E73BA1AEP.doc 24.07.

00

Operating Manual
Ultrasonic Thickness Gauge

Economy ECHOMETER 1073

Rev. 1.0 a

Subject to change without notice

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KARL DEUTSCH Prf- und Megertebau OTTO-HAUSMANN-RING 101 D 42115 WUPPERTAL

IMPORTANT NOTE

Our devices, units and accessories are designed, constructed and finished according to the state of the art. We presume that our customers similarly have knowledge of the art in respect of the restrictions in the completeness or reliability of the test process resulting therefrom. We are pleased to give full explanations where customers are in doubt. Our products are subjected to an acceptance test according to specified technical data. The release of equipment is incumbent on specialized personnel. We accept responsibility for malfunctions or defects as specified under our general terms of delivery. Our products are also used for the non-destructive testing of working materials in parts, the failure of which can represent a high risk. This applies, for example, both to working materials or component parts for the automobile industry and to the aviation or nuclear power fields. The user needs to undertake all reasonable measures to avoid workpieces from passing unnoticed. Observation units on the test units for this purpose are offered. The risk of a malfunction of the unit can be reduced by regular checks of the device, accessories, test media, operating conditions and test personnel. In particularly important cases a check needs to be carried out both before and after each test. Such checks lead to the discovery of not only systematical malfunctions but malfunctions of the system and the device occurring sporadically. When the malfunctions in function have been ascertained, then measures must be taken without delay to prevent the construction parts, which were established in the last check as perfect, from being further used without reexamination. We are ready to discuss the type and scope of checking or organisation measures prior to acceptance of the test procedure.

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Contents
1 What you should know prior to starting..........................5
1.1 1.2 1.3 1.4 1.5 1.6 Passing-on, availability and storage of this handbook .................... 5 Notes on this handbook .................................................................. 5 Requirements concerning the test personnel.................................. 6 Safety note...................................................................................... 6 Intended use ................................................................................... 6 Measuring range of probes, display resolution and unit, measuring tolerance ....................................................................... 7 1.7 CE Conformity ................................................................................ 8 1.8 Contacting KARL DEUTSCH .......................................................... 9

Putting into operation .....................................................10

2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 Connectors and controls ............................................................... 10 Display.......................................................................................... 11 Operating menu ............................................................................ 12 Erroneous inputs........................................................................... 14 Connecting the probe, switch-on, calibrating and measuring ..................................................................................... 15 Calibration..................................................................................... 17 Entering a new sound velocity ...................................................... 19 Measuring and adjusting the sound velocity on a specimen of known thickness ....................................................... 20 Alarm mode (monitoring thickness limits) ..................................... 22 2.9.1 Input of measuring limits................................................. 22 2.9.1.1 Input of the lower limit value .......................... 22 2.9.1.2 Input of the upper limit value.......................... 23 2.9.2 Displaying the limit values............................................... 24 2.9.2.1 Displaying the lower limit ............................... 24 2.9.2.2 Displaying the upper limit............................... 24 Selecting the measuring unit......................................................... 24 Adaptation of the sensitivity .......................................................... 25 Illumination of the LCD display ..................................................... 25 Energy-saving mode ..................................................................... 26

2.10 2.11 2.12 2.13

3 4 5

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

Corrogram........................................................................28 General notes ..................................................................29

5.1 Measurement principle ................................................................. 29 5.2 Operating and storage temperature.............................................. 30
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5.3 Wear and tear of the probe ........................................................... 30 5.4 Power supply ................................................................................ 31 5.4.1 Battery types................................................................... 31 5.4.2 Operating time ................................................................ 31 5.4.3 Exchanging batteries ...................................................... 32 5.5 Housing ........................................................................................ 33 5.6 Cleaning keypad and housing....................................................... 33 5.7 Type and serial number ................................................................ 33

6 7 8 9

What to do when .....? .....................................................34 Technical data .................................................................36 Use and assembly of wear protective membranes ......40 Instrument view ...............................................................42

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1
1.1

What you should know prior to starting

Passing-on, availability and storage of this handbook

This handbook is a standard accessory and comes with the ECHOMETER 1073 when delivered. Please make sure that this handbook is passed to the quality assurance dept. of your company from where it can be ... handed on to the specific user. Please store this handbook like a document. Copies of this manual can be ordered from KARL DEUTSCH.
1.2 Notes on this handbook

This manual deals with the proper use of the Ultrasonic Thickness Gauge Economy-ECHOMETER 1073. Notes marked with the symbol must be read and considered in order not to reduce the quality of the test process and, where appropriate, not to neglect safety-relevant aspects. Supplementary notes worth knowing can be recognized by the information symbol At the end of this manual a folder sheet with reference numbers is included. Subassemblies described in text or mentioned are provided with the corresponding reference numbers in order to allow an easy assignment.

