1073 Operating Manual

E73BA1AEP.doc 24.07.00

Operating Manual Ultrasonic Thickness Gauge

Economy - ECHOMETER 1073

Rev. 1.0 a Subject to change without notice

Operating Manual ECHOMETER 1073 7413.7311 p. 1

KARL DEUTSCH Prüf- und Meßgerätebau OTTO-HAUSMANN-RING 101 D 42115 WUPPERTAL

IMPORTANT NOTE

Our devices, units and accessories are designed, constructed

and finished according to the state of the art. We presume that our customers similarly have knowledge of the art in respect of the restrictions in the completeness or reliability of the test process resulting therefrom. We are pleased to give full expla-nations where customers are in doubt.

Our products are subjected to an acceptance test according to specified technical data. The release of equipment is incumbent on specialized personnel. We accept responsibility for malfunc-tions or defects as specified under our general terms of delivery.

Our products are also used for the non-destructive testing of working materials in parts, the failure of which can represent a high risk. This applies, for example, both to working materials or component parts for the automobile industry and to the avia-tion or nuclear power fields. The user needs to undertake all reasonable measures to avoid workpieces from passing unno-ticed. Observation units on the test units for this purpose are of-fered. The risk of a malfunction of the unit can be reduced by regular checks of the device, accessories, test media, operating conditions and test personnel. In particularly important cases a check needs to be carried out both before and after each test. Such checks lead to the discovery of not only systematical mal-functions but malfunctions of the system and the device occur-ring sporadically. When the malfunctions in function have been ascertained, then measures must be taken without delay to pre-vent the construction parts, which were established in the last check as perfect, from being further used without re-examination.

We are ready to discuss the type and scope of checking or or-ganisation measures prior to acceptance of the test procedure.


Contents

1 What you should know prior to starting..........................5 1.1 Passing-on, availability and storage of this handbook .................... 5 1.2 Notes on this handbook .................................................................. 5 1.3 Requirements concerning the test personnel.................................. 6 1.4 Safety note...................................................................................... 6 1.5 Intended use................................................................................... 6 1.6 Measuring range of probes, display resolution and unit,

measuring tolerance ....................................................................... 7 1.7 CE Conformity ................................................................................ 8 1.8 Contacting KARL DEUTSCH.......................................................... 9

2 Putting into operation .....................................................10 2.1 Connectors and controls ............................................................... 10 2.2 Display.......................................................................................... 11 2.3 Operating menu............................................................................ 12 2.4 Erroneous inputs........................................................................... 14 2.5 Connecting the probe, switch-on, calibrating and

measuring..................................................................................... 15 2.6 Calibration..................................................................................... 17 2.7 Entering a new sound velocity ...................................................... 19 2.8 Measuring and adjusting the sound velocity on a

specimen of known thickness ....................................................... 20 2.9 Alarm mode (monitoring thickness limits) ..................................... 22

2.9.1 Input of measuring limits................................................. 22 2.9.1.1 Input of the lower limit value .......................... 22 2.9.1.2 Input of the upper limit value.......................... 23

2.9.2 Displaying the limit values............................................... 24 2.9.2.1 Displaying the lower limit ............................... 24 2.9.2.2 Displaying the upper limit............................... 24

2.10 Selecting the measuring unit......................................................... 24 2.11 Adaptation of the sensitivity .......................................................... 25 2.12 Illumination of the LCD display ..................................................... 25 2.13 Energy-saving mode..................................................................... 26

3 Special features...............................................................27 3.1 Changing the basic presettings for unit and resolution ................. 27

4 Corrogram........................................................................28

5 General notes ..................................................................29 5.1 Measurement principle ................................................................. 29 5.2 Operating and storage temperature.............................................. 30


5.3 Wear and tear of the probe........................................................... 30 5.4 Power supply ................................................................................ 31

5.4.1 Battery types................................................................... 31 5.4.2 Operating time ................................................................ 31 5.4.3 Exchanging batteries ...................................................... 32

5.5 Housing ........................................................................................ 33 5.6 Cleaning keypad and housing....................................................... 33 5.7 Type and serial number ................................................................ 33

6 What to do when .....? .....................................................34

7 Technical data .................................................................36

8 Use and assembly of wear protective membranes ......40

9 Instrument view ...............................................................42


1 What you should know prior to starting

1.1 Passing-on, availability and storage of this handbook

This handbook is a standard accessory and comes with the ECHOMETER 1073 when delivered. Please make sure that this handbook • is passed to the quality assurance dept. of your company

from where it can be ... • handed on to the specific user. • Please store this handbook like a document.

Copies of this manual can be ordered from KARL DEUTSCH.

1.2 Notes on this handbook

This manual deals with the proper use of the Ultrasonic Thick-ness Gauge Economy-ECHOMETER 1073.

Notes marked with the symbol must be read and considered in order not to reduce the quality of the test process and, where appropriate, not to neglect safety-relevant aspects. Supplemen-tary notes worth knowing can be recognized by the information symbol At the end of this manual a folder sheet with reference numbers is included. Subassemblies described in text or mentioned are provided with the corresponding reference numbers in order to allow an easy assignment.


