PCE PCE-USC 30 Paint Thickness Tester Owner's Manual

English
User Manual
PCE-USC 30
User manuals in various languages (Deutsch,
français, italiano, español, português, nederlands,
türk, polski, русский, 中文) can be downloaded here:
www.pce-instruments.com
Last change: 15 May 2017
v1.0
© PCE Instruments
Contents
English
1
Safety notes ........................................................................................... 1
2
Specifications ........................................................................................ 2
2.1
Technical specifications ................................................................................................... 2
3
System description ............................................................................... 3
3.1
Device .............................................................................................................................. 3
3.2
Display and Side Panels .................................................................................................. 4
3.3
Function keys ..................................................................................................................11
4
Design of the Flaw Detector ............................................................... 14
4.1
Instrument Appearance ...................................................................................................14
4.2
Structural Scheme ...........................................................................................................15
4.3
Appearance of the Flaw Detector Screen ........................................................................16
4.4
Menu Structure................................................................................................................21
4.5
“TEST” Menu ..................................................................................................................21
4.6
Guidelines for Overload Processing ................................................................................30
4.7
"Conductivity" Mode ........................................................................................................30
4.8
“General Settings” Menu .................................................................................................36
4.9
View ................................................................................................................................37
4.10 “Memory” Menu ...............................................................................................................38
4.11 “Results” Menu ................................................................................................................38
4.12 “Settings” Menu ...............................................................................................................40
4.13 Set up of “Calibration” Menu ............................................................................................40
4.14 PCE-USC 30 software .....................................................................................................43
5
Labelling and Sealing ......................................................................... 49
6
Composition and Delivery Set ........................................................... 50
7
Setting-up procedures ........................................................................ 50
8
Instructions for Use ............................................................................ 51
8.1
Single Coil Probe ............................................................................................................51
8.2
Reflection, Differential Probe ...........................................................................................51
8.3
Rotation Probe ................................................................................................................52
9
Maintenance ........................................................................................ 53
© PCE Instruments
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Typical Failures and Troubleshooting .............................................. 55
11
Transportation and Storage ............................................................... 55
12
Warranty ............................................................................................... 55
13
Disposal ............................................................................................... 55
© PCE Instruments
Thank you for purchasing a PCE-USC 30 from PCE Instruments.
1
Safety notes
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The device must only be used as described in this instruction manual. If used
otherwise, this can cause dangerous situations for the user and damage to the meter.
The instrument may only be used if the environmental conditions (temperature,
relative humidity, …) are within the ranges stated in the technical specifications. Do
not expose the device to extreme temperatures, direct sunlight, extreme humidity or
moisture.
Do not expose the device to shocks or strong vibrations.
The case should only be opened by qualified PCE Instruments personnel.
Never use the instrument when your hands are wet.
You must not make any technical changes to the device.
The appliance should only be cleaned with a damp cloth. Use only pH-neutral
cleaner, no abrasives or solvents.
The device must only be used with accessories from PCE Instruments or equivalent.
Before each use, inspect the case for visible damage. If any damage is visible, do not
use the device.
Do not use the instrument in explosive atmospheres.
The measurement range as stated in the specifications must not be exceeded under
any circumstances.
In operation with the flaw detector, it is necessary to observe the safety measures
while charging the storage battery unit of the flaw detector by means of automatic
charger.
In operation with the flaw detector an operator should be governed by the safety
standards in effect at the enterprise.
Non-observance of the safety notes can cause damage to the device and injuries to
the user.
© PCE Instruments
1
English
Please read this manual carefully and completely before you use the device for the first time.
The device may only be used by qualified personnel and repaired by PCE Instruments
personnel. Damage or injuries caused by non-observance of the manual are excluded from our
liability and not covered by our warranty.
We do not assume liability for printing errors or any other mistakes in this manual.
We expressly point to our general guarantee terms which can be found in our general terms of
business.
If you have any questions, please, contact PCE Instruments. The contact details can be found
at the end of this manual.
Safety symbols
Safety-related instructions the non-observance of which can cause damage to the device or
personal injury carry a safety symbol.
English
Symbol
Designation / description
General warning sign. ATTENTION!
Non-observance can cause damage to the device and injuries to the user.
2
Specifications
2.1
Technical specifications
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Range of operating frequencies adjustment – from 10 Hz to 16 МHz.
Setup of the max. sampling frequency – 10 kHz.
Setup of the range of adjustment of ECP excitation signal voltage (double amplitude)
– from 0.5 to 6.0 V.
Preamplifier adjustment – from minus 6 to plus 40 dB with a step of 0,1; 1; 10 dB.
Gain adjustment – from 0 to 30 dB with a step of 0,1, 1 and 10 dB.
Horizontal gain adjustment – from -30 to 30 dB with a step of 0.1, 1 and 10 dB.
Vertical gain adjustment – from -30 to 30 dB with a step of 0.1, 1 and 10 dB.
When displaying the signal in a complex plane it is possible to have the following
variants: а) the complex plane center is situated in the center of display area; b) the
complex plane center is situated in the left upper corner; c) the complex plane center
is situated in the right upper corner; d) the complex plane center is situated in the left
bottom corner; e) the complex plane center is situated in the right bottom corner; f) all
frequencies and mixtures are displayed on the same page (when operating in dualfrequency mode); g) manual adjustment of the positioning of the center of the
complex plane.
There is automatic LED and sound flaw alarm (ALARM) in the flaw detector.
In processing of the testing results the flaw detector provides the following options:
− changing of ECP signal phase (the range of signal turn – from 0° to 360° with a
step of 0.1°; 1°; 10°);
− filtering of ECP signal (there are 5 types of filters: Averaging, Differential, Low-pass,
High-pass, Bandpass);
− formation of a mix of two frequencies (for combining an operator can select one of 4
algorithms: summation, subtraction, summation with horizontal inversion, summation
with vertical inversion).
© PCE Instruments
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Time of continuous operation of the flaw detector from fully charged storage battery –
no less than 8 hours.
Average mean time between failures – no less than 40000 hours.
Defined no-failure operating time – 4000 hours.
Total average service life – 10 years. The criterion of marginal state of the flaw
detector is economical inexpediency of restoration of its performance by repair.
The flaw detector is powered from the in-built storage battery with rated voltage of 12
V.
Weight of the flaw detector with a storage battery (without ECP set, cables and
casing) – no more than 0.9 kg.
Overall dimensions of the flaw detector – no more than 230 mm x 135 mm x 98 mm.
English
•
System description
3.1
Device
User manual of PCE-USC 30 portable eddy current flaw detector (hereinafter referred to as
"Flaw detector") is intended for the study of operation principles of the flaw detector and its
operating instructions, and includes the information on application, specifications, operating
principle and structure, operating instruction, and also other information allowing a full-scale
implementation of flaw detector technical capabilities.
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The flaw detector is intended for manual and mechanized testing by eddy current
method for the presence of surface and subsurface defects, such as material
discontinuity (cracks, laps, cissings, fine cracks etc.), for conductivity and thickness
measurement.
The flaw detector can be applied for the testing of products during their manufacture
and operation by NDT services and laboratories of enterprises that provide the
products quality control.
The parameters of testing objects, which limit the flaw detector application area, are
specified in regulatory documents for a specific type of testing products and materials.
The flaw detector provides the possibility of connecting and operating ECP of the
following types:
- differential ECP;
- differential ECP, connected by the bridge circuit;
- differential transformer ECP with center-point earth;
- differential transformer ECP;
- single (parametric) ECP;
- single transformer ECP.
The evaluation of resistance of the flaw detector and ECP functioning quality to the
impact of electromagnetic interferences of "В" criterion according to
© PCE Instruments
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3.2
Display and Side Panels
Rear panel of the flaw detector:
English
Fig. 1 – PCE-USC 30 Rear Panel
1 – Ethernet port for connecting a communication cable to PC;
2 – USB port for updating the flaw detector software and recording the testing results on the
external Flash-Card
© PCE Instruments
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Table 1 – Description of connector for the instrument connection to PC Ethernet port
Contact
1
2
3
4
Description
Data of transmitter «+»
Data of transmitter «–»
Data of receiver «+»
Data of receiver «–»
Ethernet
Table 2 – Description of connector for the instrument connection to external USB flash
drive
Contact
1
2
3
4
Signal
+5 V
Data Data +
Common
© PCE Instruments
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USB type A (front view)
English
ERA.0S.304.CLL
(front view)
Front Panel
English
Fig. 2 – PCE-USC 30 Front Panel
© PCE Instruments
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English
Left side panel of the flaw detector:
Fig. 3 – PCE-USC 30 Left Side Panel
1 - LEMO jack for headphones with microphone connection;
2 - Charger connector;
3 - Switching On/Off the instrument.
© PCE Instruments
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Table 3 – Description of LEMO jack for headphones with microphone connection
English
Cont.