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1.3

Requirements concerning the test personnel

To operate the ECHOMETER according to the demands of the corresponding test task, the user of the ultrasonic thickness gauge should be able to read and understand this manual. Moreover, there should be a basic knowledge of methods used in the application of measurement technique; thus the operator can judge objectively the measured values and their tolerance. By this, the possibility to recognize systematic or applicational malfunctions can be increased as well as the recognition of error caused by the gauge. By means of periodically executed check measurements using comparable test pieces with known thickness you can verify the correct function of the test system. In addition, the test personnel should be familiar with processes to be executed in the case of instrumental malfunction or error.
1.4 Safety note
The ECHOMETER 1073 must not be used in an explosive environment (e.g. in mining areas, in tanks with explosive gas mixtures etc.). Observe the respective safety rules.

1.5

Intended use

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

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1.6

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

The ECHOMETER works with dual element (TR or SE) probes. Dual element (TR) probes have separate transmitter (T) and receiver (R) elements, which must be connected to the respective transmitter output and receiver input of the thickness gauge. ECHOMETER probes are equipped with fixed twin cables of approx. 1 m length and Lemo type connectors. Corresponding probe connectors and instrument sockets have colored marks to assure proper assignment and connection. Measuring range of probes The measuring ranges depend on the specific probe type: Standard probe DSE 10.4/6 PB 4
4 MHz probe with 10 x 4 mm piezoelectric element size.,Order-no. 1465.761

1.2 to 250 mm

Miniature probe DSE 4.2/4 PB 8

8 MHz probe with 4 x 2 mm piezoelectric element size, smallest possble shape for measurements on thin materials and/or sharp contours. Order- no. 1465.661

0.7 to 25 mm

Low frequency probe DSE 18/25 PB 2 1 5 to 400 mm

2 MHz probe with 18 mm diam. half cut piezoelectric elements. Especially for measurements on rough surfaces and coarse-grained materials. Order-no. 1465.361

The stated measuring ranges are valid for fine-grain steel with plane-parallel and smooth surfaces. They are valid for probes used without wear protective membranes. With different material, geometry and surface or with wear protective membranes, the measuring ranges can be reduced. Display resolution and unit The display resolution and unit (metric or inch) of the instrument can be selected from 0.1 mm, 0.01 mm and 0.001 inch.

High sound conductivity can cause phantom echoes and wrong thickness readings of thick materials. In this case we recommend to use a probe with higher frequency. 7413.7311 p. 7

Operating Manual ECHOMETER 1073

Measuring tolerance The measuring tolerance 2 of the ECHOMETER with probes DSE 10.4/6 PB 4 and DSE 4.2/4 PB 8 is: 0.1 mm in the measuring range up to 80 mm 0.5 % of the actual thickness above 80 mm With the low frequency probe DSE 18/25 PB 2, the measuring tolerance is: 0.2 mm in the measuring range up to 80 mm 0.5 % of the actual thickness above 80 mm
The stated data for measurement and reading tolerance are valid for the a.m. respective measuring ranges of the probes. Outside these measuring ranges, either measurement is not possible or the tolerance range can be greater, possibly to a great extent. Please also note chapter 5.3.

1.7

CE Conformity

This appliance has been developed and manufactured with regard to ist electromagnetic compatibility for use not only in industrial but also in residential, commercial and trade premises and in small businesses in accordance with harmonized standards. This means that the appliance conforms to the most important protection standards of the Electromagnetic Compatibility Directive (89/336/EEC) and the German Electromagnetic Compatibility Act of 9 November 1992 in accordance with the current issue on the date of delivery of the unit. The characteristics within the meaning of the CE Directives applying to this measuring appliance and the appliance's proven quality characteristics apply to correct use of the appliance, as described in chapter 1.5 of this manual.