1.3 Requirements concerning the test personnel

To operate the ECHOMETER according to the demands of the corresponding test task, the user of the ultrasonic thickness gauge should be able to read and understand this manual. Moreover, there should be a basic knowledge of methods used in the application of measurement technique; thus the operator can judge objectively the measured values and their tolerance. By this, the possibility to recognize systematic or applicational mal-functions can be increased as well as the recognition of error caused by the gauge. By means of periodically executed check measurements using comparable test pieces with known thickness you can verify the correct function of the test system. In addition, the test personnel should be familiar with processes to be executed in the case of instrumental malfunction or error.

1.4 Safety note

The ECHOMETER 1073 must not be used in an explosive envi-ronment (e.g. in mining areas, in tanks with explosive gas mixtures etc.). Observe the respective safety rules.

1.5 Intended use

The ECHOMETER 1073 is a gauge to measure thickness of sound-conductive materials. The correct handling of the gauge is described in this manual. Section 1.6 of this manual deals with the gauge-specific proper-ties and requirements for the intended use. If accessory is required for the intended use, only gauge-specific KARL DEUTSCH accessory or accessory expressively ap-proved by KARL DEUTSCH may be employed.



1.6 Measuring range of probes, display resolution and unit, measuring tolerance

The ECHOMETER works with dual element (“TR” or “SE”) probes. Dual element (TR) probes have separate transmitter (T) and receiver (R) elements, which must be connected to the re-spective transmitter output and receiver input of the thickness gauge. ECHOMETER probes are equipped with fixed twin ca-bles of approx. 1 m length and Lemo type connectors. Corre-sponding probe connectors and instrument sockets have colored marks to assure proper assignment and connection.

Measuring range of probes The measuring ranges depend on the specific probe type: Standard probe DSE 10.4/6 PB 4 1.2 to 250 mm 4 MHz probe with 10 x 4 mm piezoelectric ele-ment size.,Order-no. 1465.761

Miniature probe DSE 4.2/4 PB 8 0.7 to 25 mm 8 MHz probe with 4 x 2 mm piezoelectric ele-ment size, smallest possble shape for meas-urements on thin materials and/or sharp con-tours. Order- no. 1465.661

Low frequency probe DSE 18/25 PB 21 5 to 400 mm 2 MHz probe with 18 mm diam. half cut piezo-electric elements. Especially for measurements on rough surfaces and coarse-grained materials. Order-no. 1465.361

The stated measuring ranges are valid for fine-grain steel with plane-parallel and smooth surfaces. They are valid for probes used without wear protective membranes. With different mate-rial, geometry and surface or with wear protective membranes, the measuring ranges can be reduced.

Display resolution and unit The display resolution and unit (metric or inch) of the instru-ment can be selected from 0.1 mm, 0.01 mm and 0.001 inch.

1 High sound conductivity can cause phantom echoes and wrong thickness readings of

thick materials. In this case we recommend to use a probe with higher frequency.


Measuring tolerance The measuring tolerance2 of the ECHOMETER with probes DSE 10.4/6 PB 4 and DSE 4.2/4 PB 8 is: • ± 0.1 mm in the measuring range up to 80 mm • ± 0.5 % of the actual thickness above 80 mm With the low frequency probe DSE 18/25 PB 2, the measuring tolerance is: • ± 0.2 mm in the measuring range up to 80 mm • ± 0.5 % of the actual thickness above 80 mm

The stated data for measurement and reading tolerance are

valid for the a.m. respective measuring ranges of the probes. Outside these measuring ranges, either measurement is not possible or the tolerance range can be greater, possibly to a great extent. Please also note chapter 5.3.

1.7 CE Conformity

This appliance has been developed and manufactured with regard to ist electromagnetic compatibility for use not only in industrial but also in residential, commer-cial and trade premises and in small businesses in ac-cordance with harmonized standards. This means that the appliance conforms to the most important protection standards of the Electromagnetic Compatibility Directive (89/336/EEC) and the German Electromagnetic Compatibility Act of 9 November 1992 in accordance with the current issue on the date of delivery of the unit.

The characteristics within the meaning of the CE Directives ap-plying to this measuring appliance and the appliance's proven quality characteristics apply to correct use of the appliance, as described in chapter 1.5 of this manual.

2 Data regarding the measuring tolerance refer to an adjusted sound velocity of 5920 m/s

(steel) and constant temperature during the measurement.

1.8 Contacting KARL DEUTSCH

We work flexitime. You surely can contact us: Monday to Thursday : 8.00 - 12.15 h / 12.45 - 15.30 h Friday: 8.00 - 12.15 h Phones: +49 (0) 202 7192-0 Fax: +49 (0) 202 714932 E-mail: [email protected] Internet homepage: http://www.karldeutsch.de Use the following address for mailing contacts: KARL DEUTSCH Prüf- und Meßgerätebau GmbH & Co. KG P.O. Box 132354 D-42050 Wuppertal We are located at: Otto-Hausmann-Ring 101 D-42115 Wuppertal


2 Putting into operation

2.1 Connectors and controls

The reference numbers in the following chapters correspond to the reference numbers on the foldable view at the end of this manual. • Housing top

On the housing top of the ECHOMETER 1073 the coaxial sockets (3), (4) for connection of the probe are located.

• Keypad The keypad (6) consists of four keys:

• ON/OFF • •

• confirmation of value • •

• menu start and selection • increment (i.e. increasing the value) • •

• menu selection • decrement (i.e. decreasing the value) • •

• Above the keypad (6) the LC-display (5) is located. • The 5 mm calibration block (7) is located below the keypad.