1
Signal
Input signal from the microphone
2
Right audio output
3
Common
4
Left audio output
Table 4 – Description of charger connector
Cont.
Signal
1
Charging device 2
Not used
3
Charging device +
4
Sync signal output
© PCE Instruments
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EGG.0B.304.CLL
(front view)
EGG.1B.304.CLL
(front view)
English
Right side panel of the flaw detector:
Fig. 4 – PCE-USC 30 Right Side
1 – Single coil (parametric) eddy current probe (ECP) connector;
2 - Universal connector for eddy current probe (ECP) and eddy current rotary
scanner;
3 - Encoder (Enc) connector
© PCE Instruments
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Table 5 – Description of single coil (parametric) eddy current probe (ECP) connector
Cont.
1
Signal
Parametric ECP
2
Common for parametric ECP
Lemo ERA.00.250CLL
English
Table 6 – description of encoder (Enc) connector
Cont.
1
2
Signal
Positive signal input "A"
Power "+5V"
3
4
Negative signal input "Z"
Positive signal input "Z"
5
Negative signal input "B"
6
Positive signal input "B"
7
Negative signal input "A"
8
Common
Lemo EGG.1B.308CLL
(front view)
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Table 7 – Description of connector for eddy current probe (ECP) and eddy current rotary
scanner
Signal
Gen Ret
Gen Out
+12V Battery
Motor Motor +
Gnd
Dif Input 1
Dif Input 2
Synchro Input
Motor On
Rotary On
Alarm LED
3.3
Function keys
Lemo EGG.2B.312CLL
(front view)
English
Pin
1
2
3
4
5
6
7
8
9
10
11
12
Automatic flaw alarm by the first and second frequencies, respectively,
and by the mix of the 1st and 2nd frequencies, as well as overloading alarm square. If ALARM
triggers during testing, the signal amplitude and phase are automatically measured and the
signal is evaluated by the calibration curve.
Function keys
Respectively:
"F1 Balancing", "F2 Full-screen mode", "F3 Centering"– in "TEST" menu;
"F1 Import data", "F2 Export data "– in “MEMORY” menu;
"F1 Load", "F2 Create/ Save","F3 Delete"– in "RESULTS"/"SETTINGS"
submenu;
"F1 An" (An - amplitude noise) – in "VIEW" menu;
"F2 OK” save calibration curve – in "CALIBRATION" menu.
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Key
Function
- automatically puts a displayed signal from lift-off (or from any
interference) in horizontal position;
- in the mode of name editing – selects a digit/letter
- changes the parameter variation step;
- in the mode of name editing – selects a digit/letter
- increases the selected parameter;
- in the mode of name editing – selects a digit/letter
English
- changes the frequency;
- in the mode of name editing – selects a digit/letter
- moves up through the menu;
- in the mode of name editing – selects a digit/letter
- decreases the selected parameter;
- in the mode of name editing – selects a digit/letter
- cancels the selection;
- in the mode of name editing – selects a digit/letter;
- pressing the key results in displaying the firmware version in
"SETTINGS" menu;
- delete point in “CALIBRATION" menu;
- freeze the display in the test menu
- moves down through the menu;
- in the mode of name editing – selects a digit/letter
- confirms the selection;
- in the mode of name editing – selects a digit/letter;
- pressing the key in "TEST" menu results in saving of current setup as a
default one (if the current item is above the ALARM item);
- add point in “CALIBRATION" menu
- quick access to "TEST" menu
- quick access to "SETTINGS" menu
- quick access to "VIEW" menu
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- quick access to "MEMORY" menu;
- confirms the saving of the entered name of the file or folder while
operating in "MEMORY" menu
- automatically sets the parameters of single coil (parametric) ECP with
switched On Single input;
- sets the number of rounds while operating with eddy current rotary
scanner
- switches On/Off the instrument
© PCE Instruments
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English
- quick access to "CALIBRATION" menu
4
4.1
Design of the Flaw Detector
Instrument Appearance
English
Fig. PCE-USC 30 eddy current flaw detector
© PCE Instruments
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4.2
Structural Scheme
English
Structural scheme of the flaw detector.
Fig. 6 – Structural Scheme of the Flaw Detector
Structurally, the flaw detector consists of:
a) casing and cover plate with the membrane keypad, indicators of ALARM and overloading,
Ethernet port for connection to PC, USB port for external flash-card connection, charger
connector, headphones and microphone;
b) connector, ECP connector;
c) TFT display;
d) processor and memory boards;
e) analog board;
f) battery.
© PCE Instruments
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4.3
Appearance of the Flaw Detector Screen
English
Fig. 7 – Display Appearance after switching on the Flaw Detector
Working filed in the testing mode is divided in 3 areas of signal reflection and display area title:
o
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Working field (display areas – complex plane, time charts);
•
Bottom horizontal field (data line);
•
Navigation menu:
FREQ – test frequency;
o
PRE AMP – preamplifier gain;
o
GAIN – main gain;
o
H GAIN – horizontal gain;
o
V GAIN – vertical gain;
o
DRIVE – probe drive level;
o
o
o
PHASE – phase adjustment;
FILTER – filter type;
POSITION – spot position;
o
GRID – grid;
o
AXIS – axis;
© PCE Instruments
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o
ALARM – short cut to ALARM Setting;
o SWEEP – number of points in a screen scan;
o PROBE – type of connector;
o RPM – rounds per minute for the eddy current rotary scanner;
o ROT PRESENT– type of connected rotary eddy current scanner.
The flaw detector displays two time charts of time dependence of signal
and eddy current signal which is displayed in a complex plane for the selected
English
frequency.
Fig. 8 – The Flaw Detector Interface
1 – Navigation menu
2 – Time charts
3 – ALARM frame
4 – Eddy current signal
5 - Signal display area
6 - Parameters of the measured signal (A – amplitude in “Volts”, P – phase in “degrees”, D –
equivalent depth of flaw in “mm” or conductivity in “MSm/m”), T - current value of a receive
circuit parameters (“…/” – load of the input circuit before the balancing; “…/” non-balance of the
input circuit; “…” – the current value of the input circuit expressed in % from the maximum
possible), F- sampling frequency
7 - Frequency number
8 - Battery life indicator
9 - Temporary memory indicator of the flaw detector
© PCE Instruments
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10 - Digital overload indicators for receiving circuit
11 - digital trigger indicators of ALARM levels for the first, second and mix of frequencies
respectively (from left to right)
Note – Parameter "T: …/…/... %" shows:
1) The value of a signal amplitude at the input of the receiving circuit
expressed in % from the maximum possible,
2) Input circuit is not balanced, after performing the balancing in %;
3) Current value of the load of the input circuit expressed in % from the
maximum possible.
English
The most suitable option is one in which the two parameters do not exceed, or exceed
but not significantly the 50%. Operation in mode, in which one of the parameters exceeds
the threshold of 90% is unacceptable and requires the adjustment of flaw detector
parameters.
Lighting of a left overload indicator (pos. 10, Fig. 8) – indicates that unacceptably large
amplitude signal came to the input of the receiving circuit.
The flaw detector electronic unit displays the signal in the complex plane that allows to foil
defects by waveform analysis (Fig. 9):
Fig. 9 – Display of signal in the complex plane (XY)
© PCE Instruments
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English
Fig. 10 – Mix of two frequencies (MIX)
The flaw detector has the mechanism of automatic flaw alarm (ALARM). It is provided for the
creation of up to 4 "frames" (threshold levels) of alarm for each frequency and mix (examples of
threshold levels see Figure 14, 15, 16, 17). These frames together with the signal form an event
(for example, the threshold level exceeding by the signal). An operator is able to adjust the
reaction to an event. Reaction to an event can be the following:
− LEDs illuminating on the instrument panel;
− or LEDs illuminating and sound alarm.
"ALARM" menu setup
This menu allows setting of ALARM (automatic flaw alarm). There is a possibility to setup
ALARM for each frequency and mix. ALARM itself is the response of flaw detector to the event
occurring at crossing or non-crossing of alarm frame (threshold level) by a signal. All in all one
alarm frame can be activated for each frequency.
Frame setup is carried out in special item of ALARM settings -
from "TEST" menu. To
change the type of the alarm frame operator should press
or
“ALARM” position (if the icon
frame setup operator should press
key on
is displayed, the frames are switched off). To enter in alarm
key.
Note. An operator is offered to set up the frame according to the frequency, he plans to
work with.
Automatic measurement of the signal amplitude and phase provides a possibility to evaluate the
defect size in analyzing the data. The measured values of the voltage phase or amplitude are
required for estimating the defect size in conformity with the selected calibration curve. Such
curve compares the parameters of signal amplitude or phase with the defect parameters in
millimeters or percent from the wall thickness. The flaw detector interface allows calibration
curves plotting both by the phase and amplitude.
