ect MAD 8D Manual

R99119 Rev 8.1 99 NOV 09

Reference Manual

TABLE OF CONTENTS

0	        HOW NOT TO READ THIS MANUAL
1.0     	GETTING STARTED
1.1     	STARTING THE MAD 8D SOFTWARE
1.2     	SYSTEM REQUIREMENTS
1.2.1   	HARDWARE REQUIREMENTS
1.2.2   	DOS REQUIREMENTS
2 	        REFERENCE MANUAL
2.0     	MAIN MENU
2.0.0.1 	ERASE
2.0.0.2 	BALANCE
2.0.0.3 	ESCAPE TO System
2.0.0.4 	HELP
2.0.0.5 	SCREEN ASSIGNMENTS
2.0.1   	FILE SERVICES
2.0.2   	DATA DIRECTORY
2.0.3   	SCREEN MODE
2.0.4   	CHART SPEED
2.0.5   	SETUP MENU
2.0.6   	ANALYZE
2.0.7   	QUIT
2.0.7.1 	QUIT TO SYSTEM
2.0.7.2 	QUIT TO REPORT
2.1     	CHANNEL MENU
2.1.1   	FREQUENCY CONTROL
2.1.1.1 	FREQUENCY SELECTION RECOMMENDATIONS
2.1.1.2 	FREQUENCY SELECTION CRITERIA
2.1.2.1		PHASE CONTROL
2.1.2.2 	PLAYBACK PHASE CONTROL
2.1.3.1 	GAIN CONTROL
2.1.3.2 	PLAYBACK GAIN CONTROL
2.1.4   	VOLT/DIV CONTROL
2.1.5   	LP FILTER CONTROL
2.1.6   	RESERVED
2.1.7   	SCREEN
2.1.8   	POSITION SPOT CONTROL
2.2     	MIXER MENU
2.2.0   	MIXER OPERATION
2.2.0.1 	MANUAL MIXING
2.2.0.2  	AUTOMATIC CANCELLATION
2.2.0.3	        OUTPUT PHASE ADJUSTMENT
2.2.1	        INPUT PHASE CONTROL
2.2.2	        OUTPUT PHASE CONTROL
2.2.3	        H WEIGHT CONTROL
2.2.4	        V WEIGHT CONTROL
2.2.5	        VOLTS/DIV CONTROL
2.2.6	        MIXER GAIN CONTROL
2.2.7	        SCREEN
2.2.8	        POSITION SPOT CONTROL
2.3	        FILE MENU
2.3.1	        DIRECTORY
2.3.2	        RETRIEVE SETTINGS AND CALIBRATION TABLE
2.3.3	        SAVE SETTINGS AND CALIBRATION TABLE
2.4	        DATA
2.4.1	        THRESHOLD
2.4.2	        ANALYZE
2.4.2.1	        THRESHOLD
2.4.2.2	        CHANNEL
2.4.2.3	        MIXER
2.4.2.4	        SAVE DEFECT
2.4.2.5	        ZONE ROW TUBE
2.4.2.6	        VIEW
2.4.2.7	        CALIBRATION TABLE
2.4.2.7.1	CHANGE CALIBRATION TABLE
2.4.2.7.2	EDIT CALIBRATION TABLE
2.4.2.7.3	PARAMETER
2.4.2.7.4	VIEW GRAPH
2.4.2.7.5	CALIBRATION TABLE SELECTION NUMBER
2.4.3   	ZONE ROW TUBE NUMBER
2.4.3.1 	CHANGING A ZONE ROW TUBE NUMBER
2.4.3.2 	PREVIOUS NEXT
2.4.3.3 	PN INDEX
2.4.3.4 	ANALYZE
2.5     	SETUP
2.5.1   	LOCK
2.5.2   	AUTO STOP
2.5.3   	DATA DIRECTORY
2.5.4   	FILE SERVICES DIRECTORY
2.5.5   	ZONE ROW TUBE FILENAME
2.5.6   	NUMBER OF SAVED CHANNELS
2.5.7   	DATA COMPRESSION
2.5.8   	USE SETTINGS
2.5.9   	SAMPLE RATE
2.5.10  	AUTOERASE TIME
2.5.11  	ect REPORT SETUP MENU
2.5.11.1	REPORT OUTPUT ON/OFF
2.5.11.2	REPORT FILE NAME
2.5.11.3	MAP FILE NAME
2.5.11.9	QUIT
2.5.12	        ISIS SETUP MENU
2.5.12.1	ISIS OUTPUT ON/OFF
2.5.12.2	ENTER COMPONENT NUMBER
2.5.12.3	ENTER ISIS FILENAME
2.5.12.4	QUIT
2.5.13   	KARTA OUTPUT
2.5.14   	DON'T ANALYZE LESS THAN % OD, % ID, VOLTS
2.5.15  	PRINTER SELECTION
2.5.16  	C-SCAN SETUP
2.5.17	        MACRO STRING
2.5.17.1 	SINGLE KEYSTROKE DATA ACQUISITION
2.5.17.2	MACRO STRING PCB SELECTION
2.5.18  	FLAW GATES
2.5.19  	HP FILTER
2.5.20  	COLORS
2.5.21  	1/5 DIVISIONS INDICATOR
2.5.22  	AUTOMAD (AUTOMATIC ANALYZE)
2.5.22.1	MASTER
2.5.22.2	AUTOMAD
2.5.22.3	SP NUMBER
2.5.22.4	TEN DEEPEST DEFECTS
2.5.22.5	TUBE SHEET THRESHOLD
2.5.22.6	SEMIAUTOMATIC OPERATION
2.5.22.7	AUTOMATIC OPERATION
2.5.23  	DON'T ANALYZE LESS THAN
2.5.23.1	DON'T ANALYZE LESS THAN % OD
2.5.23.2	DON'T ANALYZE LESS THAN % ID
2.5.23.3	DON'T ANALYZE LESS THAN VOLTS
2.5.24  	MIXER SOURCE
2.5.24.1	MIXER 1 SOURCE
2.5.24.2	MIXER 2 SOURCE
2.5.25  	ALL 4 LP SAME
2.5.26  	FREQUENCY
2.5.27  	ANGLE AMPLIFIER
2.5.99  	QUITTING SETUP MENU
2.6     	RECORD/PLAYBACK
2.6.1   	F1 ~ STOP
2.6.2   	F2 ~ PLAYBACK
2.6.2.1	        PLAYBACK BACKWARDS
2.6.2.2 	PLAYBACK SPEED
2.6.3   	F3 ~ RECORD
2.6.4   	F4 ~ STOP
2.6.5   	F5 ~ SAVE IMAGE
2.6.6   	F6 ~ RECALL
2.6.7   	F7 ~ SAVE
2.6.8   	F8 ~ ERASE
2.6.9   	F9 ~ NOT USED
2.6.10   	F10 ~ BACKWARDS
2.6.11  	F11 ~ RECALL CALIBRATION SIGNAL
2.6.12  	F12 ~ SAVE CALIBRATION SIGNAL