Data regarding the measuring tolerance refer to an adjusted sound velocity of 5920 m/s (steel) and constant temperature during the measurement. 7413.7311 p. 8

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1.8

Contacting KARL DEUTSCH

We work flexitime. You surely can contact us: Monday to Thursday : 8.00 - 12.15 h / 12.45 - 15.30 h Friday: 8.00 - 12.15 h Phones: Fax: E-mail: Internet homepage: +49 (0) 202 7192-0 +49 (0) 202 714932 info@karldeutsch.de http://www.karldeutsch.de

Use the following address for mailing contacts: KARL DEUTSCH Prf- und Megertebau GmbH & Co. KG P.O. Box 132354 D-42050 Wuppertal We are located at: Otto-Hausmann-Ring 101 D-42115 Wuppertal

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2.1

Putting into operation

Connectors and controls

The reference numbers in the following chapters correspond to the reference numbers on the foldable view at the end of this manual. Housing top On the housing top of the ECHOMETER 1073 the coaxial sockets (3), (4) for connection of the probe are located. Keypad The keypad (6) consists of four keys: ON/OFF confirmation of value menu start and selection increment (i.e. increasing the value) menu selection decrement (i.e. decreasing the value) Above the keypad (6) the LC-display (5) is located. The 5 mm calibration block (7) is located below the keypad.

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2.2

Display

The ECHOMETER is equipped with a Liquid Crystal Display (LCD). The display shows up to four symbols, letters or figures with decimal dot. Depending on the operation mode, additional special symbols are visible. These special symbols appear at the left margin of the LCD: Special symbol Meaning When this starts flashing, it tells you that the batteries are nearly dead. Usually you can go on measuring for at least 1 -3 hours but you should fit new batteries or refreshed rechargeable batteries as soon as possible. With permanent display of this message, you should replace the batteries immediately since automatic switch-off is imminent. The non-coupling mark (two dots at the left display margin) is visible when the probe is not placed on the Workpiece or coupling is not sufficient for proper measurement. With a non-coupling mark shown on the display no measurement is executed. The non-coupling mark also appears, if the back-wall echo becomes too low due to physical reasons, e.g. high acoustic absorption or scattering within the workpiece or very high thickness of the workpiece.

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2.3

Operating menu

Using the operating menu, you can select and adjust the working parameters of the ECHOMETER 1073. In measuring mode, strike Use Strike to select the desired menu item to enter the set-up level of the selected menu item.

Use one of the arrow keys (with numeric values: increase) or (with numeric values: decrease) to alter the parameters. Strike to accept the new value of the parameter The instrument changes to the measuring mode again The following table lists all set-up parameters in the same sequence as they are displayed when successively actuating the to enter the setup-level of key . (The key action Strike the menu item is denoted as .) Display Measuring parameter Thickness (sample value) Sound velocity of the material (sample value) Monitoring the upper limit off upper limit (sample value) Monitoring the lower limit off lower limit (sample value) (low threshold) (thickness)

(velocity)

(high threshold)

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Display and input unit mm Inch

(unit)

Instrument sensitivity (4 levels) (Sensitivity) Standard measuring should be executed with the highest sensitivity setting . When thickness readings have to be taken from a workpiece with a very low absorption (e.g. aluminium) the sensitivity must be reduced to . The lower sensitivity settings can also be used to avoid thickness readings from small targets within or in the vicinity of the sound beam of the probe. Display backlight (LAMP) off on (backlight is only lit during menu set-up and while probe is coupled to a workpiece)
When selecting a menu item, the current setting of this item will automatically appear in the display after a delay of about 1 second. All menu settings (measuring parameter) and instrument calibration data remain stored in a non-volatile memory even after switching the device off or removing the batteries. They can be activated again, when skipping the inquiry after switch-on by striking the key and thus not executing a new calibration. Each time a new calibration is executed after switch-on, the menu settings will be reset to default values (see section 2.6 of this manual).

