Panametrics 25DLP Instruction Manual

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t~~WarrantyThe Model 25DL PLUS Ultrasonic Gage has been designed and manufactured as a precision instrument. Under normal working conditions it will provide long, trouble-free service.

Damage in transit: Inspect the unit thoroughly immediately upon receipt for evidence of external or internal damage that may have occurred during shipment. Notify the carrier making the delivery immediately of any damage, since the carrier is normally liable for damage in shipment. Preserve packing materials, waybills, and other shipping documentation in order to establish damage claims. After notifying the carrier, contact Panametrics-NDTTM so that we may assist in the damage claims, and provide replacement equipment, if necessary.

Panametrics-NDT guarantees the Model 25DL PLUS to be free from defects in materials and workmanship for a period of two years (twenty-four months) from date of shipment. The warranty only covers equipment that has been used in a proper manner as described in this instruction manual and has not been subjected to excessive abuse, attempted unauthorized repair, or modification. DURING THIS WARRANTY PERIOD, PANAMETRICS-NDT LIABILITY IS STRICTLY LIMITED TO REPAIR OR REPLACEMETN OF A DEFECTIVE UNIT AT ITS OPTION. Panametrics-NDT does not warrant the Model 25DL PLUS to be suitable for intended use, and assumes no responsibility for unsuitability for intended use. Panametrics-NDT accepts no liability for consequential or incidental damages including damage to property and/or personal injury.This warranty does not include the transducer, transducer cable, charger, or battery. The customer will pay shipping expense to the Panametrics-NDT plant for warranty repair; Panametrics-NDT will pay for the return of the repaired equipment. (For instruments not under warranty, the customer will pay shipping expenses both ways.)Panametrics-NDT offers an optional third year warranty coverage (at an additional cost), under the same terms, at the time of purchase.Panametrics-NDT reserves the right to modify all products without incurring the responsibility for modifying previously manufactured products. Panametrics-NDT does not assume any liability for the results of particular installations, as these circumstances are not within our control.

THE WARRANTIES SET FORTH HEREIN ARE EXCLUSIVE AND ARE IN LIEU OF ALL OTHER WARRANTIES WHETHER STATUTORY, EXPRESS OR IMPLIED (INCLUDING WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, AND WARRANTIES ARISING FROM COURSE OF DEALING OR USAGE OR TRADE.)m~=@=VNMJONM` P

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q~==`Table of Contents

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Table of Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

List of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1 Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151.1 Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151.2 About this Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161.3 Audience. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161.4 Typographic Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171.5 Related Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181.6 If You have Documentation Comments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181.7 Revision History. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181.8 Technical Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2 Defining Basic Gage Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192.1 Summarizing Keypad Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192.2 Identifying Display Elements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252.3 Using the Battery Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272.4 Monitoring the Battery Charge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272.5 Charging the Battery Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272.6 Replacing the Battery Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282.7 Using AA Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282.8 Discussing Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292.9 Factors Affecting Performance and Accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3 Setting Up and Calibrating the Gage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353.1 Getting Started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353.2 Making Thickness Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363.3 Choosing a Default or User-Defined Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373.4 Performing a Quick Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393.5 Calibrating the Model 25DL PLUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

3.5.1 Velocity and Zero Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403.5.2 Velocity Calibration Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413.5.3 Zero Calibration Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

3.6 Adjusting the Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43m~=@=VNMJONM` R

3.7 Operating the Delay Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443.8 Operating the Zoom Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

j=ORai=mirp3.8.1 Zoom in Mode 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453.8.2 Zoom in Mode 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453.8.3 Zoom in Mode 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

3.9 Using the Backlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

4 Managing Special Gage Functions and SP Modes. . . . . . . . . . . . . . . . . . . 494.1 Operating Gage Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

4.1.1 Selecting a Differential Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 494.1.2 Using the Measurement Display Update Rate . . . . . . . . . . . . . . . . . . . . 524.1.3 Using the Minimum Thickness Mode . . . . . . . . . . . . . . . . . . . . . . . . . . 534.1.4 Using the Maximum Thickness Mode . . . . . . . . . . . . . . . . . . . . . . . . . . 554.1.5 Managing High/Low Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 564.1.6 Changing the Thickness Resolution. . . . . . . . . . . . . . . . . . . . . . . . . . . . 624.1.7 Using the Thickness Display Hold/Blank . . . . . . . . . . . . . . . . . . . . . . . 624.1.8 Managing the Calibration Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624.1.9 Freezing the Waveform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 634.1.10 Changing Rectification Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 634.1.11 Selecting Metric Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

4.2 Operating SP Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 644.2.1 Managing the Measurement Setup Mode . . . . . . . . . . . . . . . . . . . . . . . 64

4.3 Saving Key Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 684.3.1 Operating the ID Overwrite Protection . . . . . . . . . . . . . . . . . . . . . . . . . 694.3.2 Managing the Communication Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . 704.3.3 Managing the Gage Diagnostics Mode . . . . . . . . . . . . . . . . . . . . . . . . . 734.3.4 Operating Gage Resets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 754.3.5 Using the Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

5 Using Custom Setups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 795.1 Managing the Detect Mode Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 795.2 Defining a Setup Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 815.3 Defining a Probe Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 815.4 Varying Pulser Power Effects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 815.5 Defining Maximum Gain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 825.6 Defining Initial Gain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 835.7 Defining TDG Slope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 845.8 Viewing the Main Bang Blank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 845.9 Viewing the Echo Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

5.9.1 Echo 1 Detect and Echo 2 Detect. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 875.9.2 Interface Blank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 895.9.3 Mode 3 Echo Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 905.9.4 Making Setup Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91S

5.9.5 Saving Setup Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

q~==`6 Managing the Datalogger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 936.1 Understanding the Datalogger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 936.2 Organizing the Datalogger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

6.2.1 File Name Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 956.2.2 Identifier (ID Number) Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 956.2.3 File Name Header Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 966.2.4 Comment Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

6.3 Creating Data Files. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 986.3.1 Using the Model 25DL PLUS Standard Editing Commands. . . . . . . . . 986.3.2 Creating Files from a Computer (using the optional WIN25DL PLUS) 996.3.3 Creating Files from the Model 25DL PLUS . . . . . . . . . . . . . . . . . . . . . 99

6.4 Opening a File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1226.5 Copying a File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1236.6 Deleting a File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1246.7 Editing/Renaming a File. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1266.8 Creating or Editing Comment Tables from a Computer . . . . . . . . . . . . . . . . . . 1276.9 Creating or Editing Comment Tables from the Model 25DL PLUS . . . . . . . . . 127

6.9.1 Deleting Comments from a Comment Table . . . . . . . . . . . . . . . . . . . . 1286.9.2 Copying a Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

6.10 Saving Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1306.10.1 Saving Thickness Readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1306.10.2 Saving Thickness and Waveform. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1316.10.3 Saving Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

6.11 Using the Review ID Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1326.12 Using the Edit ID Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1346.13 Erasing Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

6.13.1 Erasing Data in the Active/Open File . . . . . . . . . . . . . . . . . . . . . . . . . 1356.13.2 Erasing a File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1366.13.3 Erasing the Entire Database . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

6.14 Using the Optional Bar Code Wand to Enter an ID Number. . . . . . . . . . . . . . . 1376.15 Generating Reports. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

7 Managing Communications / Data Transfer . . . . . . . . . . . . . . . . . . . . . . . 1417.1 Transmitting Data to a Computer or Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

7.1.1 Sending Entire Files: Data Transfer from Gage to Computer or Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

7.1.2 Sending a Specific Range of ID Numbers from a Specific File . . . . . 1437.1.3 Performing a Single Send of the Current Displayed Measurement

Data to a Computer or Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1447.1.4 Sending a Snapshot of the Model 25DL PLUS Display to a

Computer (using the optional WIN25DL PLUS Interface Program) . 1447.1.5 Sending a Snapshot of the Model 25DL PLUS Display to a Printer . . 145