INDEX

OPERATION MANUAL

REFERENCE INFORMATION

DIAGRAMS
Nine Pin Probe Connector
Fifteen Pin System Connector
DB9 – Forster Probe
PC1 MKII Probe Drive
PROBE CONNECTIONS
ASME Calibration Standard for Calibration Tube

TYPICAL CONNECTIONS
SINGLE FREQUENCY
MULTIFREQUENCY

CONNECTING THE CARBON STEEL FILTER / AMPLIFIER R1
DIFFERENTIAL AND ABSOLUTE NEAR FIELD WITH HIGH FREQUENCY DIFFERENTIAL
DIFFERENTIAL AND ABSOLUTE NEAR FIELD WITH HIGH FREQUENCY DIFFERENTIAL AND ABSOLUTE
REMOTE FIELD

FORMATTING OPTICAL MEDIA
128 MByte Magneto-Optical Disk
230 MByte Magneto-Optical Disk
640 MByte Magneto-Optical Disk
Formatting Optical Media – 4.6 GByte Magneto-Optical Disk
800 MByte WORM Drive

HOW NOT TO READ THIS MANUAL

To turn on the ect MAD 8D Eddy Current Instrument, simply turn on your computer and monitor. Type MAD8D at the DOS prompt. The MAD 8D software release version and options will appear in the computer screen. Available options include:
ect AutoMAD Software
ect Data Analysis Software
ect Data Storage Software
ect C-Scan Software

Below the options, the current ect Report output status and filename, as well as the previous next file being used can be found. Press any key to begin using the ect MAD 8D Eddy Current Instrument.

Control of the ect MAD 8D Eddy Current Instrument is through the menus appearing on the right hand side of the screen. All menu items highlight the key to press in order to achieve the function. For example, press E to Erase, or B to Balance.

As an example of how to change an eddy current instrument setting, press a N to enter the Channel Menu, a P to select the Phase Control for adjustment, then use right and left, or up and down arrow keys for changes by units or tens. Use Page Up, Page Down, Home, and End keys to change the value more quickly. All eddy current functions, mixer functions, and many other menu items are changed in the same manner.