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2.4

Erroneous inputs

Each time the key is struck, the instruments checks the current input value for plausibility and for lying within its allowed range. When the allowed range is exceeded, a brief error message is shown . The instrument switches to the input mode again and the parameter can be corrected instantaneously. The following limits should be obeyed: Range of sound velocity: 100 m/s 19999 m/s or 0.01 inch/s 1.999 inch/s. When monitoring upper and lower thickness limits: Set values for the upper limit must be higher than set values for the lower limit.
Error messages will also appear, if values calculated by the instrument exceed the allowed range.

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2.5

Connecting the probe, switch-on, calibrating and measuring

Switch off the instrument Connect the probe connection cables to the probe sockets (3), (4). Ensure the plug (1) with the red cable sleeve is inserted in the socket (4), which is marked by a red point.
red sleeve

Red point marking

Fig. 1: Connecting the probe cables

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

Strike the key

to switch the ECHOMETER on. , which is the request to start cali-

The display shows bration.

Calibrate the instrument as described in section 2.6.

On first switch-on, the ECHOMETER reads in metric units and 0.1 mm resolution (factory presetting, unless otherwise ordered). You can change the presetting to 0.01 mm resolution or to read the thickness in 0.001 inch by a special key combination. Please note section 3.1.

To read the thickness of a material, the ECHOMETER 1073 must know its sound velocity. Each time a new calibration is executed, the sound velocity is automatically set to 5920 m/s. If the material, whose thickness shall be determined, has a different sound velocity, either enter manually the exact sound velocity as decribed in section 2.7, or measure and adjust the sound velocity as decribed in section 2.8.
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 Now apply a drop of couplant (e.g. ECHOTRACE 3 , ECHOFLUID3, oil etc.) to the workpiece where the thickness shall be measured and couple the probe to the workpiece.
Probes may come with a plastic soft protective cap to avoid scratches or otherwise damage of the contact face. Remember to remove the protective cap prior to measurement.

The thickness will be read in the display, immediately, (either in mm or in inch). You can continue measuring thickness at other points of the workpiece by successively applying drops of couplant to the measuring points and coupling the probe to them. The instruments keeps the sound velocity, which was initially set, as long as a new one is entered or the instrument is calibrated again.
Altering the sound velocity will always alter the displayed thickness (due to the physical relation s=vt/2, see section 5.1).

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

High quality couplants from KARL DEUTSCH: ECHOTRACE 500 ml (order no. 9000.003) or 5 l (order no. 9000.002). ECHOFLUID 100 ml (order no. 9004.001) 7413.7311 p. 16

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2.6

Calibration

Whenever the instrument is switched on, the display shows , which is the request to start calibration (**). To calibrate the instrument, proceed as follows: Apply a drop of couplant (e.g. ECHOTRACE 4 , ECHOFLUID4, oil etc.) to the built-in calibration block (7). Place the probe on the centre of the built-in calibration block (7). Keep it coupled until the display shows (with display resolution 0.1 mm) resp. (with display resolution 0.01 mm). This value represents the thickness of the built-in precise calibration block in mm.
The equivalent inch value (0.197) will be displayed by instruments with a presetting of 0.001 inch resolution.

Lift the probe off the built-in calibration block. The instrument is calibrated now and ready to take thickness readings with the sound velocity of the instrument automatically set to 5920 m/s (typical value for steel).
The accuracy of all the following thickness readings depends strongly on how the probe is coupled to the built-in calibration block during the calibration process. For proper coupling, proceed as carefully as possible: Before applying the couplant, remove any dust or dirt from the contact surfaces of probe and calibration block. The couplant is necessary to transfer acoustic energy from the probe to the workpiece at all. But always keep in mind: The thinner the film is, the more energy will be tranferred and the better results can be expected. (**): During calibration, the ECHOMETER recognizes automatically the type of probe which is connected to the gauge, and compensates for individual probe wear and temperature changes. It is recommended to check and verify the accuracy of thickness readings from time to time by means of specimen of known thickness or by means of the built-in reference block of known thickness and, if necessary, recalibrate the instrument. A new calibration is always necessary, either when the temperature changes, the probe becomes more worn out since last calibration or when another probe is connected to the instrument.