7.2 Receiving (Downloading) Files from a Computer . . . . . . . . . . . . . . . . . . . . . . . 1457.3 Uploading/Downloading a Stored Transducer Setup to a Computer . . . . . . . . . 146m~=@=VNMJONM` T

j=ORai=mirp7.4 Setting up Serial Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1467.4.1 Defining RS-232 Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1467.4.2 Setting up Communication Parameters . . . . . . . . . . . . . . . . . . . . . . . . 147

7.5 Identifying Data Output Formats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1497.6 Performing Datalogger and Communication Resets . . . . . . . . . . . . . . . . . . . . . 150

7.6.1 Performing a Communication Reset . . . . . . . . . . . . . . . . . . . . . . . . . . 1517.6.2 Performing a DBase Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

7.7 Using the Optional WIN25DL PLUS Interface Program . . . . . . . . . . . . . . . . . 153

8 Maintaining and Troubleshooting the Model 25DL PLUS . . . . . . . . . . . . 1558.1 Providing Routine Gage Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1558.2 Maintaining Transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1568.3 Understanding Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1568.4 Resolving Battery and Charger Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1568.5 Resolving Measurement Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1578.6 Performing Diagnostic Self Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

8.6.1 Performing a Keypad Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1588.6.2 Performing a Video Display Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1588.6.3 Viewing the Hardware Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1588.6.4 Viewing the Error Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

8.7 Getting Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

Appendix A - Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

Appendix B - Sound Velocities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

Appendix C - Serial Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

Appendix D - Data Output Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

Appendix E - Remote Control Via RS-232 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

Appendix F - Accessories and Replacement Parts . . . . . . . . . . . . . . . . . . . . . 217

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

Documentation Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225U

i==q~List of Tables

Table 1 Typographic Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Table 2 Revision History. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Table 3 Keypad Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Table 4 Calculating a Low/High Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Table 5 Calculating a Percent Thickness Alarm Value. . . . . . . . . . . . . . . . . . . . . . . . . . . 60Table 6 Measurement Reset Default Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75Table 7 DtectMode and EchWindow Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86Table 8 Computer or Printer Serial Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147Table 9 Model 25DL PLUS Output Formats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149Table 10 Information Displayed on the Model 25DL PLUS Screen . . . . . . . . . . . . . . . . 163Table 11 Setup Name and Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169Table 12 Setup Parameter Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171Table 13 Sound Velocities of Various Materials (Longitudinal Wave Velocity) . . . . . . . 175Table 14 Equipment Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177Table 15 Standard 36DL PLUS I/O Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177Table 16 Model 25DL PLUS Output Formats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179Table 17 Flag Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206Table 18 Command Syntax . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214Table 19 Accessories and Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217m~=@=VNMJONM` V

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i==cList of Figures

Figure 1 Model 25DL PLUS Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Figure 2 Identifying Display Elements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Figure 3 Model 25DL PLUS Block Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Figure 4 Usual Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Figure 5 Special Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Figure 6 Initial Display Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Figure 7 Selecting a Stored Transducer Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Figure 8 Naming Convention Sample . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Figure 9 Displaying the Waveform Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47Figure 10 Comparing Normal Display to Zoom in Mode 1 . . . . . . . . . . . . . . . . . . . . . . . . . 47Figure 11 Comparing Normal Display to Zoom in Mode 2 . . . . . . . . . . . . . . . . . . . . . . . . . 48Figure 12 Comparing Normal Display to Zoom in Mode 3 . . . . . . . . . . . . . . . . . . . . . . . . . 48Figure 13 Normal Differential Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52Figure 14 Percent Ratio Differential Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52Figure 15 Thickness Shown in Large Font. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53Figure 16 Rate Reduction Shown in Large Font . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53Figure 17 Viewing the Rate Reduction Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54Figure 18 Displaying the Measurement Update Rate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55Figure 19 Displaying the Minimum Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56Figure 20 Displaying the Maximum Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57Figure 21 Displaying the Low Alarm Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Figure 22 Displaying the High Alarm Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Figure 23 Selecting an Alarm Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Figure 24 Displaying the Previous Thickness Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61Figure 25 Entering Loss/Growth Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62Figure 26 Activating the Reduction Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Figure 27 Selecting an SP Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66Figure 28 Selecting the Radix Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68Figure 29 Displaying a Waveform Trace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68Figure 30 Selecting a Waveform Trace Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69Figure 31 Activating the Supervisor Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70Figure 32 Activating ID Overwrite Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71Figure 33 Saving Measurements with Overwrite Protection activated . . . . . . . . . . . . . . . . 71Figure 34 Selecting the Communications Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73Figure 35 Changing the Communication Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73Figure 36 Detect Mode 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82Figure 37 Detect Mode 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82Figure 38 Detect Mode 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83Figure 39 Pulser Power set to 30 Volts shows a smaller initial pulse . . . . . . . . . . . . . . . . . 84Figure 40 Pulser Power set to 110 Volts shows a larger initial pulse. . . . . . . . . . . . . . . . . . 84Figure 41 Maximum Gain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85m~=@=VNMJONM` NN

Figure 42 Initial Gain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

j=ORai=mirpFigure 43 TDG Slope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86Figure 44 Main Bang Blank position for Mode 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87Figure 45 Main Bang Blank position for Mode 2 and 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . 87Figure 46 Echo Window Setting for Mode 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88Figure 47 Echo Window Setting for Mode 2 and 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89Figure 48 Echo 1 Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90Figure 49 Negative Detection Steel Back by Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90Figure 50 Positive Detection Plastic Bonded to Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90Figure 51 Mode 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91Figure 52 Mode 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92Figure 53 Gage Hanging up on Trailing Edge of Backwall 1 . . . . . . . . . . . . . . . . . . . . . . . 92Figure 54 M3Blank Set Properly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93Figure 55 Adjusting the Setup Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93Figure 56 Displaying Recall Setups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94Figure 57 Saving Recall Setups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94Figure 58 Identifying Datalogger Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96Figure 59 Creating a File Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98Figure 60 Creating a Note. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99Figure 61 Organization of Character Cycle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100Figure 62 Selecting the Create Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101Figure 63 Selecting a File Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101Figure 64 Selecting an Incremental File Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104Figure 65 Enter Incremental File Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104Figure 66 Selecting a Sequential File Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106Figure 67 Entering Sequential File Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107Figure 68 Selecting a Sequential with Custom Point File Type . . . . . . . . . . . . . . . . . . . . . 109Figure 69 Entering Sequential with Custom Point File Information . . . . . . . . . . . . . . . . . 110Figure 70 General Grid Database . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111Figure 71 One Grid for 75 Identical Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112Figure 72 Different Named Grid for Each Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113Figure 73 Selecting a 2D Grid File Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113Figure 74 Entering 2D Grid File Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114Figure 75 Selecting a 2-D Grid with Custom Points File Type . . . . . . . . . . . . . . . . . . . . . 116Figure 76 Entering 2D Grid with Custom Points File Information . . . . . . . . . . . . . . . . . . 117Figure 77 Selecting a 3-D Grid with Custom Points File Type . . . . . . . . . . . . . . . . . . . . . 119Figure 78 Entering 3D Grid File Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120Figure 79 Selecting a 3-D Custom File Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122Figure 80 Entering 3-D Custom File Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123Figure 81 Selecting Open Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124Figure 82 Opening a File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124Figure 83 Selecting the Copy Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125Figure 84 Copying a File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126Figure 85 Selecting the Delete Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127Figure 86 Deleting a File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127NO