2.2 Display

The ECHOMETER is equipped with a Liquid Crystal Display (LCD). The display shows up to four symbols, letters or figures with decimal dot. Depending on the operation mode, additional special symbols are visible. These special symbols appear at the left margin of the LCD: Special symbol Meaning

When this starts flashing, it tells you that the batteries are nearly dead. Usually you can go on measuring for at least 1 -3 hours but you should fit new batteries or refreshed re-chargeable batteries as soon as possible. With permanent display of this message, you should replace the batteries immediately since automatic switch-off is imminent.

The non-coupling mark (two dots at the left display margin) is visible when the probe is not placed on the Workpiece or coupling is not sufficient for proper measurement. With a non-coupling mark shown on the display no measurement is executed. The non-coupling mark also appears, if the back-wall echo becomes too low due to physical reasons, e.g. high acoustic absorp-tion or scattering within the workpiece or very high thickness of the workpiece.


2.3 Operating menu

Using the operating menu, you can select and adjust the working parameters of the ECHOMETER 1073. • In measuring mode, strike • Use to select the desired menu item

• Strike to enter the set-up level of the selected menu item.

• Use one of the arrow keys (with numeric values: increase) or (with numeric values: decrease) to alter the parameters.

• Strike to accept the new value of the parameter

• The instrument changes to the measuring mode again

The following table lists all set-up parameters in the same se-quence as they are displayed when successively actuating the key . (The key action “ Strike ” to enter the setup-level of the menu item is denoted as “ ”.)

Display Measuring parameter

Thickness (thickness) (sample value)

Sound velocity of the material (velocity) (sample value)

Monitoring the upper limit (high threshold)

off upper limit (sample value)

Monitoring the lower limit (low threshold)

off lower limit (sample value)


Display and input unit (unit)

mm Inch

Instrument sensitivity (4 levels) (Sensitivity) Standard measuring should be executed with the highest sensitivity setting . When thickness readings have to be taken from a workpiece with a very low absorption (e.g. aluminium) the sensitivity must be reduced to

. The lower sensitivity settings can also be used to avoid thickness readings from small targets within or in the vicinity of the sound beam of the probe.

Display backlight (LAMP) off on (backlight is only lit during menu set-up and while probe is coupled to a workpiece)

When selecting a menu item, the current setting of this item will automatically appear in the display after a delay of about 1 sec-ond.

All menu settings (measuring parameter) and instrument cali-bration data remain stored in a non-volatile memory even after switching the device off or removing the batteries. They can be acti-vated again, when skipping the inquiry after switch-on by

striking the key and thus not executing a new calibration. Each time a new calibration is executed after switch-on, the menu settings will be reset to default values (see section 2.6 of this man-ual).


2.4 Erroneous inputs

Each time the key is struck, the instruments checks the cur-rent input value for plausibility and for lying within its allowed range. When the allowed range is exceeded, a brief error message is shown . The instrument switches to the input mode again and the pa-rameter can be corrected instantaneously. The following limits should be obeyed: • Range of sound velocity: 100 m/s – 19999 m/s or

0.01 inch/µs – 1.999 inch/µs. • When monitoring upper and lower thickness limits: Set val-

ues for the upper limit must be higher than set values for the lower limit.

Error messages will also appear, if values calculated by the in-strument exceed the allowed range.


2.5 Connecting the probe, switch-on, calibrating and measuring

• Switch off the instrument • Connect the probe connection cables to the probe sockets (3),

(4). Ensure the plug (1) with the red cable sleeve is inserted in the socket (4), which is marked by a red point.

Fig. 1: Connecting the probe cables

The red colour marks the corresponding receivers of the probe and the instrument.

red sleeve

Red point marking

• Strike the key to switch the ECHOMETER on.

• The display shows , which is the request to start cali-bration.

• Calibrate the instrument as described in section 2.6. On first switch-on, the ECHOMETER reads in metric units and

0.1 mm resolution (factory presetting, unless otherwise ordered). You can change the presetting to 0.01 mm resolution or to read the thickness in 0.001 inch by a special key combination. Please note sec-tion 3.1.

To read the thickness of a material, the ECHOMETER 1073 must know its sound velocity. Each time a new calibration is executed, the sound velocity is automatically set to 5920 m/s. If the material, whose thickness shall be determined, has a differ-ent sound velocity, either enter manually the exact sound veloc-ity as decribed in section 2.7, or measure and adjust the sound velocity as decribed in section 2.8.



• Now apply a drop of couplant (e.g. ECHOTRACE3, ECHOFLUID3, oil etc.) to the workpiece where the thickness shall be measured and couple the probe to the workpiece.

Probes may come with a plastic soft protective cap to avoid scratches or otherwise damage of the contact face. Remember to remove the protective cap prior to measurement.

• The thickness will be read in the display, immediately, (either in mm or in inch).

• You can continue measuring thickness at other points of the workpiece by successively applying drops of couplant to the measuring points and coupling the probe to them. The in-struments keeps the sound velocity, which was initially set, as long as a new one is entered or the instrument is calibrated again.

Altering the sound velocity will always alter the displayed thickness (due to the physical relation s=v•t/2, see section 5.1).