For information on the use of function keys to control record and playback of signals, type a ? at any time and use the online Help.

To return to the Main Menu, type a Q. From the Main Menu, explore the File and Data Submenus.

Highlighted keys lead you through all available functions.

If specific information is required about a given menu sub-item, then refer to that specific paragraph in the manual.

We put a lot of effort into preparing this concise manual. We hope you don’t have to read it.


RECENT SOFTWARE CHANGES

OPERATING SYSTEM

The current releases of the ect MAD 8D and Report Software will now run under Windows.

It is strongly recommended that Windows not be used during Data Acquisition because the Operating System uses time slices that could result in defects being missed.

FREQUENCY SELECTION

In the Setup Menu, there is an easier way to set all four frequency channels to their optimum settings. After typing Y to select frequency for change, type A to select auto mode. It is then necessary only to set frequency for Channel 1 and the system automatically sets the frequency for Channel 2 to one half the frequency of Channel 1. The frequency of Channel 4 will be set to one quarter of the frequency of Channel 1. The frequency for Channel 3, which is intended to be the Absolute Channel, will be set to two thirds of the frequency of Channel 1.


1.0 GETTING STARTED

Log onto the directory or disk drive that contains the file MAD8D.EXE, and type MAD8D at the DOS prompt.

1.1 STARTING THE MAD 8D SOFTWARE

If you purchased the ect MAD 8D Eddy Current System from Eddy Current Technology Incorporated including a computer, it is normally supplied with the software installed on drive C:. The software will be in the subdirectory MAD8D. There will be a batch file in the root directory to make it easy to start the software. To start the software type MAD8D at the DOS prompt.

If you purchased the ect MAD 8D eddy current system from Eddy Current Technology Incorporated to be installed in a computer you supplied, then you will have to copy the software from the supplied software disk to your hard disk. It is recommended that you set up the following subdirectories on your hard disk:

Copy your MAD8D executable file and executable utilities into the MAD8D directory. The software disks supplied has eddy current instrument settings in .ST2 (control settings) and .CTB (calibration tables) files. It is recommended that these be copied to both your ECTLIB and ECTSET directories. The software disks supplied also includes files containing some sample eddy current data. It is recommended that these be copied into a directory R01, which is in the directory ECTDATA.

The provided software disk includes the MAD8D.BAT file which should be copied into your root directory. This will make it possible for you to enter the ect MAD 8D software from any DOS prompt by typing MAD8D.


1.2 SYSTEM REQUIREMENTS

1.2.1 HARDWARE REQUIREMENTS

A 386 or higher processor is required. Four MBytes of RAM are required. A color VGA adapter with 262,000 color capability and monitor with a minimum 640 x 480 resolution are required. One hard drive with at least 1.44MB of free space and one floppy disk are recommended.

1.2.2 DOS REQUIREMENTS

ect MAD 8D Software Release 2.5 (July 1992) and earlier are compatible with DOS 3.2 and later. If DOS 5.0 is being used, then DOS=HIGH must not appear in the CONFIG.SYS file.

The ect MAD 8D eddy current software release 2.6 (September 1992) and later requires DOS 5.0 or higher and it is mandated that DOS=HIGH appear in the CONFIG.SYS file.

Memory managers such as SMARTDRV.SYS and EMM386.EXE should not be used in systems with less than 8 MBytes of RAM.

The MicroSoft HIMEM.SYS does not permit the simultaneous use of expanded and extended memory (although some other suppliers of HIMEM.SYS do permit this). For this reason, if EMM386 is loaded on your computer, it is necessary to turn OFF the EMM386 System if it is on prior to starting the ect MAD 8D Software. Add the line EMM386 OFF to the Batch file for the ect MAD 8D Software.


2 REFERENCE MANUAL

The reference portion of this manual provides a detailed description of each control function of the ect MAD 8D Eddy Current System’s software. The reference manual includes all options, such as saving data on disk and data analysis, even though these options are not always supplied, depending upon customers’ requirements.

2.0 MAIN MENU

There are several functions that are available almost any time, regardless of the submenu which may be active. The only time these functions are not available is when prompted for entering text, such as when specifying a save filename. The functions available almost any time are as follows:

2.0.0.1 ERASE

At any time the screen may be erased by pushing the “E” key. The E key alone will not erase strip chart screens. To erase the strip chart screens, use a heavy duty erase, hold down the SHIFT key while typing an E.