i==cFigure 87 Deleting an Active File. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128Figure 88 Selecting the Edit-Rename Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128Figure 89 Entering New File Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129Figure 90 Entering Information for the Comment Table . . . . . . . . . . . . . . . . . . . . . . . . . . 130Figure 91 Selecting the Note-Copy Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131Figure 92 Selecting a Note to Copy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131Figure 93 Copying a Note. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132Figure 94 Selecting a Comment from the Notes Table . . . . . . . . . . . . . . . . . . . . . . . . . . . 133Figure 95 Identifying the Review ID Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135Figure 96 Example of Screen if Edited ID is Not in the Database . . . . . . . . . . . . . . . . . . . 137Figure 97 Selecting the Resets Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138Figure 98 Selecting the DBase Reset Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139Figure 99 Warning Message when Resetting DBase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139Figure 100 Selecting the Reports Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140Figure 101 Selecting the File Summary with Stats Option . . . . . . . . . . . . . . . . . . . . . . . . . 141Figure 102 Selecting a File to View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141Figure 103 Viewing File if Min/Max Summary is Selected. . . . . . . . . . . . . . . . . . . . . . . . . 142Figure 104 Viewing File if File Comparison is Selected . . . . . . . . . . . . . . . . . . . . . . . . . . . 142Figure 105 Selecting the Send Option from the File Menu . . . . . . . . . . . . . . . . . . . . . . . . . 144Figure 106 Selecting a File to Send . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144Figure 107 Identifying a Range of ID Numbers to Send . . . . . . . . . . . . . . . . . . . . . . . . . . . 145Figure 108 Selecting the Communication Option from the SP Mode Menu . . . . . . . . . . . . 150Figure 109 Viewing Communication Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150Figure 110 Viewing the Communication Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152Figure 111 Selecting the Resets Option from the SP Mode Menu. . . . . . . . . . . . . . . . . . . . 153Figure 112 Selecting Communications Reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153Figure 113 Selecting the Resets Option from the SP Mode Menu. . . . . . . . . . . . . . . . . . . . 154Figure 114 Selecting DBase Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155Figure 115 Confirming DBase Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155m~=@=VNMJONM` NP

j=ORai=mirpNQ

m~1 PrefaceThe preface provides the following introductory topics: Product Description About this Document Audience Typographic Conventions Related Documentation If You have Documentation Comments Revision History Technical Help

1.1 Product Description The Panametrics-NDTTM Model 25DL PLUS is a hand-held ultrasonic thickness gage with an A-Scan display. This precision microprocessor-based instrument uses pulse-echo techniques to measure material thickness when both sides of the test material are not easily accessible. The gage can also measure sound velocity and pulse transit time in most solids and liquids.The Model 25DL PLUS is designed with one basic goal in mind simplicity of operation. A wide thickness range with repeatable measurements make the Model 25DL PLUS extremely versatile. The gages three modes of operation and A-Scan display allow the use of contact, delay line and immersion transducers.The Model 25DL PLUS includes a function called Application Recall, which was created to simplify gaging. This function allows the use of both Stored Standard and Custom Stored Application Setups. In general, one of the 25 Stored Setups is adequate for most applications. If, however, your application requires a special setup, the Model 25DL PLUS offers 35 Custom Setup locations; either you or Panametrics-NDT can program Custom setups.The Model 25DL PLUS has an internal datalogger that can store over 18,000 fully documented thickness measurements, or 1,750 thickness readings with waveforms. You can identify each measurement reading with an alphanumeric identification number up to 16 alphanumeric characters in length. The identification number represents a physical location. The gage will increment the identification numbers automatically for each reading, or you can access any alphanumeric location randomly. This incremental process allows for maximum flexibility and easy review of the stored thickness readings for each location.The Model 25DL PLUS also comes equipped with an RS-232 communications port. This communication port allows the Model 25DL PLUS to interface with a computer or printer to download thickness readings, or to remotely setup and calibrate the Model 25DL PLUS from a host computer.Other features include:m~=@=VNMJONM` NR

j=ORai=mirp Thickness range: 0.003-20.000" (0.080-500mm), dependent on material andtransducer type

Large back lit display High-Low Alarm functions Differential Mode Maximum Resolution of 0.0001" (0.001mm) Display Hold/Blank Mode Long battery life Measurement in inches or millimeters with instant conversion Multiple Languages (English, French, German, Spanish) Min/Max Mode Rugged case and sealed, color-coded keypad provides tactile and audible feedback Semi-Automatic Keyboard Calibration Internal Self-Test Modes Keypad Lockout functions prevents accidental changing of calibration or

measurement parametersIn addition, special prompts inform you of instrument conditions such as Measurement mode, low battery, loss of signal, Calibration mode, data stored with location identification, alarms, and Differential mode.Panametrics-NDT offers a wide variety of broadband contact, delay line and immersion transducers for use with the Model 25DL PLUS to permit optimum application of the gage on most engineering materials. For applications assistance, consult Panametrics-NDT.

1.2 About this DocumentThis document is the Instruction Manual for the Model 25DL PLUS. The Instruction Manual describes routine tasks for operating the Model 25DL PLUS. These tasks include operating the Model 25DL PLUS, configuring system parameters, managing system functions, and calibrating the Model 25DL PLUS.

1.3 AudienceThis document is intended for any operator using the Model 25DL PLUS. Panametrics-NDTTM recommends that all operators have a thorough understanding of the principles and limitations of ultrasonic testing. We assume no responsibility for incorrect operational procedure or interpretation of test results. We recommend that any operator seek adequate training prior to using this equipment. Panametrics-NDT offers a full range of training courses including Level I and Level II Ultrasonic Testing, Advanced Detection and Sizing, and Ultrasonic Thickness Gaging. For further information regarding training courses, contact Panametrics-NDT.NS

m~1.4 Typographic ConventionsThe following notes and table provide a list of the typographic conventions that appear in this document.

Warning: This information indicates danger and the possibility of personalinjury.

Caution: This information indicates that loss of data or equipment damage can occur.

Note: This information provides explanatory information.

Tip: This information provides helpful guidelines for easy operation.

Convention Description

Courier Font Used for file names, lines of code, names of processes, and commands.

Heavy courier Used for command line user input.

Bold Used for textual parts of graphical user interface, including menu items, buttons, toolbar names, modes, options, and tabs.

Italics Used for screen/window names, dialog boxes and document titles.

Bold Italics Used for emphasis.

[Bold] (Square Brackets with Bold)

Used for instrument keys on the keypad.

(Angle Brackets) With italics text, used for variable data.

Used for showing the next sequential step.

Table 1 Typographic Conventionsm~=@=VNMJONM` NT

j=ORai=mirp1.5 Related DocumentationThe Model 25DL PLUS works with the optional WIN25DL PLUS Interface Program. For more information about this software program, refer to the following instruction manual: WIN25DL PLUS Interface Program, Part Number 910-222

1.6 If You have Documentation CommentsPanametrics-NDTTM is always interested in improving its documentation. We value your comments about this manual and other Panametrics-NDT documentation.Simply fill out the survey at the back of this manual and send your documentation comments to Panametrics-NDT by using one of the following methods:

Send comments to Panametrics-NDT, Attention: Technical Publications Email: [email protected].

In all your correspondence, please include the title of the document, its part number, release date, and the specific section upon which you are commenting.

1.7 Revision HistoryThis document may require updating because of corrections or changes to the product. Publication dates, printed on the front cover, are updated when a change is made to this document. In addition, the document number is also changed to reflect the revision.The table below shows a list of all revisions for this document.

1.8 Technical HelpCall Panametrics-NDT and ask for a sales engineer to assist you.

Date Issue Release version

May, 2001 910-210A First release.

July, 2001 910-210B Second release.

June, 2002 910-210C Third release.

March, 2004 910-210C Edit.

Table 2 Revision HistoryNU

a=_~=d~=l~2 Defining Basic Gage OperationThis chapter describes how to get started using basic Model 25DL PLUS operations.Topics are as follows: Summarizing Keypad Functions Identifying Display Elements Using the Battery Pack Monitoring the Battery Charge Charging the Battery Pack Replacing the Battery Pack Using AA Batteries Discussing Theory of Operation

2.1 Summarizing Keypad Functions

Figure 1 Model 25DL PLUS Keypad

The figure above shows the full keyboard layout. Refer to the following table that lists all the keystroke functions available from the Model 25DL PLUS keyboard.The table lists functions in two groups. The first group consists of single keystroke functions and the second group consists of multiple keystroke functions. Unless otherwise noted, keys shown boxed together are pressed sequentially.m~=@=VNMJONM` NV

j=ORai=mirpKey Key Color Function

Green Power On/Off - Turns the gage on and off.