The reliability and accuracy of all thickness readings depends

strongly on how the probe is coupled to the workpiece. For proper coupling of the probe, proceed as carefully as possible: Before apply-ing the couplant, remove any dust or dirt from the contact surfaces of the probe and from the workpiece where the probe shall be coupled to. The couplant is always necessary to transfer acoustic energy from the probe to the workpiece at all. But alwasy keep in mind: The thin-ner the coupling film is, the more energy will be tranferred and the better results can be expected.

3 High quality couplants from KARL DEUTSCH: ECHOTRACE 500 ml (order no.

9000.003) or 5 l (order no. 9000.002). ECHOFLUID 100 ml (order no. 9004.001)


2.6 Calibration

Whenever the instrument is switched on, the display shows , which is the request to start calibration (**). To cali-

brate the instrument, proceed as follows: • Apply a drop of couplant (e.g. ECHOTRACE4,

ECHOFLUID4, oil etc.) to the built-in calibration block (7). • Place the probe on the centre of the built-in calibration block

(7). Keep it coupled until the display shows (with display resolution 0.1 mm) resp. (with display reso-lution 0.01 mm). This value represents the thickness of the built-in precise calibration block in mm.

The equivalent inch value (0.197) will be displayed by instru-ments with a presetting of 0.001 inch resolution.

• Lift the probe off the built-in calibration block. • The instrument is calibrated now and ready to take thickness

readings with the sound velocity of the instrument automati-cally set to 5920 m/s (typical value for steel).

The accuracy of all the following thickness readings depends strongly on how the probe is coupled to the built-in calibration block during the calibration process. For proper coupling, proceed as care-fully as possible: Before applying the couplant, remove any dust or dirt from the contact surfaces of probe and calibration block. The couplant is necessary to transfer acoustic energy from the probe to the workpiece at all. But always keep in mind: The thinner the film is, the more energy will be tranferred and the better results can be ex-pected. (**): During calibration, the ECHOMETER recognizes automatically the type of probe which is connected to the gauge, and compensates for individual probe wear and temperature changes. It is recom-mended to check and verify the accuracy of thickness readings from time to time by means of specimen of known thickness or by means of the built-in reference block of known thickness and, if necessary, recalibrate the instrument. A new calibration is always necessary, ei-ther when the temperature changes, the probe becomes more worn out since last calibration or when another probe is connected to the instrument.

4 High quality couplants from KARL DEUTSCH: ECHOTRACE 500 ml (order no.

9000.003) or 5 l (order no. 9000.002). ECHOFLUID 100 ml (order no. 9004.001)

The CAL-process resets the following parameters of the ECHOMETER 1073:

the parameter “thickness” to the thickness of the internal calibra-tion block (5.0 mm resp. 5.00 mm or 0.197 inch)

the parameter “sound velocity of the material” to 5920 m/s resp. to 0.233 inch/µs.

the parameter “display and input” (mm or inch) to that unit, which corresponds with the selected presetting (0.1 mm, 0.01 mm or 0.001 inch, see section 3.1)

the parameter “instrument sensitivity” to

If you feel a new calibration not necessary after switch-on, you can override the new calibration by striking when the inquiry appears in the display. In this case the instrument keeps the previous settings of thickness, sound velocity, unit and sensitivity as well as the previous calibration data.

If you want to measure on materials different to steel with a

sound velocity of 5920 m/s, you need to adjust the parameter “sound velocity of the material” properly prior to taking thickness readings (see section 2.7). See section 2.8 for information on how to adjust the sound velocity by using a specimen of known thickness.


2.7 Entering a new sound velocity

Each time a new calibration is executed after switch-on, when the display is showing , the sound velocity is automati-cally set to 5920 m/s. If the material, whose thickness shall be determined, has a different but already exactly known sound ve-locity, you can enter the new sound velocity manually via the keypad. Proceed as follows:

• Strike key and then key or until the display shows the menu item .

• Strike . After a short time the current sound velocity value will be indicated.

• Strike key or until the display reading meets the sound velocity of the material to be measured in m/s resp. inch/µs (e.g. steel 5920 m/s resp. 0.233 inch/µs). The possible ad-justment range is 100 - 19999 m/s resp. 0.01 –1.999 inch/µs.

• Strike key , to confirm the new value and to return to the measuring mode.

The instrument has accepted the entered sound velocity and is now ready for new thickness measurements.

All subsequent measurings are based on the new sound velocity, which will be kept by the instrument - even when removing the bat-teries - , until a different value of the sound velocity is entered or adusted, or a new calibration is executed. Altering the sound velocity will always alter the displayed thickness (due to the physical relation s=v•t/2, see section 5.1)


2.8 Measuring and adjusting the sound velocity on a specimen of known thickness

Basically, the ECHOMETER 1073 is a thickness gauge. How-ever, it is also possible, to measure the sound velocity of a specimen, if its thickness is exactly known. Each time a new calibration is executed after switch-on, when the display is showing , the sound velocity is automati-cally set to 5920 m/s. If you do not know the exact sound veloc-ity of the material, whose thickness shall be determined, but a specimen of the same type of material and of known thickness is available, you can easily measure the sound velocity and adjust the parameter sound velocity of the instrument properly: • Switch the ECHOMETER on. • Calibrate the instrument as described in section 2.6. • Couple the probe to the specimen with known thickness. • A thickness reading which is based on the current sound ve-

locity (5920 m/s) appears in the display .