An automatic erase function is available which erases the screen every few seconds. Type a # sign (hold down the Shift key while typing a 3, this key is adjacent to the E key) to enter the automatic erase mode. Auto erase is “ON” when the word “Erase” is drawn in yellow. To exit the autoerase mode, type # again. The default period for automatic erase is two seconds. The autoerase time can be changed in the Setup Menu. See Section 2.5.10.

2.0.0.2 BALANCE

At any time the eddy current instrument may be balanced by pushing the B key. While the eddy current instrument is in the process of balancing, the word “Balancing” appears in red near the bottom of the screen. X and Y balance values are shown in the Setup Menu. BX and BY values close to zero indicate that very little balance correction was required. The maximum BX and BY values range from -32,767 to +32,767.

The balance function is also available in the Setup Menu.

The balance speed depends upon the setting of the LP filter. For example, with the LP filter set to 135 balance takes about 1/2 second. With the LP filter set to ten, it will take approximately 5 seconds to balance.

You may balance any one individual frequency channel by holding down the Alt key and typing the number “1”, “2”, “3”, or “4”.

The balance function performs balance at two levels. First, in record mode it determines the necessary correction voltage required and sets it accordingly in each module. Second, in both record and playback mode a final correction is made in software, which ensures that the spot on the screen will be exactly in the center after balance, even if there is a small remaining offset voltage within the circuits. This function may be overridden by holding the Alt key and typing a B. In this case, balance occurs only within the electronic circuitry without a final adjustment in software.

2.0.0.3 ESCAPE TO SYSTEM

At any time, you may Escape to System by pressing the “Esc” key. To prevent an accidental exit to System, you are asked to confirm Exit to System after pressing the Escape key. All current control settings will be lost when you exit to System.

2.0.0.4 HELP

At any time you may view the Help screen by typing a ? (Hold the Shift key while typing the question mark key). The Help feature makes an automatic determination of the subject matter on which you want help by analyzing the key strokes you have recently pressed, and will present you with information on this subject matter. The Help system first scans the manual to find a paragraph on the topic. To view the next paragraph on the subject matter,press N for next occurrence. After searching the entire manual for a paragraph on the subject matter, the Help system continues to search the manual for every occurrence of the subject matter in the manual.

To page through the manual, use the up and down arrow keys to move up or down one line. Use the Page Up and Page Down keys to move up and down one page.

If you wish to search a different topic, then type S for new search. Delete the existing search string with the Delete key and enter the word (or a few letters of the word) that you wish to search, and then press the Enter key.

When you are finished using the Help feature, type a Q to quit from the Help Screen.

Figure 2.0.0.5, Screen Assignments

Figure 2.0.0.5, Screen Assignments

2.0.0.5 SCREEN ASSIGNMENTS

Each of the four screens A, B, C and D can display any one of the four frequency channels or any one of the two mixers. To establish the Screen settings, type an “S”. The screens are now labeled A, B, C and D, and the channel or mixer currently displayed on the screen is displayed beside the letter (Fig. 2.0.0.5). Use up and down arrow keys to select the screen for adjustment. Use left and right arrow keys to select the channel or mixer to be displayed on the selected screen. Hit any other key to exit from this mode.

Note that it is possible to display any channel on any number of screens. Beside the heading for the Channel and Mixer Menus are listed all the screens on which the channel or mixer is displayed. The screen assignments are also shown in the Setup Menu. If a channel or mixer is not displayed, the word “OFF” appears.

Figure 2.0.3.1, 2XY, 2SC Screen Mode

Figure 2.0.3.1, 2XY, 2SC Screen Mode

2.0.1 FILE SERVICES

To select File Services to retrieve or save control settings and the calibration data, type an “F”. Detailed information on the File Menu is given in Section 2.3.

2.0.2 DATA DIRECTORY

To enter the Data Directory in order to track the zone, row, and tube numbers to adjust threshold and to enter the Analyze or Calibration Table Menus, type D. Detailed information on the Data Menu is given in Section 2.4.

2.0.3 SCREEN MODE

From the Main Menu, you may change the screen mode by typing a M to select Mode, and then by using up or down arrow keys to page through the available main modes, which are:

Figure 2.0.2.1, 1XY, 3SC Screen Mode

Figure 2.0.2.1, 1XY, 3SC Screen Mode

4XY 	        Four impedance planes screens
1XY 	        One large impedance plane screen (Screen A)
2SC,2XY	        Two horizontal and two vertical strip charts and two impedance plane screens
2XY,2SC 	Two impedance plane and two horizontal and two vertical strip charts (Fig. 2.0.3.1)
1XY,3SC 	Same as 2XY 2SC except that Screen C is an expanded strip chart of the channel in Screen A. (Fig. 2.0.3.2)
4 SC 	        Four horizontal and four vertical strip charts
C-Scan   	C-Scan(Screen A Only)(Optional)

Whenever you enter a mode which uses strip charts, the signals that had been displayed on the corresponding impedance plane screens become the strip chart signals. The signal from the top impedance plane screen becomes the two left traces on the strip chart. The signal from the bottom screen becomes the two right hand traces of the strip chart. Horizontal is always displayed on the left of the vertical signal.