Yellow Zero - Compensates for transducer zero or enables step block zero calibration.

Yellow Cal - Switches the gage into the semi-automatic step block Calibration mode.

Yellow Velocity - 1) Displays and enables changing the sound velocity calibration for a particular material. 2) In ID Edit mode only, the [VEL] key deletes the character at the cursor.

-

Yellow Numeric Keys - Enter numeric values from 0-9.

Red Measurement/Reset - Completes the current operation and switches the gage to Measurement mode.

Blue Range - Changes the waveform display range to the next available value.

Blue Zoom - 1) Changes the waveform display range so that the region immediately surrounding the measured echo is shown at maximum magnification. 2) In the ID Edit mode only, the [ZOOM] key inserts a blank space at the cursor.

Table 3 Keypad DefinitionsOM

a=_~=d~=l~Blue Freeze - Causes the displayed waveform to immediately hold until reset.

Orange Recall Setup - Allows recalling a stored default or custom transducer setup.

Orange Backlight - Controls the waveform display Backlight.

Gray Enter - Used to select highlighted items and accept entered values.

Green Up Arrow - 1) Adjusts the value of a selected parameter upward. 2) Selects the next higher entry in a chosen list.

Green Down Arrow - 1) Adjusts the value of a selected parameter downward. 2) Selects the next lower entry in a chosen list.

Green Left Arrow - 1) Lowers the value of a selected parameter. 2) Moves the character and highlights the cursor one space to the left during the ID Edit mode.

Green Right Arrow - 1) Increases the value of a selected parameter. 2) Moves the character and highlights the cursor one space to the right during the ID Edit mode.

Brown File - Opens File Options box where you can Open Files, Create Files, Copy Files, Delete Files, Send Files, Edit/Rename Files, Generate Reports.

Key Key Color Function

Table 3 Keypad Definitions (Continued)m~=@=VNMJONM` ON

j=ORai=mirpBrown Save - Stores measurements/waveforms in the datalogger at the current ID number.

Tan Send - Initiates transmission of stored data to a computer or printer.

Tan ID# (Identification Number) - Allows access to several functions related to changing ID numbers.

Gray 2ND F - When pressed with a key that has dual functions (the main function written on the key; the secondary function written above the key), the secondary function becomes active.

Multiple Keypress Functions

Gray

Red

Escape - Escapes from any function without changing data or parameters and returns to the Measure mode.

Gray

Orange

LCD Contrast Adjustment - Enables adjusting the waveform display contrast using the up and down arrow keys.

Gray

Yellow

Setup Adjust - Enables adjustments to a transducer setting.

Key Key Color Function

Table 3 Keypad Definitions (Continued)OO

a=_~=d~=l~Gray

Yellow

IN/MM - Toggles the measurement units between inches and millimeters.

Gray

Blue

Rectification Type - Cycles among the available types of waveform rectification i.e., full-wave, negative half-wave, positive half-wave, or unrectified RF.

Gray

Yellow

Setup Mode (SP Mode) - Allows user to modify gage parameters and perform special test functions.Options in the Setup Mode include:

Measurement Setup Communication

Setup Diagnostic Self Tests Resets Clock Section

Gray

Yellow

Resolution - Toggles thickness display resolution between default.Standard: 0.001in or 00.01mmHigh: 0.0001in or 0.001mmLow: 0.01in or 0.1mm

Gray

Yellow

Status - Shows an information screen with the following data:1) Software version2) Available memory3) Error explanation, if applicable

Key Key Color Function

Table 3 Keypad Definitions (Continued)m~=@=VNMJONM` OP

j=ORai=mirpGray

Orange

Waveform - Stores a measurement and waveform in the datalogger at the current ID#.

Gray

Tan

Print - Prints an image of the display including the waveform with the current thickness.

Gray

Tan

Notes - Allows you to create or select comments to store at an ID# location.

Gray

Tan

Clear Memory - An alternative method to erase an entire file. Also used to erase a range of data in a file or a single ID# location.

Gray

Yellow

Hold/Blank Thickness Display - Toggles between holding and blanking the thickness display during an LOS condition.

Gray

Yellow

Alarm - Views, enables, and allows changing Alarm setpoints.

Key Key Color Function

Table 3 Keypad Definitions (Continued)OQ

a=_~=d~=l~2.2 Identifying Display ElementsThe gage screen is a Liquid Crystal Display (LCD) and best viewed from straight above or slightly below the surface rather than from the side. The display may be slow at temperatures below 32oF (0oC).

The figure below identifies the various sections of the Model 25DL PLUS display.

Gray

Yellow

Differential - Views, enables and allows changing the Differential Reference Value.

Gray

Yellow

Measure Rate - Allows you to change the measurement rate by using the up and down arrows. The selected measurement rate is displayed in the message window. To remove message from displays, press [MEAS].

Gray

Yellow

Min/Max Measure - Selects Minimum Measure mode, Maximum Measure mode, or Default Measure mode.

Yellow

Yellow

Calibration Lock - Controls the calibration key lock.

Key Key Color Function

Table 3 Keypad Definitions (Continued)m~=@=VNMJONM` OR

j=ORai=mirpFigure 2 Identifying Display Elements

General Information: The main function of the display is to show the echo waveform and to display the thickness reading received by the transducer as measurements are made. The received echoes are amplified before being shown on the display. The waveform trace is called the A-Scan display. This type of waveform allows a skilled operator to verify that the gage signal being used to make a thickness measurement is the correct backwall echo and not a noise, material anomaly, or the second multiple echo. This verification waveform along with all pertinent calibration information can be stored with the thickness value in the internal datalogger. An experienced operator can also use the echo waveform to learn more about the quality of the measurement than is given just by the thickness value, which includes observation of indications that may be too small to be measured by the gage.Press the [FREEZE] key to freeze the display. Adjust the thickness range (horizontal scale) or expand the measured echo by using the Zoom mode.When operating in the Minimum or Maximum Measure mode, the waveform associated with a minimum or maximum reading is internally captured and recalled to the screen when the transducer is uncoupled. Furthermore, any waveform that is stored in the datalogger memory can be shown on the waveform display for review or comparison to the current measured waveform. Such recalled waveforms may have been recently saved or may have been downloaded from a computer data file.Thickness Display: The top portion of the display shows the current Filename, ID number, Comments, and any previous stored thickness values.

ID LocationStored Thickness

Measurement Marker

Delay

Setup Adjustment

Meas Mode/Update

Help Text

Available Keys Box

ThicknessUnits

Battery Life

Range

Rectification

Zoom Flag

Freeze Flag

Comments/ID#

Date and TimeFile Name

Download Flag

Setup Value

Q Bar

Min/Max

AlarmOS

a=_~=d~=l~The lower part of the display functions as a general purpose thickness measurement display; as a control panel for calibrating and setting up the gage, in addition to displaying status conditions, error messages and warnings. The large characters are used to show numerical values such as thickness and velocity. This area also shows flags that describe the numeric data and/or the gage operating modes, and the battery status.

2.3 Using the Battery PackThe Model 25DL PLUS Gage is powered by an internal 6V battery pack using rechargeable NiCad batteries or 6 AA alkaline batteries. The NiCad battery pack is recharged through the Model 36CA PLUS Charger/AC Adapter unit that is supplied with the gage. The 36CAPLUS does not recharge the alkaline batteries; you must replace the alkaline batteries after discharging. The Model 25DL PLUS can also be operated directly from AC power using the Charger/Adapter.The batteries are fully charged when shipped, but for maximum operating time, recharge before using. Recharge batteries only with the Model 36CA PLUS Charger/Adapter supplied with the gage. Other chargers may reduce battery life and/or damage the battery and void the warranty on the gage.Even a discharged battery maintains the internal stored calibration values and thickness data for several weeks. However, to maintain optimum battery life, do not leave discharged batteries for long periods of time.