High quality couplants from KARL DEUTSCH: ECHOTRACE 500 ml (order no. 9000.003) or 5 l (order no. 9000.002). ECHOFLUID 100 ml (order no. 9004.001) 7413.7311 p. 17

Operating Manual ECHOMETER 1073

The CAL-process resets the following parameters of the ECHOMETER 1073: the parameter thickness to the thickness of the internal calibration block (5.0 mm resp. 5.00 mm or 0.197 inch) the parameter sound velocity of the material to 5920 m/s resp. to 0.233 inch/s. the parameter display and input (mm or inch) to that unit, which corresponds with the selected presetting (0.1 mm, 0.01 mm or 0.001 inch, see section 3.1) the parameter instrument sensitivity to If you feel a new calibration not necessary after switch-on, you can override the new calibration by striking when the inquiry appears in the display. In this case the instrument keeps the previous settings of thickness, sound velocity, unit and sensitivity as well as the previous calibration data.

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

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2.7

Entering a new sound velocity

Each time a new calibration is executed after switch-on, when the display is showing , the sound velocity is automatically set to 5920 m/s. If the material, whose thickness shall be determined, has a different but already exactly known sound velocity, you can enter the new sound velocity manually via the keypad. Proceed as follows: Strike key and then key the menu item . or until the display shows

. After a short time the current sound velocity Strike value will be indicated. Strike key or until the display reading meets the sound velocity of the material to be measured in m/s resp. inch/s (e.g. steel 5920 m/s resp. 0.233 inch/s). The possible adjustment range is 100 - 19999 m/s resp. 0.01 1.999 inch/s. Strike key , to confirm the new value and to return to the measuring mode.

The instrument has accepted the entered sound velocity and is now ready for new thickness measurements.
All subsequent measurings are based on the new sound velocity, which will be kept by the instrument - even when removing the batteries - , until a different value of the sound velocity is entered or adusted, or a new calibration is executed. Altering the sound velocity will always alter the displayed thickness (due to the physical relation s=vt/2, see section 5.1)

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2.8

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

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

Strike key and then key is in the display. Strike

or

until the menu item

The previously measured thickness is displayed. and to adjust the displayed thickness to Use the keys the actual thickness of the specimen. Finally strike again.

The velocity is now adjusted to the sound velocity of the specimen. To see the value of the measured sound velocity, strike key , use the key or and select the menu item . After a short time the sound velocity of the specimen is displayed

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All subsequent measurments are based on the new sound velocity. It will be kept by the instrument - even when removing the batteries - , until a different value of the sound velocity is entered or adusted, or a new calibration is executed. Please refer to section 2.4, when the error message should be displayed during adjustment.

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2.9

Alarm mode (monitoring thickness limits)

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

2.9.1.1

Input of the lower limit value

Strike

and then key

or

until the menu item

appears in the display. Strike . Use the keys shown. or until the required lower limit value is

Strike to accept the adjusted limit value and to return to measuring operating mode. During measurement: With measured values dropping below the lower limit, the display reading will start flashing. In addition, a low tone alarm signal will be heard. (Exceeding the upper limit - see following section - is announced by means of a high tone alarm signal).
Please refer to section 2.4, if the error message played during adjustment of the lower limit. is dis-

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

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2.9.1.2

Input of the upper limit value

Strike key and then key or appears in the display. Strike . or Use the keys shown.

until the menu item

until the required upper limit value is

Strike to accept the adjusted limit value and to return to measuring operating mode. During measurement: With measured values exceeding the upper limit, the display reading will start flashing. In addition, a high tone alarm signal will be heard. (thickness readings dropping below the lower limit - see previous section are announced by means of a low tone alarm signal).
Please refer to section 2.4, if the error message played during adjustment of the upper limit. is dis-

Switching the alarm mode off: By adjusting the menu item and parameter to the alarm mode for the lower limit is switched off.
The limits may be entered in arbritary sequence. Furthermore, it is not required to enter both limit values: A single upper or lower limit, depending on the testing task, is sufficient.

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2.9.2

Displaying the limit values

The stored limit values can be read in the display.

2.9.2.1 Displaying the lower limit

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

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

2.10

Selecting the measuring unit

When you want occasionally that the thickness is read or converted in another unit (mm or inch) than corresponding to the presetting of the instrument, proceed as follows: Strike key and then key or until the menu item appears in the display. Strike . or to select the measuring unit (inch). Use the arrow keys (mm) or Strike

to accept the selection.

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

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2.11

Adaptation of the sensitivity

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

maximum sensitivity high sensitivity low sensitivity Strike minimum sensitivity, to accept the selection.
.