© PCE Instruments
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The flaw detector connectors for the eddy current probes connection (see Fig. 4) provide the
possibility of ECP connection of various constructions (see Fig. 11):
•
•
•
•
•
•
differential ECP, connection by the bridge circuit;
single transformer ECP;
differential ECP, connection by the bridge circuit;
differential transformer ECP with center-point ground;
single (parametric) ECP;
differential transformer ECP.
English
Fig.11 – Circuits of probe connection
© PCE Instruments
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Menu Structure
English
4.4
Fig. 12 – Menu Structure
Navigation of the menu map described below is performed with the help of the following keys:
The instrument menu is divided in five inserts: "TEST", "SETTINGS", "VIEW", "MEMORY",
"CALIBRATION", the first and the fourth ones are also divided in submenus.
4.5
“TEST” Menu
"Test" menu is displayed immediately after switching on the instrument (see Figure 13) and
contains main settings an operator will need to set during operation.
Fig.13 – “TEST” menu
© PCE Instruments
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In this menu, an operator can set (change) the settings of the selected frequency, the values of
operating frequency, gain and preamplifier, generator voltage, initial phase of signal, filter type
and its parameter, input type, general scale and independently to axles, position of complex
plane center as well as set up ALARM and general flaw detector parameters.
Moving through the vertical menu of the electronic unit parameters is carried out by
keys. In order to change the value of any parameter one should use
keys. A step of parameter variations can be changed by multiple pressing of
,
,
key.
English
Quick selection to "TEST", "SETTINGS", "VIEW", "MEMORY",
"CALIBRATION" inserts is carried out by pressing
keys.
"Hot keys" which are operated by "F1", "F2", "F3" function keys are situated on the keypad of
the flaw detector:
− F1 (Balancing)1 – to balance the signal (place it in the screen center) and
clear the flaw detector screen;
− F2 (Full-screen mode) – the complex plane and time chart is maximized to
fill the entire screen.
− F3 (Clearing) – clear the flaw detector screen;
“Balancing” – it is hardware compensation of input signal. It is carried out by summation of
input signal with reference signal of the same amplitude but opposite in phase. Current
procedure is conducted after preamplifier according to radio signal (before signal detecting).
Balancing algorithm is iterative and takes some time. The procedure is necessary for ECP nonbalance voltage compensation. After the balancing of flaw detector the centering is carried out
automatically.
Balancing should be applied in case if:
− ECP type was changed;
− One of following parameters was changed: ECP frequency, gain
coefficient, preamplification coefficient, ECP excitation voltage;
− Testing object was changed;
− The auto-adjustment of ECP was activated (if Single input was used).
Clearing should be used if persistence is switched off.
1 Balancing of the flaw detector is required after the ECP operating frequency was set or changed. Also, the
balancing should be carried out after the ECP replacement. If the flaw detector was once balanced and its
operating frequencies were not changed, it is possible to carry out centring.
© PCE Instruments
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“
F, Hz"- operating frequency of probe2; varied in the range from 10 Hz to 16
MHz with a step of 1, 10, 100, 1000, 10000, 100000, 1000000, 10000000 Hz. Here
you adjust the test frequency of the probe that is connected to the instrument. The
frequency depends on the probe you use and the application at hand. You can select
the frequency between 10 Hz and 16 MHz.
2.
“
PRE AMP” - preamplifier for amplifying the probe voltage; varied in the range
from -6 to 40 dB with a step of 0,1, 1, 10 dB. To adapt the eddy current probe that is
to be used, you can adjust the preamplification in 0.1; 1; 6; 10 dB steps between 0dB
and 40dB. Please avoid a preamplification overload because it may tamper with the
results of the measurement. The overload is indicated by the amber light of the
ALARM-LED.
3.
"
GAIN" - gain for amplifying the probe voltage; varied in the range from 0 to 30
dB with a step of 0,1; 1; 10 dB. Here you adjust the signal amplitude for the best
possible display of the eddy current signal by moving the probe across a reference
defect while slowly increasing the gain. You can adjust the gain between 0 dB and 30
dB. The display shows the overall gain simultaneously for X and Y- coordinates.
4.
"
H GAIN" – horizontal gain for amplifying the probe voltage; varied in the range
from 0 to 30 dB with a step of 0,1; 1; 10 dB.
5.
"
V GAIN dB" – vertical gain for amplifying the probe voltage; varied in the range
from 0 to 30 dB with a step of 0,1; 1; 10 dB. This item is often used to set up single
coil probe for visual increase of angle between lift-off signal and signal from defect.
6.
"
DRIVE" - ECP excitation voltage3; it is possible to set specified values of 0.5; 1;
2; 4; 6 V (double amplitude value). The maximum voltage for single coil probe is 2V.
The maximum voltage for other types of probes is limited by 6V. High voltage is used
for subsurface defects detection.
7.
"
PHASE" - signal phase change (signal turn) – from 0 to 360˚ with a step of
0.1˚, 1˚, 10˚.
8.
"
FILTER" - Filter type: Averaging, Differential, Low-pass, High-pass, Bandpass;
Filters setup is carried out for the channel Frequency 1 and Frequency 2.
2 Operating frequency of probe is selected from the rage of frequencies indicated in the registration certificate
for the given ECP.
3 ECP exciting voltage is selected from the range indicated in the registration certificate for the given ECP.
© PCE Instruments
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English
1.
Averaging Filter
Switching on of the averaging filter "Avrg" sets a number of points N to be averaged
from 2 to 127 points with a step of 1, 10, 100 points. Can be used when working with
high gains and scales to reduce noise signal by smoothing it.
Differential Filter
Switching on of a differential filter “Diff” activates its settings, where L – filter depth,
set in the range from 2 to 127 units with a step of 1, 10, 100.
English
Low-Pass Filter
Switching on of a low-pass filter activates the field for setting up the frequency LF
from 1 to 4000 Hz with a step of 1, 10, 100, 1000 Hz. The frequencies from 0 Hz to
the set value of Hz are allowed.
The low-pass filter is used to reduce the noise respectively high-frequency nonessential signal components by displaying only those signals whose alternating
frequency is lower (i. e. slower) than the frequency of the selected low-pass filter.
Since electronic noise is usually caused by high- frequency signals, the noise on the
screen is lower, if the frequency of the low-pass filter is set low, too.
The low-pass filter is used for static applications (usually with hand-held probes). It is
important that the low-pass filter is not too low, because defect signals are not
displayed anymore, if you move the probe across the crack at a speed that is too high
with regards to the filter frequency. If for example you move the probe very slowly
across the crack, then the dot slowly tracks the full defect signal at a low-pass
frequency of 10 Hz. If, one the other hand, you move the probe across the crack more
quickly at the same low-pass frequency, you will see only a small amplitude on the
screen. This happens because the frequency of the signals is now too high for the
low-pass filter frequency you selected.
If, however, you increase the low-pass filter frequency, the full amplitude of the defect
signal is displayed, i. e. the higher the test speed the higher the frequency of the lowpass filter to be selected. Since differential probes generate a dual signal that
changes more quickly than that of an absolute probe at the same speed, you should
select a higher low-pass frequency for differential probes than for absolute probes.
Thus the minimum low-pass frequency to be selected for a particular application
depends on the test speed and the coil system of the probe you use. The easiest way
to determine the minimum low-pass frequency is probably by trial and error.
High-Pass Filter
Switching on of a high-pass filter activates the field for setting up the frequency HF
from 1 to 5000 Hz with a step of 1, 10, 100, 1000 Hz. The frequencies from the set
value of Hz to Fsampling /2 Hz (where Fsampling – sampling frequency) are allowed.
If you use a high-pass filter, the signal dot always returns to the selected
compensation point, if the probe is not moved relative to the surface of the test
specimen. This can be likened to an „automatic reset". Thus, if you move the probe
across materials with varying electric conductivity, the signal dot briefly moves to a
© PCE Instruments
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position on the screen that varies depending on the material; the dot then returns to
the selected compensation point.
The filter frequency does not depend on the alternating frequency of the current that
flows through the coils, but on how frequently the test signals change. If for example
you move a probe across a crack, the frequency depends on how fast you do so. The
high-pass filter is designed so that only those signals whose frequency is greater than
that of the high-pass filter are depicted by deflecting the signal dot. If the high-pass
filter is active the signal dot on the screen remains on the compensation point.
Bandpass
Switching on of a bandpass filter activates its settings:
Carrier frequency F is set from 1 to 5000 Hz with a step of 1; 10; 100; 1000 Hz;
F≤
Fsampling
2
where Fsampling – frequency is set in "SETTINGS" (sampling frequency);
WF bandpass is set from 1 to 5000 Hz with a step of 1; 10; 100; 1000 Hz.
You can use the bandpass-function to adjust both the high pass and the low pass.
This is very helpful when you want to quickly determine the frequency band for the
best possible defect display - especially for rotor applications or inspections of rotating
parts.
Note. Only one filter can be set in the frequency selected by an operator.
Activation of the other filter makes the earlier selected filter inactive within the set
frequency.
9.