2.4 Monitoring the Battery ChargeThe battery charge indicator, or battery status meter, displays the percentage of battery remaining capacity in bottom right hand corner of the display. Remember that if the battery is charged for at least 2 hours, then 99% charge indication corresponds to over 25 hours of operation. However, if the battery is charged for less than 2 hours, then 99% charge indication corresponds to proportionally fewer hours of operation.

Note: The battery charge indicator shows a rotating bar when the when the chargeris plugged in; however, it cannot be used to indicate when full charge isreached while charging. The gage displays a C indicating that the battery ischarging. The gage displays a S indicating that charging is complete.

2.5 Charging the Battery PackThe gage operates for at least 25 hours between charges under normal conditions (4Hz measure update rate in Mode 1 with the Backlight turned off.) The current battery status is always indicated in the lower right corner of the gage display. This indicator shows a percentage of the battery charge remaining. The maximum percentage that can be displayed is 99%. (See Monitoring the Battery Charge on page 27.)When the battery is insufficiently charged, the gage automatically powers off to prevent damage to the battery. Recharge the battery using the Model 36CA PLUS charger.m~=@=VNMJONM` OT

j=ORai=mirpTo charge the NiCad battery pack, plug the 36CA PLUS AC Charger Adapter into an appropriate source of AC power, and plug the cable from the Charger/Adapter into the charger socket on the top of the gage. The battery recharges whether the gage is OFF or ON. Do not attempt to use the battery charge indicator to determine when batteries have reached full charge. For a fully discharged battery, allow approximately 2 hours to fully recharge. You can use the gage for normal measurements while the Charger/AC Adapter is connected with little effect on the recharge time.

2.6 Replacing the Battery PackAfter several hundred recharges, the NiCad batteries lose the ability to hold a full charge.To replace an old battery pack, follow these steps:

1. Open the battery panel on the back of the gage case by loosening the four captive screws.

2. Remove the battery, once the case is open, by gently pulling the black strap at the right end of the battery.

3. Remove the plug that connects the wire from the battery pack to the circuit board of the gage.

4. Connect the new battery pack, and install with the label side facing outward.5. Replace the battery panel and tighten the screws.

Note: The internal memory is maintained for over an hour when the battery isremoved. If a new battery is installed in less than an hour, no calibration orthickness data is lost.

2.7 Using AA BatteriesNon-rechargeable alkaline batteries are available for use with the Model 25DL PLUS.To replace the NiCad Rechargeable batteries with alkaline batteries, follow these steps:

1. Remove the NiCad pack.2. Insert 6 AA Alkaline batteries into provided alkaline battery holder.3. Connect the Alkaline battery holder to the gage using the same connector as the

NiCad.4. Place the Alkaline holder into battery compartment.5. Replace the battery panel and tighten screws.

Note: It is also possible to charge the Nicad battery outside of the Model 25DLPLUS using a special external battery charger adapter. Contact Panametrics-NDTTM for more information on external battery charging.OU

a=_~=d~=l~2.8 Discussing Theory of OperationThe Model 25DL PLUS operates on the Pulse/Echo principle. This principle works by precisely timing the reflection of high frequency sound waves from the transducer to the far wall of a test piece. This technique, derived from sonar, has been widely applied to nondestructive testing because it permits accurate measurement of material thickness even though access may be available from only one side.The Model 25DL PLUS uses a variety of piezoelectric transducers that generate bursts of mechanical vibrations, or sound waves, when excited by short electrical pulses. The frequency of these sound waves is far beyond the limit of human hearing; from one million to twenty million cycles per second, versus a typical limit of less than twenty thousand cycles per second for the human ear. Sound at these very high frequencies does not travel well through air, so a coupling medium such as a drop of liquid (usually propylene glycol, glycerin, water, or oil) is used between the transducer and the test piece.The sound waves generated by the transducer are coupled into the test piece and reflected back from the opposite side. The same transducer then receives the reflected sound waves and converts them into electrical pulses. The gage amplifies the received signal, digitizes a selected portion of the wavetrain, and then very precisely measures a time interval corresponding to one round trip of the sound waves in the test piece. This measurement is made in one of three modes as described below. The gage, which has been calibrated to the speed of sound in the test material, computes the thickness of the test material using the relationship:

The Model 25DL PLUS can employ any of three measurement modes to calculate pulse transit time. Mode 1: Use with contact transducers. In this mode, measurement is made from the initial excitation pulse to the first returning echo from the backwall of the test piece. The MTI marker indicates the Measured Time Interval. Mode 2: Use with delay line and immersion transducers. In this mode, measurement is made between an interface echo marking the time the sound wave enters the test piece and the first backwall echo. The MTI marker indicates the Measured Time Interval.

where:

x = the thickness of the material

V = the velocity of sound in the material

t = the measured round-trip transit time of the pulse

t0 = the zero offset factor (to correct for transducer wearplate delay, cable delay, and other fixed delays)

xV t t0( )

2----------------------=m~=@=VNMJONM` OV

j=ORai=mirpMode 3: Use with delay line and immersion transducers. In this mode, measurement is made between two successive backwall echoes that follow an interface echo. The MTI Marker indicates the Measured Time Interval.

Figure 3 Model 25DL PLUS Block Diagram

The figure above is a block diagram of the Model 25DL PLUS. The pulser, under the control of the microprocessor, provides a unidirectional broadband spike voltage impulse to a heavily damped broadband ultrasonic transducer. The broadband ultrasonic pulse generated by the transducer is coupled to the test piece by means of liquid couplant. Echoes returning from the back or inside surface of the test piece are received by the transducer and converted to electrical signals, which in turn are fed to the receiver AGC amplifier. The microprocessor-based control and timing logic circuits both synchronize

Battery PowerSupplyROM RAM

Detector

LCD

Keyboard

Transducer Charger RS-232 Output

Control and MeasurePulser AGCAmplifierPM

a=_~=d~=l~the pulser and select the appropriate echo signals that will be used for the time interval measurement.

If echoes are not detected during a given measurement period, the gage will shut down to save power until a new measurement cycle is required. If echoes are detected, the timing circuit will precisely measure an interval appropriate for the selected Measurement mode, and then repeat this process a number of times to obtain a stable, averaged reading. The microprocessor then uses this time interval measurement, along with sound velocity and zero offset information stored in the Random Access Memory (RAM), to calculate thickness. Finally, the thickness is shown on the LCD and updated at a selected rate.

2.9 Factors Affecting Performance and Accuracy Calibration: The accuracy of any ultrasonic measurement is only as good as the

accuracy and care with which the gage is calibrated. The gage is shipped from thefactory with standard setups for a number of transducers and applications. In somecases, it is desirable to optimize these setups for specific measurement situations, asdescribed in Chapter 3. In all cases, it is essential that the velocity and zerocalibrations, described in Chapter 3, are performed whenever the test material ortransducer is changed. Periodic checks with samples of known thickness arerecommended to verify that the gage is operating properly.

Surface Roughness of the Test Piece: The best measurement accuracy is obtainedwhen both the front and back surfaces of the test piece are smooth. If the contactsurface is rough, the minimum thickness that can be measured will increase because ofsound reverberating in the increased thickness of the couplant layer. Additionally, ifeither surface of the test piece is rough, the returning echo may be distorted due to themultiplicity of slightly different sound paths seen by the transducer, and measurementinaccuracies will result.

Coupling Technique: In Mode 1 (contact transducer) measurements, the couplantlayer thickness is part of the measurement and is compensated by a portion of the zerooffset. If maximum accuracy is to be achieved, the coupling technique must beconsistent. This is accomplished by using a couplant of reasonably low viscosity,employing only enough couplant to achieve a reasonable reading, and applying thetransducer with uniform pressure. A little practice shows the degree of moderate tofirm pressure that produces repeatable readings. In general, smaller diametertransducers require less coupling force to squeeze out the excess couplant than largerdiameter transducers.In all modes, tilting the transducer distorts echoes and cause inaccurate readings, as noted below.