Without need to reduce the sensitivity, measuring should always be executed with the highest sensitivity

2.12

Illumination of the LCD display

The LCD display is equipped with a backlight, enabling reading it even in darkness. To switch the internal backlight on or off, proceed as follows: Strike key and then key or until the menu item appears in the display. Strike . , if or to select resp. Use the arrow keys you want to switch the illumination on or off. Strike to accept the selection.

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

2.13

Energy-saving mode

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

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3
3.1

Special features
Changing the basic presettings for unit and resolution

The ECHOMETER 1073 can be preset to read thickness in mm or inch with 0.1 mm, 0.01 mm or 0.001 inch resolution.
If your selected basic presetting is 0.1 mm or 0.01 mm and you want only occasionally your instrument to read in inch, or vice versa, use the menu item UNIT 2.10 of this manual. as described in section

To select 0.1 mm, 0.01 mm or 0.001 inch as the new basic presetting of the instrument, proceed as follows: Switch off the instrument Press simultaneously a key according to the desired display unit and resolution (see following table) and the key. basic presettings for unit and resolution metric with display resolution 0.1 mm metric with display resolution 0.01 mm key combination to change the presettings + +

inch with display resolution + 0.001 inch After releasing both keys the display will show which is the request to start a new calibration.

Calibrate the instrument. After calibration the new basic presettings for unit and calibration are valid. They remain stored in the memory of the instrument even after switch-off or replacing the batteries -, until they are changed again by the described procedure.
When the presetting has been changed by the described procedure, the instrument must read at least one thickness value, before a parameter of the menu can be changed.

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

useful range

Fig. 2: Corrogram ECHOMETER 1073 Example: If you expect targets as small as 1 mm in diameter lying in a depth between 1 and 5 mm, take the probe DSE 4.2/4 PB 8. No other probe covers that region better.

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5
5.1

General notes
Measurement principle

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

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5.2

Operating and storage temperature

The ECHOMETER 1073 can be operated in environmental temperatures from -10 C to 50 C. The permissible storage temperatures of the ECHOMETER 1073 with inserted batteries lies in the same range -10 C to +50 C. With batteries removed, you can store the instrument in a temperature ranging between 20 C and 60 C.
Temperatures in the inside of a car or generally behind glass can easily be higher than 60 C, when the sun is shining!

5.3

Wear and tear of the probe

Depending on the surface roughness of the workpieces mechanical wear can reduce the length of the probe. Wear of up to 1 mm will not affect the measurement accuracy. Wear exceeding this limit can decrease the accuracy compared to the usually expected measuring tolerances of section 1.6. The following table gives information on the effects of wear with regard to the various probe types:
Shortening limits without influence on accuracy total usable shortening (add 0.1 mm to the normal tolerance) length of housing ex works

probe type DSE 10.4/6 PB 4 DSE 4.2/4 PB 8 DSE 18/25 PB 2

1 mm 1 mm 1 mm

up to 5 mm up to 2 mm up to 5 mm

30 -0.2 mm 15 -0.1 mm 33 -0.2 mm

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

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5.4

Power supply

The ECHOMETER can be used with 1,5 V alkali-manganese or 1,5 V lithium batteries (dry cells) or with 1,2 1,5 V rechargeable batteries.
5.4.1 Battery types

For operation, you need two batteries of Mignon/AA/LR6/AM3 size. Ex works, the instrument comes with two alkali-manganese batteries. Alternatively you can use rechargeable NiCd- or NiMH-batteries of same size. Both rechargeable and non-rechargeable batteries are available in all shops selling electro devices or entertainment electronics. This is where to find suitable chargers, too. High-quality NiMH rechargeable batteries can be ordered from KARL DEUTSCH by order no. 6016.001 (2 ea.). A suitable charger is also available by order no. 6015.001. If you are going to use rechargeable batteries, we recommend NiMH-batteries since they feature a higher capacity against NiCd and are less harmful to the environment.
Use leak-proof battery types only! Remove batteries from the unit when it is stored for a longer period. Dead batteries should be removed immediately and handed-on to a recycling system. Prior to disposal of the gauge, you need to remove the batteries from the instrument and dispose them non-polluting.