Of course, when the actual sound velocity of the specimen is not 5920 m/s, this thickness reading is not true.

• Strike key and then key or until the menu item is in the display.

• Strike

• The previously measured thickness is displayed.

• Use the keys and to adjust the displayed thickness to the actual thickness of the specimen.

• Finally strike again. The velocity is now adjusted to the sound velocity of the speci-men. To see the value of the measured sound velocity, strike key

, use the key or and select the menu item . Af-ter a short time the sound velocity of the specimen is displayed


All subsequent measurments are based on the new sound veloc-ity. It will be kept by the instrument - even when removing the bat-teries - , until a different value of the sound velocity is entered or adusted, or a new calibration is executed.

Please refer to section 2.4, when the error message should be displayed during adjustment.


2.9 Alarm mode (monitoring thickness limits)

The instrument can monitor the thickness readings on being within allowed limits. Maximum and minimum thickness values can be entered as up-per and lower measuring limits via the parameter set-up of the ECHOMETER 1073. When these limits are exceeded, a special alarm sound is generated and the display flashes. The limits can be entered any time during measurement.

2.9.1 Input of measuring limits

2.9.1.1 Input of the lower limit value

• Strike and then key or until the menu item appears in the display.

• Strike .

• Use the keys or until the required lower limit value is shown.

• Strike to accept the adjusted limit value and to return to measuring operating mode.

During measurement: With measured values dropping below the lower limit, the dis-play reading will start flashing. In addition, a low tone alarm signal will be heard. (Exceeding the upper limit - see following section - is announced by means of a high tone alarm signal).

Please refer to section 2.4, if the error message is dis-played during adjustment of the lower limit.

Switching the alarm mode off: By adjusting the menu item and parameter to the alarm mode for the lower limit is switched off.


2.9.1.2 Input of the upper limit value

• Strike key and then key or until the menu item appears in the display.

• Strike .

• Use the keys or until the required upper limit value is shown.

• Strike to accept the adjusted limit value and to return to measuring operating mode.

During measurement: With measured values exceeding the upper limit, the display reading will start flashing. In addition, a high tone alarm signal will be heard. (thickness readings dropping below the lower limit - see previous section - are announced by means of a low tone alarm signal).

Please refer to section 2.4, if the error message is dis-played during adjustment of the upper limit.

Switching the alarm mode off: By adjusting the menu item and parameter to the alarm mode for the lower limit is switched off.

The limits may be entered in arbritary sequence. Furthermore, it is not required to enter both limit values: A single upper or lower limit, depending on the testing task, is sufficient.


2.9.2 Displaying the limit values

The stored limit values can be read in the display.

2.9.2.1 Displaying the lower limit

Strike key and then key or until the menu item appears in the display. Wait for approximately one second. The display will then show the current lower limit value.

2.9.2.2 Displaying the upper limit

Strike key and then key or until the menu item appears in the display. Wait for approximately one second. The display will then show the current lower limit value.

2.10 Selecting the measuring unit

When you want occasionally that the thickness is read or con-verted in another unit (mm or inch) than corresponding to the presetting of the instrument, proceed as follows: • Strike key and then key or until the menu item

appears in the display.

• Strike .

• Use the arrow keys or to select the measuring unit (mm) or (inch).

• Strike to accept the selection.

Each time a new calibration is executed after switch-on, the in-strument is reset to read in “mm” or “inch” according to the selected presetting. When skipping a new calibration after switch-on by striking the key, after the display shows , the unit keeps reading in “mm” or “inch” according to the latest setting of the menu item “UNIT” before switch-off.


2.11 Adaptation of the sensitivity

When thickness readings have to be taken from a workpiece with a very low absorption (e.g. aluminium), the sensitivity must be reduced to . The lower sensitivity settings can also be used to avoid thickness readings from small targets within or in the vicinity of the sound beam of the probe. Proceed as follows to select the sensitivity level: • Strike key and then key or until the menu item


• Strike .

• Use the arrow keys or to select the sensitivity to

maximum sensitivity

high sensitivity

low sensitivity

minimum sensitivity, • Strike to accept the selection.

Without need to reduce the sensitivity, measuring should al-

ways be executed with the highest sensitivity .

2.12 Illumination of the LCD display

The LCD display is equipped with a backlight, enabling reading it even in darkness. To switch the internal backlight on or off, proceed as follows: • Strike key and then key or until the menu item


• Strike .

• Use the arrow keys or to select resp. , if you want to switch the illumination on or off.

• Strike to accept the selection.


For energy saving reasons, the backlight is lit only during menu adjustment and while the probe is coupled to a workpiece. The latter feature could also be used as an optical indication of a good coupling to the workpiece. However be aware of the fact, that the power con-sumption is much higher with a lit backlight and that the lifetime of the battery will considerably be reduced.

2.13 Energy-saving mode

The instrument switches automatically to an energy-saving stand-by mode after about 1 minute of not being used. A triple alarm beep will sound and the display then shows two horizontal lines . Press to return the instrument to normal operation again. The operating condition will be the same as before the stand-by mode.


3 Special features

3.1 Changing the basic presettings for unit and resolution

The ECHOMETER 1073 can be preset to read thickness in mm or inch with 0.1 mm, 0.01 mm or 0.001 inch resolution.