Curvature of the Test Piece: A related issue involves the alignment of the transducerwith respect to the test piece. When measuring on curved surfaces, it is important toplace the transducer approximately on the centerline of the part and held as nearlynormal to the surface as possible. In some cases, a spring-loaded V-block holder ishelpful for maintaining this alignment. In general, as the radius of curvaturedecreases, the size of the transducer is reduced, and the more critical transduceralignment becomes. For very small radiuses, an immersion approach is necessary. Insome cases, it is useful to observe the waveform display via the PC Scope option as anm~=@=VNMJONM` PN

j=ORai=mirpaid in maintaining optimum alignment. Practice with the aid of a waveform displayprovides the operator a proper feel for the best way to hold the transducer.On curved surfaces, it is important to use only enough couplant to obtain a reading. Excess couplant forms a fillet between the transducer and the test surface where sound reverberates and possibly creates spurious signals that can trigger false readings.

Taper or eccentricity: If the contact surface and back surface of the test piece aretapered or eccentric with respect to each other, the return echo will be distorted due tothe variation in sound path across the width of the beam. Accuracy of measurement isreduced. In severe cases, no measurement is possible.

Acoustic Properties of the Test Material: There are several conditions found incertain engineering materials that can potentially limit the accuracy and range ofultrasonic thickness measurements: Sound Scattering: In materials such as cast stainless steel, cast iron, fiberglass,

and composites, sound energy will be scattered from individual crystallites in the casting or boundaries of dissimilar materials within the fiberglass or composite. Porosity in any material can have the same effect. Gage sensitivity must be adjusted to prevent detection of these spurious scatter echoes. This compensation can in turn limit the ability to discriminate a valid return echo from the back side of the material, thereby restricting measurement range.

Sound Attenuation or Absorption: In many organic materials such as low density plastics and rubbers, sound energy is attenuated very rapidly at the frequencies used for ultrasonic gaging. This attenuation typically increases with temperature. The maximum thickness that can be measured in these materials are often limited by attenuation.

Velocity Variations: An ultrasonic thickness measurement is accurate only to the degree that material sound velocity is consistent with gage calibration. Some materials exhibit significant variations in sound velocity from point to point. This happens in certain cast metals due to the changes in grain structure that result from varied cooling rates, and the anisotropy of sound velocity with respect to grain structure. Fiberglass can show localized velocity variations due to changes in the resin/fiber ratio. Many plastics and rubbers show a rapid change in sound velocity with temperature, requiring that velocity calibration be performed at the temperature where measurements are made.

Phase Reversal or Phase Distortion: The phase or polarity of a returning echo isdetermined by the relative acoustic impedances (density x velocity) of the boundarymaterials. The gage assumes the customary situation where the test piece is backed byair or a liquid, both of which have lower acoustic impedances than metals, ceramics,or plastics. However, in some specialized cases (such as measurement of glass orplastic liners over metal, or copper cladding over steel) this impedance relationship isreversed, and the echo appears phase reversed. In these cases, it is necessary to changethe appropriate Echo Detection polarity, as discussed in Chapter 3, in order tomaintain accuracy.PO

a=_~=d~=l~Figure 4 Usual Case

Figure 5 Special Case

A more complex situation can occur in anisotropic or inhomogeneous materials such as coarse-grain metal castings or certain composites, where material conditions result in the existence of multiple sound paths within the beam area. In these cases, phase distortion can create an echo that is neither cleanly positive nor negative. Careful experimentation with reference standards is necessary, in these cases, to determine effects on measurement accuracy.

Material backed by air or water. Use Default Echo Detect, NEG.

Plastic or glass backed by metal. Change Echo Detect to POS.m~=@=VNMJONM` PP

j=ORai=mirpPQ

p=r=~=`~~==d~3 Setting Up and Calibrating the GageThis section demonstrates how to make basic thickness measurements with the Model 25DL PLUS. The unit ships from the factory set up with default conditions for the transducer(s) you have purchased. You can change Setups easily after becoming familiar with the more sophisticated features of the gage. The default conditions are selected to facilitate gage usage for your applications. This section contains a detailed explanation of these default conditions.Topics are as follows: Getting Started Making Thickness Measurements Choosing a Default or User-Defined Setup Performing a Quick Setup Calibrating the Model 25DL PLUS Adjusting the Range Operating the Delay Function Operating the Zoom Mode Using the Backlight

3.1 Getting StartedTo setup the Model 25DL PLUS for the first time, use the test block included with the gage and the default settings, and follow these steps:

1. Plug the transducer cable into the transducer connector at the top end of the Model 25DL PLUS case.

2. Connect the transducer to the other end of the cable if it is not already connected.3. Press the [ON/OFF] key to power on the gage.

Ensure that the probe type shown in the information window matches the transducer you have attached to the gage. This part number is engraved on the back or side of the transducer. (See Performing a Quick Setup on page 39 if the probe type does not match the transducer type.)m~=@=VNMJONM` PR

j=ORai=mirpApproximately 2.5 seconds after the gage is powered on, the following screen opens:

Figure 6 Initial Display Screen

4. The current units are indicated on the right of the thickness display. To change either inches (IN) or millimeters (MM) to the alternate measurement unit, press the [2ND F] key, then the [3] (IN/MM) key.The gage is now ready to make measurements based on the default settings and the included test block.

Note: The procedure mentioned above is not a substitute for doing a propercalibration.

3.2 Making Thickness MeasurementsTo begin making thickness measurements, follow these steps:

1. Apply couplant to the test block or material at the location to be measured.

In general, smooth material surfaces allow the use of thinner couplants such as propylene glycol, glycerin, or water. Rough surfaces require more viscous couplant such as gel or grease. See Appendix F - Accessories and Replacement Parts on page 217 for a list of available couplants.

2. Press the tip of the transducer to the surface of the material to be measured. Use moderate to firm pressure and keep the transducer as flat as possible on the material surface.

3. Read the material thickness on the gage display.

Note: For highest accuracy, you must perform both a velocity and zero calibration.See Calibrating the Model 25DL PLUS on page 40 for more information.PS

p=r=~=`~~==d~3.3 Choosing a Default or User-Defined SetupThe Model 25DL PLUS uses a wide variety of transducers through the Application Recall feature. Stored within the gage are 25 pre-defined and 35 user-defined application setups that provide maximum flexibility for a wide range of applications. The pre-defined setups always remain in the gage as defaults and cannot be removed. This section discusses how to choose an appropriate stored transducer setup and how to calibrate the Model 25DL PLUS for a specific application.To select a stored transducer setup, follow these steps:

1. Select a transducer for the desired application and connect it to the gage.

Note: See Appendix A - Technical Specifications on page 161 to determine anappropriate transducer. See Table 11 on page 169 as a guideline only; exactthickness ranges will vary depending on the application.

2. While the gage is in the Measure mode, press [RECALL SETUP].

Figure 7 Selecting a Stored Transducer Setup

3. Press [ ] and [ ] to scroll through the available stored setups until the correct setup for the application is highlighted. Below is an example of a default setup naming convention and a complete list of available stored setup choices:

Figure 8 Naming Convention Sample

D E F M 1 - 2 0 . 0 / M 1 1 6

Default

Material:M-MetalP-Plastic

Mode:Mode 1Mode 2Mode 3

Frequency

Probe Part Numberm~=@=VNMJONM` PT

j=ORai=mirpAvailable stored setup choices:ACTIVE DEF1-20.0/M116DEF1-10.0/M112DEF1-5.0/M110DEF1-5.0/M109DEF1-2.25/M106DEF1-10.0/M1016DEF1-2.25/M1036DEFM2-20.0/M208DEFM3-10.0/M208DEFP2-20.0/M208DEFM2-10.0/M202DEFM3-10.0/M202DEFP2-10.0/M202DEFP2-15.0/V260DEFM3-15.0/V260DEFP2-5.0/M206DEFM2-5.0/M206DEFM3-5.0/M206DEFP2-2.25/M207DEFM2-2.25/M207DEFM3-2.25/M207DEFP2-20.0/M316DEFM3-20.0/M316DEFP2-10.0/M312DEFM3-10.0/M312USER -1USER-2USER-3-

-

-

USER- 35PU

p=r=~=`~~==d~Note: You can rename the setups listed as USER-1 through USER-35 for specialapplications. See Using Custom Setups on page 79.