"
" - selection of the position of complex plane centre. Can be set in the following
positions:
- complex plane centre,
the right upper corner,
corner,
- in the right centre of the screen,
- in the upper centre of the screen,
- in the left centre of the screen,
10.
"
Grid"– variants of marking for the complex plane: "
" – Off.
11.
"
Axis"– activates coordinate axes.
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- in the left upper
- in the left bottom corner,
bottom centre of the screen,
- in the right bottom corner,
when operating in double frequency mode.
- in
- in the
- per-channel display
"– square, "
" – radial, "
English
The filters are intended to improve the signal/noise ratio and/or supress undesired
signals so that the signal evaluation and test sensitivity are optimized. The noise can
be “electronic” (caused by the instrument or the probe), or it can be caused by other
factors such as scanning rough surfaces. You can easily identify electronic noise by
the so-called “fuzzy” signal image instead of a steady dot. This happens frequently, if
you carry out inspections with low frequencies or high gain.
12.
"
ALARM" – activation and setting of frames (threshold levels). Types of frames:
- frames are switched off,
sector frame type,
- circle frame type,
- threshold frame type,
-
- cut-off frame type.
English
13.
"SWEEP" – number of samplings displayed on time charts (see Figure 8, pos. 4) 256; 512; 1024; 2048; 4096; 8192; 16384, 32768 measurements.
14.
"PROBE" – Connector type: "Refl", "Bridge", "Single".
15.
"RPM" – rounds per minute for the eddy current rotary scanner. Selected from the
standard range: 600, 840, 1020, 1200, 1500, 1800, 2100, 2400, 2700, 3000.
16.
"ROT" – type of connected rotary eddy current scanner SVR-02 or MINI DRIVE.
17.
"Mix type" – is selected for the frequencies mixing (setting is available in double
frequency mode), where: "+" – summation, "–" – subtraction, "~X+" - summation with
inversion in Х-direction, "~Y+" - summation with inversion in Y-direction.
If the mix type is "+", then:
XCi=X1i*M1+X2i*M2;
YCi=Y1i*M1+Y2i*M2.
If the mix type is "-», then:
XCi=X1i*M1-X2i*M2;
YCi=Y1i*M1-Y2i*M2.
If the mix type is «~Y+», then:
XCi=X1i*M1-X2i*M2;
YCi=Y1i*M1+Y2i*M2.
If the mix type is «~X+», then:
XCi=X1i*M1+X2i*M2;
YCi=Y1i*M1-Y2i*M2.
Where XCi, X1i, X2i – horizontal components of the mix of the 1st and 2nd frequencies,
respectively;
YCi, Y1i, Y2i – vertical components of the mix of the 1st and 2nd frequencies,
respectively;
M1, M2 – scales of the 1st and 2nd frequencies, respectively.
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Threshold levels setup
•
Setup of "Circle" type frame
To set up circle type frame, operator should select "Type:
(see Figure 14).
English
ALARM –
" in special item of settings
Fig. 14 – Setup of “Type:
“ threshold level
"R:" parameter variation allows change the inner radius of threshold level. Height parameter
variation is carried out in the range from 0 to 32768 with a step of 1, 10, 100, 1000, 10000 (see
Fig.14).
•
Setup of "Threshold" type frame
To set up threshold type frame, operator should select "Type:
ALARM –
" in special item of settings
(see Fig. 15).
Fig. 15 – Setup of “Type:
“ threshold level
"H:" parameter variation allows change the height of the threshold level. Parameter variation is
carried out in the range from 0 to 32768 with a step of 1, 10, 100, 1000, 10000 (see Fig. 15).
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•
Setup of "Sector" type frame
To set up sector type frame, operator should select "Type:
item of settings ALARM –
" in special
(see Figure 16).
English
Fig. 16 – Setup of “Type:
“ threshold level
"R:" parameter variation allows change the inner radius of threshold
level. Height parameter variation is carried out in the range from 0 to 32768
with a step of 1; 10; 100; 1000; 10000 (see Fig. 16).
"W:" parameter variation allows change the width of threshold level.
Radius parameter variation is carried out in the range from 0 to 32768 with a
step of 1; 10; 100; 1000;10000 (see Fig. 16).
"α:" parameter variation allows change turning angle of threshold level
relative to the complex plane centre. Turn angle variation is carried out in the
range from 0˚ to 359˚ with a step of 1˚; 10˚; 100˚ (see Fig. 16).
"β" parameter variation allows change turning angle of threshold level.
Turn angle variation is carried out in the range from 0˚ to 180˚ with a step of
1˚; 10˚; 100˚ (see Fig. 16).
Select the frame polarity "Pol:", which makes the alarm trigger:
– the signal gets beyond the limits of the threshold level;
– the signal is within the limits of the threshold level.
If the symmetrical displaying of threshold level on the position “Symm:”
with
,
keys is required, this parameter can be activated.
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•
Setup of "Trapezium" type frame
To set up cut-off type frame, operator should select "Type:
" in special
(see Figure 17).
English
item of settings ALARM –
Fig. 17 – Threshold level setup "Type:
"
"X1:" parameter variation allows to change the angle position of threshold level in X1-direction.
X1 parameter variation is carried out in the range from - 32768 to 0 with a step of 1; 10; 100;
1000; 10000 (see Fig. 17).
"X2:" parameter variation allows to change the angle position of threshold level in X2-direction.
X2 parameter variation is carried out in the range from 0 to 32768 with a step of 1; 10; 100;
1000; 10000 (see Fig. 17).
"Y1:" parameter variation allows to change the angle position of threshold level in Y1-direction.
Y1 parameter variation is carried out in the range from - 32768 to 32768 with a step of 1; 10;
100; 1000; 10000 (see Fig. 17).
"Y2:" parameter variation allows to change the angle position of threshold level in Y2-direction.
Y2 parameter variation is carried out in the range from 32768 to - 32768 with a step of 1; 10;
100; 1000; 10000 (see Fig. 17).
Select the frame polarity "Pol:", which makes the alarm trigger:
– the signal gets beyond the limits of the threshold level
– the signal is within the limits of the threshold level.
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4.6
Guidelines for Overload Processing
For the Input – "Refl", "Bridge":
4.6.1
1.
Reduce the probe drive;
2.
Perform the probe balance by pressing
key.
For the Input – "Single":
4.6.2
English
1.
Choose the capacitor by pressing
key
2.
3.
Perform the probe balance by pressing
key;
If the recommendations specified in paras 4.6.2.1-4.6.2.2 didn`t resolve the overload,
then it is necessary to reduce the probe drive and repeat paras 4.6.2.1-4.6.2.2.
Lightning of the right overload indicator (pos. 10, Fig. 8) – indicates the general overload of
the input of the receiving circuit. General overload may include: overload by the input of the
receiving circuit (exceeding the maximum allowed signal amplitude at input of the receiving
circuit), ADC overload (exceeding the maximum allowed signal amplitude at ADC input).
For the input – "Refl", "Bridge" and "Single":
4.6.3
1.
If the left indicator lights, then repeat the steps described for overload processing for
the left indicator (see above);
2.
If the right indicator lights only, then it is required alternately reduce the “
AMP” and “
4.7
GAIN”. After each gain change it is required to press
PRE
key.
"Conductivity" Mode
Basics of Conductivity
The SI derived unit for conductivity is the Siemen per meter, but conductivity values are often
reported as % IACS. IACS is an acronym for International Annealed Copper Standard, which is
the material used to make traditional copper electrical wire. The conductivity of the annealed
copper is 5.8 x 107 S/m and copper is defined to be 100 % IACS at 20 °C. All other conductivity
values are related back to this conductivity of annealed copper.
Conductivities of metals at ambient temperature are typically in the range of 1 to 60
MegaSiemens per meter.
The PCE-USC 30 measures the conductivity of non-magnetic metals and alloys in the range 0.8
to 110.0 % IACS. It uses the Eddy Current technique for measuring the conductivity of materials
in % IACS, or MSiemens/meter.
It is important to understand that eddy current measurement is essentially a ‘skin’ effect.
The eddy current field intensity is greatest at the surface and decreases exponentially with
depth. The depth at which the field strength reduces to 1/e (37 %) of its surface value is referred
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to as the ‘standard depth of penetration’. This depends primarily on the operating frequency and
the conductivity of the metal.
Care must also be taken when measuring non-homogeneous materials, for example materials
which have been surface heat-treated, clad or plated, or where the surface is rough or corroded.
Measurements at different frequencies will give different results due to the different distribution
of energy within layers of different conductivity. Care must be taken to always measure such
materials at the same frequency (usually 60 kHz).
Setting up the device for measuring the conductivity and the thickness of nonconductive coatings
To use the PCE-USC 30 for Conductivity measurement requires the following:
PCE-USC 30 flaw detector;
Standard 60 kHz Probe (CP-13) and Cable (Lemo 12 - Lemo 04 Conductivity).