If your selected basic presetting is “0.1 mm” or “0.01 mm” and you want only occasionally your instrument to read in inch, or vice versa, use the menu item “UNIT” as described in section 2.10 of this manual.

To select 0.1 mm, 0.01 mm or 0.001 inch as the new basic pre-setting of the instrument, proceed as follows: • Switch off the instrument • Press simultaneously a key according to the desired display

unit and resolution (see following table) and the key.

basic presettings for unit and resolution

key combination to change the presettings

metric with display resolution 0.1 mm

+

metric with display resolution 0.01 mm

+

inch with display resolution 0.001 inch

+

• After releasing both keys the display will show , which is the request to start a new calibration.

• Calibrate the instrument. After calibration the new basic pre-settings for unit and calibration are valid. They remain stored in the memory of the instrument – even after switch-off or replacing the batteries -, until they are changed again by the described procedure.

When the presetting has been changed by the described proce-dure, the instrument must read at least one thickness value, before a parameter of the menu can be changed.


4 Corrogram

A "Corrogram" shows the usable thickness range of the instru-ment together with a specific probe, when echoes are reflected from small targets compared to the cross section of the sound beam of the probe instead from a plane and extended back-wall. A corroded back-wall even acts as if the echo is reflected from small targets. The “Corrogram” shows, which probe is most sen-sitive in an expected thickness range. In the "Corrogram" the minimum diameter of a flat bottom hole ("FBH"), whose depth can be determined by the specific instru-ment and probe combination, is plotted against the depth. The useful range lies within the u-shaped field, which is limited by the respective curve marked by the probe name.

Fig. 2: Corrogram ECHOMETER 1073

Example: If you expect targets as small as 1 mm in diameter lying in a depth between 1 and 5 mm, take the probe DSE 4.2/4 PB 8. No other probe covers that region better.

useful range


5 General notes

5.1 Measurement principle

The ECHOMETER 1073 is a measuring instrument based on ul-trasound technique. It can be used for measuring the thickness of various materials. Basically, the instrument determines the tran-sit time of ultrasonic pulses. All readings are deducted from a measured transit time. Periodically, an electrical pulse transmitter excites the piezoelec-tric transmitter element of an ultrasonic probe to high-frequency thickness vibrations. The frequency of these vibrations is in the range between 1 and 10 MHz and cannot be heard by the human ear. When putting the probe on a sound-conductive specimen, the vibrations can be transfered to the specimen by means of a liquid couplant and propagate as an ultrasonic wave straight forward. At interfaces, e.g. at the rear side of a workpiece, the wave is re-flected and returns to the probe, where it is picked up and con-verted into an electrical pulse again by the piezoelectric receiver element of the probe. The transit time (t) between transmitting and receiving of the electrical pulse is determined by the instrument and converted into thickness (s) or velocity (v). Conversion to thickness is car-ried out according to s = v t/2. The sound velocity (v) must be known in this case. Conversion to sound velocity (v) is done ac-cording to v = 2s/t. The thickness (s) must be known in this case. The factor 2 is caused by the fact, that the actual sound path equals two times (forth and back) the thickness s. For the con-venience of the user, thickness gauges read thickness instead of sound path, always.


5.2 Operating and storage temperature

The ECHOMETER 1073 can be operated in environmental tem-peratures from -10 °C to 50 °C. The permissible storage temperatures of the ECHOMETER 1073 with inserted batteries lies in the same range -10 °C to +50 C. With batteries removed, you can store the instrument in a tem-perature ranging between –20 °C and 60 °C.

Temperatures in the inside of a car or generally behind glass can easily be higher than 60 °C, when the sun is shining!

5.3 Wear and tear of the probe

Depending on the surface roughness of the workpieces mechani-cal wear can reduce the length of the probe. Wear of up to 1 mm will not affect the measurement accuracy. Wear exceeding this limit can decrease the accuracy compared to the usually ex-pected measuring tolerances of section 1.6. The following table gives information on the effects of wear with regard to the various probe types:

probe type

Shortening lim-its without in-fluence on accu-racy

total usable shortening (add ± 0.1 mm to the normal tolerance)

length of housing ex works

DSE 10.4/6 PB 4 1 mm up to 5 mm 30 -0.2 mm

DSE 4.2/4 PB 8 1 mm up to 2 mm 15 -0.1 mm

DSE 18/25 PB 2 1 mm up to 5 mm 33 -0.2 mm

You can verify the actual shortening by comparison the actual length with the original length of the housing ex works.


5.4 Power supply

The ECHOMETER can be used with 1,5 V alkali-manganese or 1,5 V lithium batteries (dry cells) or with 1,2 – 1,5 V recharge-able batteries.

5.4.1 Battery types

For operation, you need two batteries of Mignon/AA/LR6/AM3 size. Ex works, the instrument comes with two alkali-manganese batteries. Alternatively you can use rechargeable NiCd- or NiMH-batteries of same size. Both rechargeable and non-rechargeable batteries are available in all shops selling electro devices or entertainment electronics. This is where to find suitable chargers, too. High-quality NiMH rechargeable batteries can be ordered from KARL DEUTSCH by order no. 6016.001 (2 ea.). A suitable charger is also available by order no. 6015.001. If you are going to use rechargeable batteries, we recommend NiMH-batteries since they feature a higher capacity against NiCd and are less harmful to the environment.