4. Press [MEAS] once the correct setup is highlighted. This action automatically recalls the setup parameters for the chosen setup and brings you back to the Measure screen.

5. Begin taking measurements.

3.4 Performing a Quick SetupNormally, custom application setups are changed by selecting the application setup list using [RECALL SETUP]. Slew down to the desired setup name and press [MEAS]. This process is adequate for typical setups that are changed infrequently. However, when it is necessary to change frequently between two or more custom setups, a more direct short-cut procedure is available, known as Quick Setup.When this Quick Setup procedure is activated, a single keystroke (held for a moment to prevent errors) quickly switches to any of the first nine custom setups.To activate the Quick Setup feature, follow these steps:

1. Press [2nd F], [0] (SP Mode). 2. Press [ ], [ ], or [ENTER] to select Measurement.3. Press [ ] or [ ] to select Quick Setup.4. Press [ ] or [ ] to select On or OFF.5. Press [MEAS] to return to Measure mode.

To change the active application setup to any of the first nine custom setups when Quick Setup is activated, follow these steps:

1. Press and hold any numeric key [1] through [9] until the beep sounds (about 1 1/2 seconds). The momentary message USER N is now active and is displayed on the first status line, and the active setup is changed to the displayed name.

Note: USER-N refers to the Nth custom setup where N is the numeric key pressed.

2. Numeric keys may be used repeatedly in this way to quickly move between setups. When preceded by the [2nd F] key, numeric keys always perform the indicated second function, e.g. [2nd F], [5] selects MIN or MAX Measure mode even when Quick Setup is activated. Quick Setup remains enabled until turned off by following the procedure described in step 1 above.m~=@=VNMJONM` PV

j=ORai=mirp3.5 Calibrating the Model 25DL PLUSCalibration is the process of adjusting the gage, prior to testing, to a known reference value for a specific material and transducer. Calibrating the gage is always necessary before measuring specific material by one of the methods described below. Remember, the gages measurement accuracy is only as good as the calibration that is performed.The Model 25DL PLUS calibration procedure falls into one of the following three categories: Velocity and Zero Calibration Velocity Calibration Only Zero Calibration Only

Note: In sections 3.5.13.5.3, the following notes are applicable:

Caution: Save all changes made to Active Setups. Unsaved data will be lost when adifferent application setup is recalled.

3.5.1 Velocity and Zero Calibration

Velocity and Zero Calibration find both sound velocity and zero offset when you do not know either of these elements. This calibration process requires two pieces of test material of known thickness values, which are within the measurement range of both the transducer and setup specifications. See Table 11 on page 169 for more information.One of the test materials must be thicker than the other. The thicker piece, used to measure velocity, should be equal to or greater than the upper range of thickness to be measured. The thinner piece, used for the zero offset, should be equal to or less than the lower range of minimum thickness to be measured. To calibrate for the thickness range represented by these test samples, follow these steps:

1. Power on the gage and wait for the Measure screen display.

If a mistake is made or any problem is experienced during the calibration, press [MEAS] and return to Step 1.

After completing Step 2, if the prompt CAL LOCK appears on the bottom of the display instead of CAL, then unlock the calibration by following the steps below:- Press the [MEAS] key.- Press the [6] and [3] keys simultaneously.- The gage will beep and display a message, CAL LOCK is off at the bottom of the gage.- Repeat steps 1 and 2.QM

p=r=~=`~~==d~2. Place a drop of couplant on the surface of the thicker material sample, and couple the transducer to the sample using moderate to firm pressure. A thickness reading appears on the display while the LOS prompt in the upper right corner of the display disappears.

3. Press [CAL] when a stable reading is on the display and the LOS prompt is not on the screen. Observe the CAL (calibration) prompt on the display.

4. Remain coupled to the standard test piece and ensure that there is still a stable reading on the display. Press [VEL]. A prompt appears on the display: Enter value for thick standard.

5. Remove the transducer from the sample. The thickness value remains on the display.6. Using the numeric keys on the gage, enter the actual known thickness of the test

material.

Continue with the following steps:

1. Put a drop of couplant onto the thin material sample and couple the transducer to it using moderate to firm pressure.

2. Press [CAL]. A thickness reading appears on the display.3. Remain coupled to the test piece and ensure that there is a stable reading on the

display. Press [ZERO]. A prompt appears on the display: Enter value for this sample.

4. Remove the transducer from the sample. The thickness value remains on the display.5. Using the numeric keys, enter the actual known thickness of the test material.6. Press [MEAS] to finalize the calibration.

Note: You can Lock the calibrated readings to ensure that it is not accidentallychanged. (Refer to Section 4.1.8Calibration Lock.) From the Measuremode, press [3] and [6] simultaneously. The gage displays a message: CALLOCK is on...

3.5.2 Velocity Calibration Only

Use the Velocity Calibration Only procedure when the gage is calibrated for a particular transducer/material combination, and that same transducer is used with a different material and sound velocity. The procedure requires test material of known thickness, equal to or greater than the upper range of thickness to be measured. To calibrate for the thickness range represented by this test sample, follow these steps:

1. Power on the gage and wait for the Measure screen display.2. Place a drop of couplant on the surface of the test material, and couple the transducer

to the sample using moderate to firm pressure. A thickness reading appears on the display while the LOS prompt in the upper right corner of the display disappears.m~=@=VNMJONM` QN

j=ORai=mirp3. Press [CAL] when a stable reading is on the display and the LOS prompt is off. The gage displays a message: Couple to standard; press VEL or ZERO.

4. Remain coupled to the test piece and ensure that there is still a stable reading on the display. Press [VEL]. A prompt appears on the display: Enter value for thick standard.

5. Remove the transducer from the sample. The thickness value remains on the display.6. Use the numeric keys to enter the actual known thickness of the sample being

measured.7. Press [MEAS] to finalize calibration.

Note: You can LOCK the calibrated readings to ensure that it is not accidentallychanged. (See Managing the Calibration Lock on page 62.) From theMeasure mode, press [3] and [6] simultaneously. The gage displays amessage: CAL LOCK is on...

If the sound velocity of the test material is known, then enter the velocity directly. To enter a known velocity, follow these steps:

1. Turn the gage on and wait for the Measure screen.2. Press [VEL]. The Velocity prompt appears and the gage displays the current sound

velocity.3. Use the numeric keys to enter the new velocity.4. Press [MEAS].

3.5.3 Zero Calibration Only

Use the Zero Calibration Only procedure when the gage is calibrated for a particular transducer/material combination, but the transducer is replaced and the test material remains the same.

Note: See Choosing a Default or User-Defined Setup on page 37 if a transducer ischanged to a different type of transducer after calibrating. See Performing aQuick Setup on page 39 to repeat this procedure.

The Zero Calibration Only procedure requires test material of known thickness, preferably near the lower end of the desired measurement range, but not below the gages minimum measurement range for both the transducer and setup specifications. To calibrate for the thickness range represented by this test sample, follow these steps:

1. Power on the gage and wait for the Measure screen display.2. Place a drop of couplant on the surface of the material sample, and couple the

transducer to the sample using moderate to firm pressure. A thickness reading appears on the display while the LOS prompt in the upper right corner of the display disappears.QO

p=r=~=`~~==d~3. When a stable reading is on the display and the LOS prompt is off, press [CAL]. The gage displays a message: Couple to standard; press VEL or ZERO.