Conductivity standards of known value in a range from 0.59 MS/m (1.02 % IACS) to 63.8 MS/m
(110 % IACS). To connect the flaw detector with Cable and the eddy current probe CP-13 for
measuring the electrical conductivity.
Connect the flaw detector with cable and the eddy current probe CP-13 for measuring the
electrical conductivity.
ATTENTION! THE INSTRUMENT SETUP AND ELECTRIC CONDUCTIVITY
MEASUREMENT SHOULD BE CARRIED OUT AT AN AMBIENT AND TEST OBJECT
TEMPERATURE OF 20 ˚ С (68 ˚ F). BEFORE CARRYING OUT THE SETTING UP
PROCEDURE AND ELECTRIC CONDUCTIVITY MEASUREMENT, IT IS REQUIRED THAT
THE INSTRUMENT TO BE OPERATED AT LEAST OF 15 MINUTES AT A TEMPERATURE
OF 20 ˚ С (68 ˚ F).
To press the
button for entering the instrument menu «SETTINGS» and to choose «Test
mode» - «CONDUCTIVITY».
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English
It is generally considered that materials of thickness greater than 3 standard depths of
penetration can be measured without any correction factors being required. For example, at 60
kHz this figure (the “effective depth of penetration”) is around 0.05” (1.25 mm) in Aluminium
Alloys (conductivity approximately 35 % IACS) and 0.32” (8 mm) in Titanium alloy, (conductivity
approximately 1% IACS). At 500 kHz the corresponding values are 0.02” (0.5 mm) and 0.11”
(2.8 mm).
English
Fig.18 – “Conductivity” Test Mode
To press
to enter the «TEST» menu. In the menu «TEST» under the position «Current
set», to choose by
,
buttons the appropriate setting for the measurement at a
specified frequency and to press the
«CP13 – 480 kHz».
button to activate the settings. «CP13 – 60 kHz»;
Fig. 19 – Choosing and activating Settings “CP 13 – 60 KHZ”
After settings activation make calibration at standard samples
Note – For setting up procedure, use certified calibration blocks only.
To determine the material by its conductivity the setting up samples should generate the range
of the conductivity, wherein the first sample value is lower and the second sample value is
higher than the conductivity of the material being measured.
Conductivity measurement tolerances are:
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-
±0.5 % IACS [±0.3 MS/m] for the conductivity range from 0.9 % to 62 % IACS [0.5 to
36 MS/m];
±1.0 % IACS [±0.6 MS/m] for the conductivity range from 62 % to 110 %. Tolerances
for coating thickness measurement:
±1 mil [±0.0254 mm] for the thickness range 0-20 mil [0-0,508 mm].
Note – The narrower the range is, formed by the setting up samples, the more accurate
is the measurement.
samples, which will be calibrated, using the
,
buttons.
To set up the coatings thickness measurement there must be used the 20 mil [0.5 mm] film
thickness. Gap value is 20 mil [0.5 mm] to be set.
For beginning the calibration - to press the
on the screen of the flaw detector.
button and to follow the instructions displayed
Hold the eddy current probe in the air at a considerable distance from metal objects and press
.
Set the eddy current probe on the sample with Cond 1 conductivity and press
.
Figure 20 – Entering the conductivity value for the sample Cond 1
Set the eddy current probe on the sample with Cond 2 conductivity and press
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.
English
Before beginning the calibration at the positions of Cond 1 (the lower conductivity value) and
Cond 2 (higher conductivity value) there must be set the values of the conductivity of the
English
Figure 21 – Entering the conductivity value for the sample Cond 2
To put on the sample with Cond 1 conductivity the gap element (20 mil [0.5 mm]), set the eddy
current probe on the sample and press
.
Figure 22 – Entering the gap value for setting on the Cond 1 sample
After carrying out the setting up procedure, you can proceed with the measurement of electric
conductivity at real objects. During the operation it is required periodically to check the accuracy
of measurement of electric conductivity at calibration blocks.
In case, the value measured at calibration block differs from the nominal one and exceeds the
measurement tolerance, then it is required to reactivate the operating setup and perform the
adjustment at calibration blocks.
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Measuring Conductivity and Coating Thickness with the PCE-USC 30
Guidelines for successful operation:
For accurate measurement of conductivity, the surface coating thickness should be
0.5 mm (0.020 inches).
The surface to be measured should be flat, or of the same curvature as the calibration
standards. Where curved surfaces must be measured, additional error may be
introduced.
Measurement close to edges and on thin materials may give erroneous results.
Check on a known consistent material to establish the influence of these effects.
The coating thickness measurement function does not require further calibration, it
should be accurate to better than 10 % of the displayed value on base materials
having a conductivity between approximately 1 % and 100 % IACS.
The electric conductivity measurement should be carried out at an ambient and test
object temperature of 20 ˚ С (68 ˚ F).
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English
Note. In case, the ambient and test object temperature will be different from 20 ˚С (68˚
F), then the displayed value will be with an error.
Setting up the threshold level in the mode of electric conductivity measurement
set up the low value of electric conductivity Min;
set up the high value of electric conductivity Max;
set up the trigger logic for threshold level:
-light and sound ALARM shall be triggered, when the measured value of electric conductivity
gets into the middle of a selected range
Min – Max;
light and sound ALARM shall be triggered, when the measured value of electric conductivity
gets beyond the selected range
Min – Max.
4.8
“General Settings” Menu
When selecting "General settings" menu, the flaw detector displays the window with margins for
the flaw detector settings correction
English
Fig. 23 – “General Settings" menu
An operator sets the following values in the corresponding menu lines:
- "Test mode" – test mode. Can be "Expert" and "Simple". In "Simple" mode the part of
operating settings is not displayed.
- "Max smp frequency" – measurement frequency for the "TEST" mode. Samplings frequency in
Hz (sampling frequency of ECP per 1 second) from 1 kHz to 10 kHz. If the value of the selected
frequency from a fixed number of measurement set a given operating frequency of ECP is not
supported, then the instrument will automatically determine the maximum possible frequency of
measurement.
- "Double frequency mode" – activated when there is a possibility to remove the interfering
factor by means of frequencies mixing.
- "Persistence" – time value, on the expiry of which all data on the flaw detector screen is
deleted (at the switched on "Persistence"), from (0.1 s, 0.5 s, 1 s, 2 s, 3 s, 4 s);
- "Сolor scheme" – 1. "Light" - for operation with faint outer lighting; 2. "Dark" - for operation with
intense outer lighting; 3. "Standard" – standard scheme.
- "Brightness" – display brightness in % - from 10 to 100 with a step of 10%;
- "Rounds"– the number of full turns of rotating ECP displayed in time chats.
- "Sound" – sound alarm if the ALARM triggers.
- "Language" - language selection.
- "TRIGGERING":
1) Internal – synchronization from inner generator;
2) Enc – synchronization from encoder;
Cenc (pulses/mm)4 – number of pulses per 1 mm generated by encoder – from 10 to10000
pulses/mm with a step of 1; 10; 100; 1000 pulses/mm;
- N meas/mm – number of measurements per 1 mm.
- "Input" – active connector for ECP – 1) Single (for single coil ECP), 2) Refl (for other ECP);
- "Date" – selection of current date (year, month, date);
- "Time" – selection of current time (hours, minutes, seconds)
4
Cenc value (pulses/mm) is indicated in the registration certificate for the scanning device
where an encoder (Enc) is used
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4.9
View
When entering "VIEW" menu, an operator is offered to view and analyze current testing results
as well as the saved results. In order to view the current testing results, it is necessary to press
English
key.
Fig. 24 – "VIEW" menu
Note. To view previously saved testing results, it is necessary to press
the "RESULTS" submenu and press
press
key, choose
key. Then, move the cursor to the certain result and
key – "F1 Load". Then, an automatic enter in "VIEW" is carried out.
Position “Position” – moves the measurement cursor in the time chart.
Position “Width” – sets the width of the measuring cursor.
Position “Type” – the type of cursor measurement. Four types of measurement are available.
° Pk-Pk – the measurements are made between two points situated at the max. distance from
each other in cursor width.
° Cnt-Pk - the measurements are made between the cursor centre and the point situated at the
max. distance from the centre in cursor width.
° Cnt-K - the measurements are made between the centre and the cross point of cursor centre
signal.
° Vrt-M – vertical maximum - the measurements are made between two points situated at the
max. distance from each other in the cursor width in vertical projection.
Position “Measurer” – is intended for meter signal parameters displaying in complex plane.
Position “Scan” – is for changing the number of points in a strip chart. When moving the cursor
in the strip chart, the complex plane display is updated with the signal, which is located within
the cursor width. The values of amplitude in volts, phase in degrees and defect depth in
millimetres or percent are displayed in the information line.
Note. The flaw detector has a feature, which allows the quick signal/noise ratio
measurement. In order to measure the ratio, first place the measuring cursor on defect free-area
© PCE Instruments
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in the strip chart and press
– defect free area "F1 An" key, then move the centre of
measuring cursor to the signal peak from a defect. The result appears in the right bottom corner
of the flaw detector electronic unit at the "К= …" position, the measured signal/noise ratio will be
displayed.
