Setup the communications software using the following parameters Data Bits 8 Parity None Stop Bits 1 Baud Rate 1200 4 Set the communications software COMM port to the port number that the TI 007 is connected to 5 After taking a measurement press the SEND key to send the measurement to the computer The measurement will be displayed on the computer screen NOTE Communications software p
19. or single measurements In Scan Mode however the tool per forms eight measurements every second but does not display them While the transducer is in contact with the material being measured the TI 007 is keeping track of the lowest measurement it finds The transducer may be scrubbed across a surface and any brief interruptions in the signal will be ignored When the transducer loses contact with the sur face for more than a second the TI 007 will display the smallest measurement it found When the TI 007 is not in calibration mode press the SCAN key to turn Scan Mode on and off A brief message will appear in the display confirming the operation While scan ning the display will show a moving series of dashes instead of a thickness value When the transducer is removed from the material being scanned the TI 007 will after a brief pause display the smallest measurement it found Alarm Mode The Alarm Mode feature of the TI 007 allows the user to set an audible and visual Hi Lo parameter when taking measurements If the measurement falls below or above the Hi Lo limits set by the user a red light will be illuminated on the front panel of the gauge and an audible indication beep will sound This improves the speed and efficiency of the inspection process by eliminating constant viewing of the actual reading displayed The following page outlines how to enable and set up this feature Using the Beeper 1 While the unit is off
20. the beam becomes diffused and scattered in all directions In addition to posing obstacles to measurement rough surfaces contribute to excessive transducer wear particularly where the transducer is scrubbed along the surface Selecting Measurement Mode The TI 007 is equipped with four measurement mode options echo echo interface echo plastic auto In echo echo mode the gauge can read thin metals down to 006 inches 15 millimeters The echo echo mode also allows the user to measure the thickness of metals that have been previously coated or painted on the surface This enables the user to determine the thickness of the metal without having to remove the paint In interface echo mode the gauge can read plastics and thicker materials The TI 007 s auto mode will auto matically switch between modes according to the different materials being measured The following section outlines how to switch between measurement modes Measurement Modes 1 Make sure the TI 007 is ON 2 Press the UP arrow key to toggle between measurement modes The gauge will display PLAS followed by I E Interface Echo E E Echo Echo PLAS Plastic or AutO Auto depending on which TI 007 mode was last used 3 Repeat step 2 until the desired mode has been displayed Calibration In order for the TI 007 to make accurate measurements it must be set to the correct sound velocity for the material being measured Different types of material have differ
21. ue displayed will most likely be erroneous When the IN symbol is on the TI 007 is displaying a thickness value in inches The maximum thickness that can be displayed is 1 0000 inches When the MM symbol is on the TI 007 is displaying a thickness value in millimeters If the displayed thickness exceeds 20 00 millimeters the decimal point will shift automatically to the right allowing values up to 25 40 millimeters to be displayed When the IN symbol is on in conjunction with the us symbol the TI 007 is displaying a sound velocity value in inches per microsecond When the M symbol is on in conjunction with the s symbol the TI 007 is displaying a sound velocity value in meters per second 7 0 APPENDIX C SOUND VELOCITIES OF SOME COMMON MATERIALS Material in ps m s Aluminum 0 250 6350 Bismuth 0 086 2184 Brass 0 173 4394 Cadmium 0 109 2769 Cast Iron 0 180 approx 4572 Constantan 0 206 5232 Copper 0 184 4674 Epoxy Resin 0 100 approx 2540 German Silver 0 187 4750 Glass crown 0 223 5664 Glass flint 0 168 4267 Gold 0 128 3251 Ice 0 157 3988 0 232 5893 Lead 0 085 2159 Magnesium 0 228 5791 Mercury 0 057 1448 Nickel 0 222 5639 Nylon 0 102 approx 2591 Paraffin 0 187 2210 Platinum 0 156 3962 Plexiglass 0 106 2692 Polystyrene 0 092 2337 Porcelain 0 230 approx 5842 PVC 0 094 2388 Quartz glass 0 222 5639 Rubber v
22. ulcanized 0 091 2311 Silver 0 142 3607 Steel common 0 233 5664 Steel stainless 0 223 5664 Stellite 0 275 approx 6985 Teflon 0 056 1422 Tin 0 131 3327 Titanium 0 240 6096 Tungsten 0 210 5334 Zinc 0 166 4216 Water 0 058 1473 243 6 0 APPENDIX APPLICATION NOTES Measuring tubing When measuring a piece of tubing for wall thickness it may prove beneficial to have multiple delay lines with different radiuses for different tubing diameters The delay lines can be easily radiused by placing a piece of emery cloth around the tubing and moving the transducer back and forth until a radius has formed on the tip of the delay line Measuring hot surfaces The velocity of sound through a substance is dependant upon its temperature As materials heat up the velocity of sound through them decreases In most applications with surface temperatures less than about 200 F 100 C no special procedures must be observed At temperatures above this point the change in sound velocity of the material being measured starts to have a noticeable effect upon ultrasonic measurement At such elevated temperatures it is recommended that the user perform a calibration procedure refer to page 6 on a sample piece of known thickness which is at or near the temperature of the material to be measured This will allow the TI 007 to correctly calculate the velocity of sound through the hot material When performing measurements on hot surfaces it
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