5.4.2

Operating time

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

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

5.4.3

Exchanging batteries

Batteries are inserted into the compartment in the bottom side of the instrument. To exchange the batteries proceed as follows: Switch-off the instrument. Remove Phillips screws of the battery compartment cover (10). Carefully lift off cover. Ensure that the rubber sealing will not be damaged or removed from the guiding notch. Insert new batteries into the battery compartment (8). Ensure correct orientation according to the sketch. Re-assembling is made in the reverse order.

Fig. 3: Rear view with open battery compartment

All measuring parameter and calibration data are stored in a non-volatile memory and will not get lost, when removing and changing the batteries. Skip the request for calibration by striking the key after switch on, if you want to work with the same parameter and calibration data again.

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5.5

Housing

The ECHOMETER housing is made from sturdy plastics (ABS / polyester). The housing is splash proof according to IP 54.
Please note section 5.4.3 regarding the correct handling of the rubber sealing, in order not to risk the protection class.

5.6

Cleaning keypad and housing

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

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

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What to do when .....?

What to do when the display shows Cause: ?

The combination of current or just entered parameter leads to a value that exceeds the permissible parameter limits (see section 2.4). Remedy: Alter the parameter values correspondingly. What to do when the non-coupling mark appear? won't dis-

Cause: Insufficient acoustic coupling Remedy: Remove dust or dirt from the contact face of the probe and the workpiece, where the thickness shall be measured. Apply a sufficient drop of couplant (ECHOTRACE, ECHOFLUID, oil etc.) to the probe or to the workpiece. If necessary increase the coupling pressure a little bit (do not apply too much force !!). Cause: High sound attenuation in the workpiece Remedy: Try a probe with a lower frequency (see section 1.6). Low frequencies are less attenuated and can penetrate lossy materials better than higher frequencies. Remember that the measuring tolerance will become higher with low frequencies. You are welcome to get in touch with the application laboratory of KARL DEUTSCH if you need help to solve a special application problem. What to do when the display shows ?

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

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

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Technical data
DISPLAY Display technique Display size Display format Display window Character height Liquid crystal display (LCD) Standard 5 inch = 50.8 x 30.5 mm2 4 characters. Seven segments 44 x 16 mm2 10.2 mm

ADJUSTMENT LIMITS Wall thickness (thi) Resolution 0.1 mm >= 1.0 mm to s(max) Resolution 0.01 mm >= 0.1 mm to s(max) Resolution 0.001 inch >= 0.01 inch to s(max) Note: s(max) = s(o) * v(max) / v(o) ; s(o). v(o) = last adjusted values (of thickness and sound velocity) prior to adjustment of thi, v(max) = 19999 m/s resp. 1.9999 inch/us Sound velocity (VEL) Resolution 0.1 mm >= 100 m/s to 19999 m/s Resolution 0.01 mm >= 100 m/s to 19999 m/s Resolution 0.001 inch >= 0.0100 inch/us to 1.9999 inch/us Limits (Loth, Hith) (Loth) < (Hith) Calibration block Built-in calibration block MEASUREMENT UNCERTAINTY OF GAUGE Resolution 0.1 mm Resolution 0.01 mm Resolution 0.001 inch MEASURING RANGES Standard probe Measuring uncertainty with : Resolution 0.1 mm Resolution 0.01 mm Resolution 0.001 inch Miniature probe Measuring uncertainty with : Resolution 0.1 mm Resolution 0.01 mm Equivalent to 5 mm steel (5920 m/s)

0.1 mm 0.05 mm 0.002 inch (DSE 10.4/6 PB 4) 1.5 to 250 mm

0.1 mm, above 80 mm +/- 0.5% 0.1 mm, above 80 mm +/- 0.5% 0.002 inch, above 80 mm +/- 0.5% (DSE 4.2/4 PB 8) 0.7 to 25 mm

0.1 mm, above 80 mm +/- 0.5% 0.1 mm, above 80 mm +/- 0.5%
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Operating Manual ECHOMETER 1073

Resolution 0.001 inch Low frequency probe Measuring uncertainty with : Resolution 0.1 mm TRANSMITTER Shape of transmitter pulse Transmitter properties : Voltage of transmitter pulse