Use leak-proof battery types only! Remove batteries from the unit when it is stored for a longer period. Dead batteries should be removed immediately and handed-on to a recycling system.

Prior to disposal of the gauge, you need to remove the batteries from the instrument and dispose them non-polluting.

5.4.2 Operating time

With AlMn dry cells, the average operating time is more than 200 h (permanent operation). With fully charged NiMH-batteries permanent operation of ap-prox. 90 h is possible.


The power consumption of the instrument increases when the

LCD backlight is switched on (see menu item ). The a.m. op-erating time will then be reduced. When the backlight is permanently used, only 30 % of the a.m. operation time may be left. To spare battery lifetime, you should avoid unnecessary use of the backlight.

5.4.3 Exchanging batteries

Batteries are inserted into the compartment in the bottom side of the instrument.

Fig. 3: Rear view with open bat-tery compart-ment

To exchange the batteries proceed as fol-lows: • Switch-off the instrument. • Remove Phillips screws of the battery

compartment cover (10). • Carefully lift off cover. Ensure that the

rubber sealing will not be damaged or removed from the guiding notch.

• Insert new batteries into the battery compartment (8). Ensure correct orien-tation according to the sketch.

Re-assembling is made in the reverse or-der.

All measuring parameter and calibration data are stored in a non-volatile memory and will not get lost, when removing and chang-ing the batteries. Skip the request for calibration by striking the key

after switch on, if you want to work with the same parameter and calibration data again.


5.5 Housing

The ECHOMETER housing is made from sturdy plastics (ABS / polyester). The housing is splash proof according to IP 54.

Please note section 5.4.3 regarding the correct handling of the rubber sealing, in order not to risk the protection class.

5.6 Cleaning keypad and housing

To clean housing and keypad you can use a cloth soaked with a soft cleansing agent. Make sure that there are no solvents or scratching agents in the cleanser. If you are using a plastics-cleanser make sure that it does not dissolve ABS and polyester.

5.7 Type and serial number

The ECHOMETER 1073 described in this man-ual is assigned to the type number 1073.001. If there are any questions concerning the instru-ment, please quote the serial number, too. The serial number of your instrument is shown on the type label (9) on the rear of the unit.


6 What to do when .....?

What to do when the display shows ?

Cause: The combination of current or just entered parameter leads to a value that exceeds the permissible parame-ter limits (see section 2.4).

Remedy: Alter the parameter values correspondingly.

What to do when the non-coupling mark won't dis-appear?

Cause: Insufficient acoustic coupling Remedy: Remove dust or dirt from the contact face of the

probe and the workpiece, where the thickness shall be measured. Apply a sufficient drop of couplant (ECHOTRACE, ECHOFLUID, oil etc.) to the probe or to the workpiece. If necessary increase the cou-pling pressure a little bit (do not apply too much force !!).

Cause: High sound attenuation in the workpiece Remedy: Try a probe with a lower frequency (see section 1.6).

Low frequencies are less attenuated and can penetrate lossy materials better than higher frequencies. Re-member that the measuring tolerance will become higher with low frequencies. You are welcome to get in touch with the application laboratory of KARL DEUTSCH if you need help to solve a special appli-cation problem.

What to do when the display shows ?

This is no error message. The instrument has switched automati-cally to its stand-by mode. You can return to measuring mode by striking once.


What to do when measured thickness is changing from specimen to specimen despite same physical thickness ? Remember that the thickness readings depend on the sound ve-locity of the material. The sound verlocity may not be homoge-neous throughout the bulk material or may differ between differ-ent production lots due to a modified production process. Al-ways ensure that you have entered the correct sound velocity of the respective material.


7 Technical data

DISPLAY Display technique Liquid crystal display (LCD) Display size Standard 5 inch = 50.8 x 30.5 mm2 Display format 4½ characters. Seven segments Display window 44 x 16 mm2 Character height 10.2 mm ADJUSTMENT LIMITS Wall thickness (thi) Resolution 0.1 mm >= 1.0 mm to s(max) Resolution 0.01 mm >= 0.1 mm to s(max) Resolution 0.001 inch >= 0.01 inch to s(max) Note: s(max) = s(o) * v(max) / v(o) ; s(o). v(o) = last adjusted values (of thickness and sound velocity) prior to adjustment of thi, v(max) = 19999 m/s resp. 1.9999 inch/us Sound velocity (VEL) Resolution 0.1 mm >= 100 m/s to 19999 m/s Resolution 0.01 mm >= 100 m/s to 19999 m/s Resolution 0.001 inch >= 0.0100 inch/us to 1.9999 inch/us Limits (Loth, Hith) (Loth) < (Hith) Calibration block Built-in calibration block Equivalent to 5 mm steel (5920 m/s) MEASUREMENT UNCERTAINTY OF GAUGE

Resolution 0.1 mm 0.1 mm Resolution 0.01 mm 0.05 mm Resolution 0.001 inch 0.002 inch MEASURING RANGES Standard probe (DSE 10.4/6 PB 4) 1.5 to 250 mm Measuring uncertainty with : Resolution 0.1 mm 0.1 mm, above 80 mm +/- 0.5% Resolution 0.01 mm 0.1 mm, above 80 mm +/- 0.5% Resolution 0.001 inch 0.002 inch, above 80 mm +/- 0.5% Miniature probe (DSE 4.2/4 PB 8) 0.7 to 25 mm Measuring uncertainty with : Resolution 0.1 mm 0.1 mm, above 80 mm +/- 0.5% Resolution 0.01 mm 0.1 mm, above 80 mm +/- 0.5%