English
In the view menu it is possible to estimate the saved or just taken data; carry out the
assessment of detected defects depth. By changing the position of measuring cursor, change
the cursor width in such way that the signal from defect stays within the cursor width. In this
case, the amplitude “A: ”, phase “P: ” and estimated defect size in millimetres or percent “D: ”
will be displayed in the flaw detector bottom information bar; the path data in mm will be
displayed in the top panel during the testing with ENC. By moving the cursor to the next signal
from defect, the data corresponding to the marked defect will be displayed on the screen.
The depth of the defect will be displayed only if the correct calibration curve is created!
4.10
“Memory” Menu
In order to load/save testing results or device settings, it is necessary to press
- key,
choose submenu "RESULTS" or "SETTINGS" and press
key. The flaw detector is capable
of storing of more than 1000 settings and up to 1000 testing results (depending on the
defectogram size) in the memory.
Fig. 20 – "RESULTS" menu
4.11
“Results” Menu
The given menu allows storing and loading of the testing results.
In selecting "Results" menu the flaw detector displays the window with a list of results (Figure
26). The list of results contains catalogues (folders) and files. The catalogues are displayed in
the top part of the list (and are marked with the folders icon), the files – in the bottom part and
are numbered. The catalogues, in their turn, can comprise subdirectories and files.
A new catalogue is created by placing the cursor on the line with colon or on the existing
catalogue and pressing
key ("F2 Create"). The existing catalogue is deleted by pressing
key ("F3 Delete").
Having placed the cursor on an empty string or on the existing file, function keys change their
function for the operation with files of results or settings.
© PCE Instruments
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English
Fig. 26 – "RESULTS" menu. List of catalogues and files
Note. To prevent an accidental deleting of catalogues with useful information, the flaw
detector has a protection, which allows only empty catalogues deleting. In order to delete the
catalogues, firstly you need to delete its contents.
With the help of function keys
,
,
– "F1 Load", "F2 Save",
"F3 Delete" (see Figure 27) – an operator can load the selected result (settings and data are
automatically loaded), save the current result and delete the selected result.
Fig. 27 - Operations with the testing results
When loading the saved testing results, the setups which were used while the testing are set in
the instrument and the automatic transition (move) to "VIEW" menu is carried out.
When saving the results (and anywhere where it is necessary to enter the text information), "
,
,
" function keys delete the previous character – "backspc", move left – “move”
and cancel the information input – "cancel".
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4.12
“Settings” Menu
When selecting "Settings" menu the flaw detector displays the window with a list of settings (see
Figure 23). The given menu allows the testing results saving and loading.
After a setups file loading, automatic enter in "Testing" menu is carried out.
English
Fig. 28 – "Settings" menu
4.13
Set up of “Calibration” Menu
The calibration curve plotting will be illustrated using the calibration block. To plot the calibration
curve, it is essential to set up all parameters of the flaw detector for operation with a specific
probe (i.e. select the ECP operating frequency from the range indicated in the registration
certificate, the required ECP exciting voltage, gain, scale) and take the calibration block (Ra
1.25).
In the "TEST" menu place the ECP on the flaw-free section before an artificial flaw with the
depth of 0.1 mm 5 and press
key (balancing). Pass all defects, having chosen such
scanning speed to have all signals from defects of regular shape (i.e. max symmetric relative to
the peak signal on time charts, see Figure 29).
The signals from the defect are not bound to stay only within the limits of one screen scan.
5
When operating with MDF probes, the mark on ECP case must coincide with the direction of
scanning trajectory.
© PCE Instruments
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English
Fig. 29 – Appearance of defectogram for the calibration curve plotting
After the acquisition of defectogram, press
menu.
key, for the quick transition to "CALIBRATION"
Fig. 30 – "Calibration" menu
1 - Set a curve for evaluation of the defect depth (Amplitude, Phase);
2 - Select the units of defect measurement (mm, %);
3 - Calibration marker by the registered calibration blocks;
4 - Calibration block selection
5 - Position of the measuring cursor on the time chart;
6 - Width of the measuring cursor on the time chart;
7 - The type of the measuring cursor, see item 3.9
© PCE Instruments
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Note. After plotting the calibration curve, there is no point in changing the units of defects
measurements.
Before plotting the calibration curve, it is necessary to delete all points of previous calibration
curve by pressing
key.
Select the type of measurement in the cursor "Type" – Pk-Pk. Move to the "Position: " menu
item and by the
,
and
keys, position the central line of the cursor on the peak of
signal from the min defect. Move to the “Width:” menu item and increase the cursor width to
such an extent that only one friendly signal could get there, i.e. the signal from the defect (see
English
Figure 31). Having placed the cursor on a defect, press the
curve point.
With the help of
,
key – add the calibration
keys, move to the "CURVE POINTS" – 1) and by
,
and
keys, set the depth of the first defect of the calibration curve, i.e.0.1 mm (see Fig. 31).
Then it is essential to perform similar operations for all other defects by setting corresponding
depth.
Fig. 31 – Plotting of the calibration curve
Each newly added point of the calibration curve is assigned with a number (1), 2), 3) and so on).
The max number of the calibration curve points – 128.
© PCE Instruments
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Note. If calibration is carried out on any of the listed calibration blocks in pos. 4, Figure
30, then an operator can easily activate marker STD (pos.3, Fig. 30) and select an appropriate
type of the calibration block before adding of the calibration curve points. Then add in order,
starting with a minimum, all signals from defects of a given calibration block and the flaw
detector will automatically assign the wanted depth to the defects.
4.14
PCE-USC 30 software
4.14.1
Running the Program
To run the program it is required:
- to copy the files to the PC hard disk drive from the disk, that is included to the flaw detector
delivery set;
- run the file “.exe”.
4.14.2
Program Description
The operating window of the program includes the following areas (Fig. 32):
Fig. 32 – Active window of PCE-USC 30 program
1 - main menu; 2 - tab panel; 3 - time diagrams area; 4 – signal display area (active area); 5 –
bottom status bar
© PCE Instruments
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English
The PC software for the PCE-USC 30 is used to view and analyze saved measurements and
operating setups. Furthermore it is possible to generate a print-out and to create a report.
4.14.2.1
Main Menu
Main menu bar includes the following menu items:
- File;
- Report.
"File" menu item includes the subitems:
English
Fig. 33
When selecting "Open" subitem, there appears a window for selection the path to the saved
testing results (by default the "RESULTS" folder is proposed, saved on the hard disk drive of PC
in the program directory of «PCE-USC 30»). This file can be located on a USB flash drive or on
the hard disk drive of the PC if the data has been previously copied to the hard disk drive (see
4.14.3). Double-click of the left mouse button opens the file.
“Loading” subitem allows to view the files of all testing results saved on a USB drive and to copy
them to the hard disk drive.
When selecting “Device settings” subitem, there appears a window with the flaw detector
settings of the carried out testing (Fig. 34).
Fig. 34 – “Flaw detector settings” window
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Fig. 35 – “Selecting the interface language” window
Note – Reload the program to change the interface language.
Select "Exit" subitem to finish the "PCE-USC 30" program.
When selecting "Report" item of the main menu, there appears a window for filling in the report
form of the testing carried out (Fig. 36).
Fig. 36 – Report form of a testing carried out
© PCE Instruments
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English
When selecting "Language" subitem, there appears a window for selecting the language of
program interface.
After pressing
button, there appears a window to preview the testing protocol.
There is an option to select between: weather to print out the setting parameters of the flaw
detector or not.
To abstain from printing out the flaw detector settings, put a tick in front of "Disable setting".
To print-out the testing protocol, press "Print"
protocol window.
button in the upper part of a testing
To save the testing protocol in a «*.pdf» format, press
button.
To exit the review mode of a testing protocol it is required to press
English
4.14.2.2
button.
Tab Panel
Tab panel includes three tabs. Each tab corresponds to the selected frequency or to the mix of
frequencies (MIX): Frequency 1, Frequency 2, MIX.
Note - Frequency 2 and MIX are available for viewing only if the testing is carried out in a
two-frequency mode.
4.14.2.3
Time diagram area
Two diagrams of signal to time dependence are displayed in time diagram area (item 3, Fig. 32).
4.14.2.4
Signal display area (active area)
In the display area of eddy current signals is displayed the eddy current signal, which is
represented by an image in the complex plane for the frequency selected (item 4, Fig. 32). In
the active area are displayed the signals that come into the area covered by the measuring
cursor.
4.14.2.5
Bottom status bar
Fig. 37 Status bar
"Duration of time sweeps" – sets the number of measurements to be displayed on time
sweeps. Duration of time sweep is measured in a range from 256 to 32768.