0.002 inch, above 80 mm +/- 0.5% (DSE 18/25 PB 2) 5.0 to 400mm

0.2 mm, above 80 mm +/- 0.5%

Unipolar (negative) needle pulse (adapted to a.m. probes) Vpo = 70 V, +/ -10% at 180 (power adapted) Rise time of pulse t = 20 ns +/- 10% Pulse length t = 300 ns +/- 10% Frequency spectrum see below: additional data acc. to prEN 12668-1 Mesurement repetition frequency 2 Hz AMPLIFIER and DAMPING Nominal frequency range Maximum input sensitivity Equivalent input impedance Adjustable damping, four steps 0.6 15 MHz (-3dB) 1.5 mVpp for 100% coupling (adjust value) 180 +/- 10% "Hi =" 0dB (maximum sensitivity) "Hi -" - 6dB (high sensitivity) "Lo -" - 9dB (low sensitivity) "Lo =" - 12dB (minimum sensitivity) > 80 dB Selectable mm and inch Automatical per calibration ("CAL), by means of measurement of delay line. Confirms keystroke and limit excess by a spezific tone signal The parameters reading, sound velocity, upper and lower limit remain memorized after switch-off and battery change.

Damping of crossover talking MISCELLANEOUS Measurement systems Probe recognition Beeper Parameter memory

VOLTAGE SUPPLY Battery operation

By two alkali-manganese primary cells. Type AA/IEC R6. 2 x 1.5 V Operating time (with max. power More than 200 hrs consumption) Rechargeable battery operation By two NiMH batteries. Type AA/IEC
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R6. 2 x 1.2 V Operating time (with max. power approx. 90 hrs (new) consumption) Battery capacity indication approx. 1 to 3 hrs. Prior to reaching low voltage state the alarm indication "Lo Batt will show in the display Automatic switch off With undervoltage of batteries (< 1.6 V) Stability vs. voltage deviation Within the range of permissible battery voltage of 2.0 to 5.0 V the deviation of amplitude at the amplifier output is lower than 0.1 % PERMISSIBLE AMBIENT CONDITIONS Operating temperature -10 to +50 C Storage temperature - w/o batte- -20 to +60 C ry! Dust and humidity Protective class IP54 (splash-proof) MECHANICS Size (H x W x D) Front foil (H x W) Weight Case material Keypad material Probe connectors ADDITIONAL DATA acc. to prEN 12668-1 Transmitter (definitions)
tr
0% 10 %

120 x 65 x 25 mm3 with calibration block 55 x 80 mm2 115 g w/o batteries. 150 g w/ batteries ABS (UL-94 HB) Polyester Lemo 00

td

V50 90% 100 %

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Pulse shape and frequency spectrum of transmitter

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Use and assembly of wear protective membranes Wear protective membranes made of Vulcollan (available as assesories) can optionally be used for probes, when the surface of the workpiece to be measured is very rough. Vulcollan is a special wear resistant plastic material.
Wear Protective membranes not only protect the probe from being scratched, when it is scanned over a rough surface, but they can also improve the coupling in this case. On a smooth surface, however, the sensitivity of the probes and, therefore, the measuring range and the accuracy will be reduced when using protective membranes. We do not recommend to use protective membranes, where it is not necessary ( e.g. on smooth surfaces).

1. Insert probe into handling sleeve.

2. Put membrane into retaining ring.

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3. Distribute oil (dont use any other couplant) on the inner side of the membrane. (Dont use too much couplant. A few drops are sufficient.)

4. Screw retaining ring with membrane onto handling sleeve (do not yet tighten the ring!)

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

6. Finally verify visually, that there are no air bubbles between probe and the membrane.
Ultrasound is reflected by air. Therefore, any air bubbles between probe and membrane can reduce the transfered sound energy considerably, thus reducing the accuracy of readings and/or the measuring range. Too much oil (cushion like thick oil layer) can also affect the measurements.

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Instrument view

(1) (2) (3) (4) (5) (6) (7)

probe connector for receiver element (red sleeve) probe connector for transmitter element (black sleeve) probe socket for transmitter element probe socket for receiver element (red dot mark, see arrow) LC display keypad calibration block (5 mm steel with v = 5920 m/s) (0.197 inch steel with v = 0.233 inch/s) (8) battery compartment (open) (9) type label (10) cover for battery compartment

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