4. Remain coupled to the test piece and ensure that there is still a stable reading on the display. Press [ZERO]. A prompt appears on the display: Enter value for thin standard.

5. Remove the transducer from the sample. The thickness value remains on the display.6. Use the numeric keys to enter the actual known thickness of the sample being

measured.7. Press [MEAS] to finalize the calibration.

Note: You can LOCK the calibrated readings to ensure that it is not accidentallychanged. (See Managing the Calibration Lock on page 62.) From theMeasure mode, press [3] and [6] simultaneously. The gage displays amessage: CAL LOCK is on...

If you know the zero offset number for a particular transducer, enter it directly. See Velocity and Zero Calibration on page 40 to determine the zero number for a given transducer and calibrate the gage according to the procedure (See Zero Calibration Only on page 42 also.) Press [ZERO] to read the zero offset number. Record this number for each probe for future reference.

Note: You must use the same transducer cable lengths in order to maintainaccuracy of the zero offset number recorded for each probe. This rule isespecially true when using cable lengths over 10 ft. (approximately 3Meters) in 0.0001" or 0.001mm resolution.

To enter a known zero offset number, follow these steps:

1. Power on the gage and wait for the Measure screen display.2. Press [ZERO]. The gage displays the prompt: Enter value for zero. The gage

displays the zero offset number to which it is presently calibrated.3. Use the numeric keys to enter the new zero offset.4. Press [MEAS] to enter the new zero offset into the gage.

3.6 Adjusting the RangeThe range of the waveform display is the distance spanned by the horizontal axis of the display in the non Zoom mode. (See Operating the Zoom Mode on page 45.) The left end of the horizontal-axis is always zero thickness, and the right end is the thickness representing the endpoint of the range unless the delay was adjusted. There are fixed ranges available for each transducer frequency. The available ranges are also material velocity dependent; for steel they are:

.500 in (10.0mm)1.00 in (20.0mm)m~=@=VNMJONM` QP

j=ORai=mirp2.00 in (50.0mm)5.00 in (100.0mm)10.00 in (200.0mm)20.00 in (508.0mm)

These selectable ranges let you adjust the thickness span of the waveform display to encompass only the thickness range being measured and thus obtain maximum waveform resolution for each application. The range setting affects the waveform display only. You can still make measurements even when the display range does not encompass the thickness being measured.To change the range at any time the display is active, follow these steps:

1. Press [RANGE]. The waveform range changes to the next higher available range.2. Continue to press [RANGE] until the desired range is obtained. The range value

recycles to the minimum range value following the maximum range value.

Tip: Press [ ] prior to pressing [RANGE] to either increase or decrease therange direction. You can change the range direction back to increasingvalues by pressing [ ] prior to pressing [RANGE] again.

3.7 Operating the Delay FunctionThe Range Delay of the waveform display adjusts the beginning of the horizontal span in the non Zoom mode. The left end of the horizontal-axis is normally set to zero thickness. The Delay function allows you to adjust the left end of the horizontal axis so the waveform can be centred over a portion of the waveform that occurs later in time. This function is very useful when using delay line or immersion transducers or when measuring thick material so that the measured echoes can be seen in greater detail.To operate the Delay function, follow these steps:

1. Press [2ndF], [Range] (DELAY).2. Press [ ] or [ ] to adjust the waveform Delay.QQ

p=r=~=`~~==d~Figure 9 Displaying the Waveform Delay

3.8 Operating the Zoom ModeThe Zoom mode allows the thickness region surrounding the measured echoes to expand to full screen width. The resulting zoomed waveform depends on the Measurement mode that the gage is using. The zoom adjusts the Range and Delay so the measured echoes are on screen are shown in the greatest detail. The Zoom mode also tracks the measured echoes adjusting the Range and Delay automatically, always keeping the measured echoes on the waveform screen.

3.8.1 Zoom in Mode 1

Zoom in Mode 1 centers the first Backwall echo on the screen.

Figure 10 Comparing Normal Display to Zoom in Mode 1

3.8.2 Zoom in Mode 2

Zoom in Mode 2 adjusts the Waveform Range and Delay so that the Interface Echo and First Backwall echo are shown on the Waveform screen.m~=@=VNMJONM` QR

j=ORai=mirpFigure 11 Comparing Normal Display to Zoom in Mode 2

Note: In the Zoom mode, the gage automatically adjusts the Range and Delay totrack the Interface and first Backwall echo. If you adjust the Range, the gageremains at the selected Range and automatically adjusts the Delay to trackthe Interface Echo.

3.8.3 Zoom in Mode 3

Zoom in Mode 3 adjusts the Waveform Range and Delay so that the Interface Echo and Second Measured Backwall echoes are shown on the Waveform screen.

Figure 12 Comparing Normal Display to Zoom in Mode 3

Note: In Zoom mode, the gage automatically adjusts the Range and Delay to trackthe Interface and second Backwall echo. If you adjust the Range, the gageremains at the selected Range and automatically adjusts the Delay to trackthe Interface Echo.

Not Zoomed ZoomedQS

p=r=~=`~~==d~3.9 Using the BacklightThe display has the greatest contrast when viewed in bright light. However, it is easily readable in subdued light or even complete darkness by using the built-in backlight.To activate the backlight, press the orange key with the lightbulb symbol. Deactivate the backlight by pressing the lightbulb key again. See Managing the Backlight on page 67 for more information.

Note: Use the backlight only when needed because it drains the battery about threetimes faster when activated.

The contrast of the display may require occasional readjustment. To adjust the waveform display contrast, follow these steps:

1. Press [2nd F], [LIGHTBULB] (LCD ADJ)2. Press [ ] to darken the display, or [ ] to lighten the display.

To stop adjusting the contrast, press [ENTER] or [MEAS]. This action disables the [ ] and [ ] keys from adjusting the contrast.m~=@=VNMJONM` QT

j=ORai=mirpQU

j~~=p~=d~=c=~=pm=j4 Managing Special Gage Functions and SP ModesThis chapter describes how to operate the Model 25DL PLUS using special functions and modes.Topics are as follows: Operating Gage Functions Operating SP Modes Saving Key Selection

4.1 Operating Gage FunctionsThe Model 25DL PLUS has many thickness measurement features. Although the features outlined in this section are not required for basic thickness operation, they can make the gage a more versatile instrument.

4.1.1 Selecting a Differential Mode

The Model 25DL PLUS has three Differential modes Normal Differential Percent Ratio Rate Reduction (RR)

Normal Differential: Shows the actual thickness along with the difference between the actual thickness measurement and a user set reference value.

[(Normal Differential) = (Actual Thickness) (Differential Reference Value)]The actual thickness appears on the thickness display and the differential thickness appears in the differential display area. See the following figure:m~=@=VNMJONM` QV

j=ORai=mirpFigure 13 Normal Differential Mode

Percent Ratio: Shows the actual thickness along with the percent difference from a user set reference value.[(Percent Ratio)] = [(Actual Thickness) - (Differential Reference Value)] /(Differential

Reference Value)]*(100)The actual thickness appears on the thickness display and the Percent Ratio thickness appears in the differential display area as shown below:

Figure 14 Percent Ratio Differential Mode

Rate Reduction: A Special type to Percent Ratio that is used to show the Percent thinning (Rate Reduction) in metal forming applications. Enter the original thickness of the metal (Former Thickness) and the gage shows the actual thickness along with the Reduction Rate from your set Former value. Both the Reduction Rate and Actual Thickness appear on the display. You can choose to show either the Rate Reduction or the Actual Thickness in large font.

[(Rate Reduction) = [(Actual Thickness)-(Former Value)]/(Former Value)]* (100)

Differential Value

Active Thickness

Percent Diffe