“Type of measurement” – allows to select the required type of cursor measurement from the
following list:
- Peak-Peak (the measurement is made between two points situated at the max. distance from
each other in cursor width);
- Vrt-M (vertical maximum – the measurement is made between two points situated at the max.
distance from each other in cursor width in vertical projection);
- Cnt-Pk (centre peak - the measurements is made between the cursor centre and the point
situated at the max. distance from the centre in cursor width);
- Cnt-K (centre cursor - the measurements is made between the centre and the cross point of
cursor centre signal);
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English
ENC (encoder) – displays the reference number by encoder when synchronizing from ENC.
Cursor position – displays the current vertical position of a measuring cursor in readings.
Fig. 38 Cursor
To change the cursor position, it is required to place the "mouse" cursor onto the centre of a
measuring cursor (item 2, Fig. 38), and when there is a
cursor, move the measuring cursor
to the required position by holding the left mouse button down.
- Cursor width – displays a set width of a measuring cursor (in readings).
To change the width of a measuring cursor, place the "mouse" cursor to the extreme position of
the measuring cursor (item 1, Fig. 38), and, when there is a cursor, set the required width of a
measuring cursor by holding the left mouse button down.
"Signal angle" – allows to change the signal phase:
- selects the step for signal phase change (from 0 to 90°);
- changing the signal phase with counter clockwise rotation considering the selected
step;
- changing the signal phase with clockwise rotation considering the selected step;
- restoring the initial signal phase.
Scale (HV) - simultaneous horizontal and vertical scaling of a signal image:
- scaling-up the signal image;
;
- scaling down the signal image
- restoring the initial horizontal to vertical ratio.
Scale (H) – allows to adjust the horizontal scaling of a signal image:
- scaling-up the signal image horizontally;
- scaling down the signal image horizontally;
- restoring the initial scale horizontally.
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Scale (V) - allows to adjust a vertical scaling of a signal image:
- scaling-up the signal image vertically;
- scaling down the signal image vertically;
- restoring the initial scale vertically.
English
Signal parameters located in a measuring cursor are displayed in information area of a bottom
status bar:
− Amplitude (V);
− Phase (deg.);
− D (mm) - conditional defect depth;
− Аn (dB) - noise amplitude;
− S/N – measured value of signal to noise ratio.
Note – In order to measure the S/N ratio, place the measuring cursor on defect free-area
and press "An" key, then move the measuring cursor to the signal peak from the defect. The
measured signal/noise ratio will be displayed in the amplitude area.
4.14.3
4.14.3.1
Working with the program
Transfer flaw detector memory to PC
The transfer of measurements from the flaw detector memory to a PC requires a USB flash
drive. A direct connection of the flaw detector to a PC with a USB cable is prohibited in order to
prevent accidental deletion of important system files of the flaw detector.
After the flaw detector has been turned off, a FAT32 formatted USB drive can be connected to
the USB port of the flaw detector. The measurements are exported to the USB drive by turning
on the flaw detector and selecting the MEMORY menu with the
button. In this menu the
shortcut button
“F3 Export data” copies the data from the internal memory to the USB flash
drive. Before removing the USB drive it is required to turn off the flaw detector again in order to
prevent memory corruption.
After the data has been transferred, the USB drive can be connected to the PC in order to view
the measurements and to create a report. In the menu of «PCE-USC 30» program select the
item "Loading", and after, in the program window there are displayed the files of all the testing
results stored in the flaw detector memory. Then, the program window asks to select the files
that can be automatically copied to the selected location on the hard disk drive of PC.
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4.14.3.2
View results of testing
In "File" item of the main menu choose the sub-item "Open". In the window that appears,
choose the path to USB flash drive - move the cursor to the necessary file with the testing
results and click "Open".
Note - Viewing a list of data on the testing results from the USB drive does not store this
data automatically in PC memory.
4.14.3.3
Printing out results of testing
To print out the testing results it is required:
- Select "Report" item in the main menu.
- Fill in the report form (Fig. 36).
- In the preview window of testing results click "Print"
5
.
Labelling and Sealing
1.
The flaw detector labelling complies with the manufacturer’s set of documents and
includes:
•
manufacturer’s name and trade mark;
•
name and designation of the flaw detector;
•
year and quarter of manufacture;
•
serial number;
•
designation of specifications (TU);
•
pattern approval mark.
•
Labelling is performed in English.
2.
Labelling is made on the flaw detector casing by polygraphic technique.
3.
Pattern approval mark is made on the flaw detector electronic unit by at least two
seals made on screws of casing cover.
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English
After opening the file in the time diagrams window and in the active area of the program there is
displayed the stored defectogram and there is the possibility to view the testing results,
measurements of the signal parameters, as well as to make the report protocol followed by its
printing out.
6
Composition and Delivery Set
Basic delivery set consists of the following components:
English
Table 8
Name and reference designation
PCE-USC 30 defectoscope / material tester
SS340K09DA0 eddy current probe in protective case
Calibration block SOP 2353.08 (Rz 40, D16T)
Connection cable (Electronic unit/ECP)
EC Probe CP13 (for conductivity measurement)
Battery
Battery charger
Carrying case
User manual
7
Quantity
1
1
1
1
1
1
1
1
1
Setting-up procedures
1.
The flaw detector is operated by one operator who has a corresponding level of
qualification and has studied the present operation manual.
2.
Before operating charge the battery of flaw detector (if required) governed by the
passport of automatic charging device.
ATTENTION! WHEN CHARGING THE BATTERY, FLAW DETECTOR ELECTRONIC
UNIT MUST BE SWITCHED OFF.
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8
8.1
Instructions for Use
Single Coil Probe
1. Connect the ECP to the flaw detector using a connecting cable.
2. Set the ECP frequency in a range specified in the registration certificate for the ECP.
3. Set the ECP drive not more than 2 V.
6. Press
key to balance the ECP.
7. Put a signal from a lift-off in the horizontal plane. For this, it is necessary to decline the ECP
from the vertical axis at an angle of 15-45 ˚. While the vector end is deviated, press
key. In
case, if the first attempt to put the signal from the lift-off horizontally failed it is necessary to
repeat the steps described above, or put the lift-off signal manually using the phase change (
parameter). The signal from a defect should be appeared in the first or second quadrant
of the complex plane.
8. By increasing the gain on preamplifier
and amplifier
you should maximize the
signal amplitude, but at the same time monitor behind parameters of the input circuit.
9. After changing any parameter that affects the absolute value of the signal it is necessary to
perform balancing by pressing
key.
10. While testing aluminium alloys it is recommended to use the vertical gain "
V GAIN" for
the visual spread of signals from the distortion and signals from a defect in a phase.
11. Select the required type of a threshold level.
12. Move the probe across the artificial defect at calibration block for several times and visually
set up the ALARM relative to the signal from the defect. After the ALARM was properly set up,
the light alarm while detecting the defect will be triggered on the flaw detector keypad (digital
indicators on the display) and sound alarm (if it has not been turned off in "SETTINGS" menu).
8.2
Reflection, Differential Probe
1 Connect the ECP to the flaw detector using a connecting cable.
2 Set the ECP frequency in a range specified in the registration certificate for the ECP.
3 Set the ECP drive not more than recommended in a registration certificate for the ECP.
4 Place the ECP to the flaw-free area of a calibration block.
5 Press
key to balance the ECP.
6 It is recommended, the signal from the defect to be placed in the first or second quadrant of
the complex plane. To correct the ECP phase use
parameter.
7 Increasing the gain on preamplifier
and amplifier
you should maximize the signal
amplitude, but at the same monitor behind parameters of the input circuit.
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English
4. Press
key to select the capacity.
5. Place the ECP to the flaw-free area of a calibration block.
8 After changing any parameter that affects the absolute value of a signal it is necessary to
perform balancing by pressing
key.
9 Select the required type of a threshold level.
10 Move the probe across the artificial defect at calibration block for several times and visually
set up the ALARM relative to the signal from the defect. After the ALARM was properly set up,
the light alarm while detecting the defect will be triggered on the flaw detector keypad (digital
indicators on the display) and sound alarm (if it has not been turned Off in "SETTINGS" menu).
8.3
Rotation Probe
English
1. Connect the rotary scanner to the flaw detector using the connection cable.
2. Connect the ECP to the rotary scanner. Approximate marks on the case of the probe and
scanner should coincide.
3. Without applying excessive force insert the ECP in the scanner. In case, when carrying out
the connection you felt that the mating connectors have rested at each other, but the marks on
the cases match, you must slightly decline the ECP from the vertical axis and insert the ECP
until it stops. When the ECP is properly placed in the scanner, the o-rings should not be seen.
4. Set the ECP frequency in a range specified in the registration certificate for the ECP.
5. Set the ECP drive not more than recommended in a registration certificate for the ECP.
6. At "ROT PRESENT" position, set up "On". In displayed menu choose the type of the rotary
scanner and press
key.
7. At "RРМ" position, firstly set the min rounds – 600.
8. Press the switched On button on the case of the rotary scanner. The ECP should be in the
air.