Resolution 0.001 inch 0.002 inch, above 80 mm +/- 0.5% Low frequency probe (DSE 18/25 PB 2) 5.0 to 400mm Measuring uncertainty with : Resolution 0.1 mm 0.2 mm, above 80 mm +/- 0.5% TRANSMITTER Shape of transmitter pulse Unipolar (negative) needle pulse Transmitter properties : (adapted to a.m. probes) Voltage of transmitter pulse Vpo = 70 V, +/ -10% at 180 Ω

(power adapted) Rise time of pulse t = 20 ns +/- 10% Pulse length t = 300 ns +/- 10% Frequency spectrum see below: additional data acc. to prEN

12668-1 Mesurement repetition frequency 2 Hz AMPLIFIER and DAMPING Nominal frequency range 0.6 – 15 MHz (-3dB) Maximum input sensitivity 1.5 mVpp for 100% coupling (adjust va-

lue) Equivalent input impedance 180 Ω +/- 10% Adjustable damping, four steps "Hi =" 0dB (maximum sensitivity)

"Hi -" - 6dB (high sensitivity) "Lo -" - 9dB (low sensitivity) "Lo =" - 12dB (minimum sensitivity)

Damping of crossover talking > 80 dB MISCELLANEOUS Measurement systems Selectable mm and inch Probe recognition Automatical per calibration ("CAL“), by

means of measurement of delay line. Beeper Confirms keystroke and limit excess by

a spezific tone signal Parameter memory The parameters reading, sound veloci-

ty, upper and lower limit remain memo-rized after switch-off and battery chan-ge.

VOLTAGE SUPPLY Battery operation By two alkali-manganese primary cells.

Type AA/IEC R6. 2 x 1.5 V Operating time (with max. power consumption)

More than 200 hrs

Rechargeable battery operation By two NiMH batteries. Type AA/IEC



R6. 2 x 1.2 V Operating time (with max. power consumption)

approx. 90 hrs (new)

Battery capacity indication approx. 1 to 3 hrs. Prior to reaching low voltage state the alarm indication "Lo Batt“ will show in the display

Automatic switch off With undervoltage of batteries (< 1.6 V) Stability vs. voltage deviation Within the range of permissible battery

voltage of 2.0 to 5.0 V the deviation of amplitude at the amplifier output is lo-wer than 0.1 %

PERMISSIBLE AMBIENT CONDITIONS

Operating temperature -10 to +50° C Storage temperature - w/o batte-ry!

-20 to +60° C

Dust and humidity Protective class IP54 (splash-proof) MECHANICS Size (H x W x D) 120 x 65 x 25 mm3 with calibration

block Front foil (H x W) 55 x 80 mm2 Weight 115 g w/o batteries. 150 g w/ batteries Case material ABS (UL-94 HB) Keypad material Polyester Probe connectors Lemo 00 ADDITIONAL DATA acc. to prEN 12668-1

Transmitter (definitions)

0 %10 %

90%100 %

tdtr

V50

Pulse shape and frequency spectrum of transmitter


8 Use and assembly of wear protective mem-branes

Wear protective membranes made of Vulcollan (available as assesories) can optionally be used for probes, when the surface of the workpiece to be measured is very rough. Vulcollan is a special wear resistant plastic material.

Wear Protective membranes not only protect the probe from be-ing scratched, when it is scanned over a rough surface, but they can also improve the coupling in this case. On a smooth surface, however, the sensitivity of the probes and, therefore, the measuring range and the accuracy will be reduced when using protective membranes. We do not recommend to use protective membranes, where it is not necessary ( e.g. on smooth surfaces).

1. Insert probe into handling sleeve.

2. Put membrane into retaining ring.


3. Distribute oil (don´t use any other couplant) on the inner side of the membrane. (Don´t use too much couplant. A few drops are suffi-cient.)

4. Screw retaining ring with mem-

brane onto handling sleeve (do not yet tighten the ring!)

5. Press probe with membrane onto a smooth surface so that air bubbles can leak out and the coupling agent is distributed homogeneously. Screw retaining ring tightly while probe is still pressed.


6. Finally verify visually, that there are no air bubbles between probe and the membrane.

Ultrasound is reflected by air. There-fore, any air bubbles between probe and membrane can reduce the transfe-red sound energy considerably, thus reducing the accuracy of readings and/or the measuring range. Too much oil (cushion like thick oil layer) can also affect the measurements.

9 Instrument view

(1) probe connector for receiver element (red sleeve) (2) probe connector for transmitter element (black sleeve) (3) probe socket for transmitter element (4) probe socket for receiver element (red dot mark, see arrow) (5) LC display (6) keypad (7) calibration block (5 mm steel with v = 5920 m/s)

(0.197 inch steel with v = 0.233 inch/µs) (8) battery compartment (open) (9) type label (10) cover for battery compartment


1073 Operating Manual

Documents

high quality

transfer acoustic

karl deutsch

wear protective

exact sound

error message

menu item

current lower