9. To set the scanner rounds properly, press
key and wait for the end of the procedure.
10. Press the switched On button of the rotary scanner.
11. Set the required rounds for the scanner.
12. Put the ECP into the hole of the calibration block.
13. Press the switched On button on the case of the rotary scanner.
14. Press
key to balance the ECP.
15. It is recommended, the signal from the defect to be placed in the first or second quadrant of
the complex plane. To correct the ECP phase use
parameter.
16. Increasing the gain on preamplifier
and amplifier
maximize the signal amplitude,
but at the same monitor behind parameters of the input circuit.
17. After changing any parameter that affects the absolute value of the signal it is necessary to
perform the balancing by pressing
key.
18. Select the Bandpass filter and perform it`s setting. First of all, minimize the distortion signals
from ECP in the hole by setting the "LB" parameter, and then proceed the "HB" setting. The
filter is set by trial and error.
19. During the ECP rotation in a hole perform the ALARM setup. Visually set the ALARM
relative to the signal from a defect. After the ALARM was properly set up, the light alarm will be
triggered on the flaw detector keypad at detecting the defect (digital indicators on the display)
and sound alarm (if it has not been turned off in "SETTINGS" menu).
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Maintenance
1.
The flaw detector maintenance includes the maintenance inspection, operating repair
and calibration.
2.
Intervals between the maintenance inspections are set depending on the industrial
conditions, but no less than once per month. Connecting cable fixation, condition of
controls and indicators are checked during the maintenance inspection.
3.
The maintenance inspection includes an external examination and is performed by
attending personnel before starting the flaw detector electronic unit operation.
4.
Replacement of the battery pack.
5.
Unscrew two screws (item 1 Fig. 39).
Fig. 39
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English
9
6.
Open the contact terminal (item 1 Figure 40), pressing the clip (item 2 Figure 40).
English
Fig. 40
7.
Remove the battery pack (item 1 Figure 41).
Fig. 41
8.
Battery pack mounting is carried out strictly in reverse order.
© PCE Instruments
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10
Typical Failures and Troubleshooting
The list of the most common and probable failures is given in Table 9.
Remedy
Charge the storage battery
Charge the storage battery
ATTENTION! THE FLAW DETECTOR MUST BE SWITCHED OFF WHEN NONTYPICAL IMAGES APPEAR ON THE FLAW DETECTOR SCREEN AND SOFTWARE
PROGRAMS BUZZ. IF REPEATED SWITCHING ON OF THE FLAW DETECTOR (NOT
EARLIER THAN IN 3 MINUTES) DOES NOT LEAD TO THE RESETTING OF NORMAL
OPERATION, THE FLAW DETECTOR SHOULD BE SENT TO THE MANUFACTURER FOR
REPAIR OR IT IS NECESSARY TO ADDRESS THE SERVICE CENTER.
11
Transportation and Storage
1. Climatic conditions for transportation of the eddy current flaw detector electronic unit – 2 (C)
according to GOST 15150, but for operating temperature range from minus 20 °C to plus 40 °C.
2. Transportation of the packed eddy current flaw detector may be shipped by any type of
closed transport (except for the sea one) that protects the eddy current testing system from
direct impact of precipitations, with a possibility of transshipping from one type of transport to
the other. Air shipments are allowed only in the pressurized modules. Arrangement and fixation
of boxes in transport vehicles should prevent them from displacement, shocks or impacts.
3. The flaw detector storage conditions in the manufacturer’s packing should meet the
requirements 2 (C) according to GOST 15150, but for operating temperature range from minus
20 °C up to plus 40 °C.
4. Storing the flaw detector in one room with acids, reagents, paints and other chemicals and
materials, the vapors of which may have a harmful effect on the instrument is not permitted.
5. In storage, the flaw detector and ECP should not be affected by electromagnetic fields.
Evaluation of stability of the flaw detector and ECP performance under the effect of
electromagnetic interferences should correspond to "B" criterion according to GOST 29073.
12
Warranty
You can read our warranty terms in our General Business Terms which you can find here:
https://www.pce-instruments.com/english/terms.
13
Disposal
For the disposal of batteries in the EU, the 2006/66/EC directive of the European Parliament
applies. Due to the contained pollutants, batteries must not be disposed of as household waste.
They must be given to collection points designed for that purpose.
In order to comply with the EU directive 2012/19/EU we take our devices back. We either re-use
them or give them to a recycling company which disposes of the devices in line with law.
© PCE Instruments
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English
Table 9 – Typical failures and troubleshooting
Failure
Probable cause
When pressing "Power"
The storage battery is
key, the screen is not
discharged
lightened
When the instrument is
The storage battery is
switched On, the inscription
discharged
"Storage battery needs
charging"
is displayed
For countries outside the EU, batteries and devices should be disposed of in accordance with
your local waste regulations.
If you have any questions, please contact PCE Instruments.
APPENDIX A
English
Requirements to Charging Device for Portable Eddy Current Flaw
Detector PCE-USC 30
1 Special-purpose charging device for Li-Ion battery charging (3 elements) with rated voltage of
12 V and capacity of 4.5 Аhour.
2 Charge type – accelerated.
3 Charge rate – (2.3 ± 10%) А.
4 After accelerated charging, the trickle charge mode is activated.
5 Electric supply of charging device: AC mains voltage from 100 to 240 V and frequency of (47
÷ 63) Hz. Current consumption at full load up to 0.9 A.
6 Cable length of charging device – no more than 2.0 m.
Lemo FGG.1B.304.CLАD42
Front
1
2
3
4
Component side view
“-“ Charging device
“+” Charging device
Fig. A.1 – Soldering pattern of charging device output cable for the flaw detector
connection
© PCE Instruments
56
Germany
France
Spain
PCE Deutschland GmbH
Im Langel 4
D-59872 Meschede
Deutschland
Tel.: +49 (0) 2903 976 99 0
Fax: +49 (0) 2903 976 99 29
[email protected]
www.pce-instruments.com/deutsch
PCE Instruments France EURL
76, Rue de la Plaine des Bouchers
67100 Strasbourg
France
Téléphone: +33 (0) 972 3537 17
Numéro de fax: +33 (0) 972 3537 18
[email protected]
www.pce-instruments.com/french
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Calle Mayor, 53
02500 Tobarra (Albacete)
España
Tel. : +34 967 543 548
Fax: +34 967 543 542
[email protected]
www.pce-instruments.com/espanol
United States of America
United Kingdom
Italy
PCE Americas Inc.
711 Commerce Way suite 8
Jupiter / Palm Beach
33458 FL
USA
Tel: +1 (561) 320-9162
Fax: +1 (561) 320-9176
[email protected]
www.pce-instruments.com/us
PCE Instruments UK Ltd
Units 12/13 Southpoint Business Park
Ensign Way, Southampton
Hampshire
United Kingdom, SO31 4RF
Tel: +44 (0) 2380 98703 0
Fax: +44 (0) 2380 98703 9
[email protected]
www.pce-instruments.com/english
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Via Pesciatina 878 / B-Interno 6
55010 LOC. GRAGNANO
CAPANNORI (LUCCA)
Italia
Telefono: +39 0583 975 114
Fax: +39 0583 974 824
[email protected]
www.pce-instruments.com/italiano
The Netherlands
Chile
Hong Kong
PCE Brookhuis B.V.
Institutenweg 15
7521 PH Enschede
Nederland
Telefoon: +31 (0) 900 1200 003
Fax: +31 53 430 36 46
[email protected]
www.pce-instruments.com/dutch
PCE Instruments Chile SPA
RUT 76.423.459-6
Badajoz 100 oficina 1010 Las Condes
Santiago de Chile / Chile
Tel. : +56 2 24053238
Fax: +56 2 2873 3777
[email protected]
www.pce-instruments.com/chile
PCE Instruments HK Ltd.
Unit J, 21/F., COS Centre
56 Tsun Yip Street
Kwun Tong
Kowloon, Hong Kong
Tel: +852-301-84912
[email protected]
www.pce-instruments.cn
China
Turkey
Pingce (Shenzhen) Technology Ltd.
West 5H1,5th Floor,1st Building
Shenhua Industrial Park,
Meihua Road,Futian District
Shenzhen City
China
Tel: +86 0755-32978297
[email protected]
www.pce-instruments.cn
PCE Teknik Cihazları Ltd.Şti.
Halkalı Merkez Mah.
Pehlivan Sok. No.6/C
34303 Küçükçekmece - İstanbul
Türkiye
Tel: 0212 471 11 47
Faks: 0212 705 53 93
[email protected]
www.pce-instruments.com/turkish
© PCE Instruments
57
English
PCE Instruments contact information
User manuals in various languages
(German, French, Italian, Spanish, Portuguese, Dutch, Turkish, Polish,
Russian, Chinese)
can be downloaded here: www.pce-instruments.com
Specifications are subject to change without notice.
© PCE Instruments