Any of the strip chart modes (SC) have submodes, which display only the horizontal strip charts, only the vertical strip charts or the horizontal and vertical strip charts from only one channel. The 1XY, 3SC mode which will display an expanded horizontal and vertical strip chart of Screen A along with two strip charts or only horizontal or vertical strip charts. To access these modes, use the left arrow key for horizontal only and the right arrow key for vertical only. Type the right arrow key twice for horizontal and vertical from one channel.

The 1XY screen mode has a submode. The submode is titled AC and is a variable persistence mode. To enter the AC mode, type the right hand arrow key from the 1XY mode, when the word mode is highlighted for change. It is recommended to enter the Setup Color’s Menu and set color 3 “old trace” to black and color 7 “trace” to white. This makes it possible to easily see small signals which may have been hidden by a previously stored trace.

2.0.4 CHART SPEED

From the Main Menu, you may also change the chart speed by typing a C. Use the up or down arrow keys to add or subtract 10 from the current chart speed setting. Use the right or left arrow keys to add or subtract one from the current chart speed setting.

Press the Page Up or Page Down key to add or subtract 100 from the chart speed setting. Press the Home key to set the chart speed to 1. Press the End key to set the chart speed to its maximum value.

Note that the speed of the strip chart also controls the Auto Stop feature which is discussed under the sectionPlayback.

2.0.5 SETUP MENU

To enter the Setup Menu type a U. The Setup Menu provides control over many convenience features of the ect MAD 8D Eddy Current System. Detailed information on the Setup Menu is given in Section 2.5.

2.0.6 ANALYZE

It is possible to move directly to the Analyze Menu from the Main Menu by typing an A. For detailed information on the Analyze Menu, see Section 2.4.2.

2.0.7 QUIT

From the Main Menu, you may also choose Quit to System by typing a Q.
After typing a Q for Quit to System, you will see:
Quit? Y/N Report

2.0.7.1 QUIT TO SYSTEM

Type Y to Quit to SYSTEM.

When the Quit to System function is executed, the ect MAD 8D saves all of the current instrument settings to the filename ECTLAST.ST2 in the default directory, saves the calibration table to the filename ECTLAST.CTB, and saves string data entered in the Setup Menu to ECTLAST.STR. This information is recalled from disk the next time the ect MAD 8D is started.

2.0.7.2 QUIT TO REPORT

If you have the ect Report Software option, you may quit and start the report software by typing an R. When you execute this function, the ect Report Software will start and run loading the .ECA data file which was last used in the ect MAD 8D software.


2.1 CHANNEL MENU

From the Main Menu or from the Mixer Menu, press N to enter the Channel Menu. Having pressed the N key to enter the Channel Menu, you will note that all the frequency channel control functions are now highlighted. This indicates that the control functions may be selected for adjustment by pressing the highlighted letter of each control function word.

From the Channel Menu, you can press the first letter of any control you wish to set. Listed are Frequency,Phase, Gain, Volts/Div, LP Filter, and Screen. Hyperlinks are available to move to the Analyze, Mixer Menus,or SetUp. Angle Amplifier adjustment is in the Setup Menu.

Any of the controls (except Screen) are adjusted by pressing the highlighted letter of the word in the menu, followed by using the up and down arrow keys for coarse adjustments and the left and right arrow keys for fine adjustments. Page up, Page down, Home, and End are used for coarser adjustments. After selecting a control function to adjust, you may adjust that value, or, select a different control function to adjust by pressing the first letter of that control function.

The MAD 8D can have up to four separate frequency channels. To adjust other frequency channels, type an N. After typing an N, type left or right arrow keys to decrease or increase the channel number.

The frequency channel is selected, as indicated by the number after the word chaNnel. When the channel number is changed, the values for Frequency, Phase, Gain, Horizontal and Vertical Volts per Division are changed to indicate the correct values for the selected frequency channel. After the channel number on the channel line appears a letter or letters, which indicates the screens on which that channel is viewed. The word “OFF” appears if the selected channel is not on any of the screens. To mark the four screens, A, B, C, and D on the screen, type an S whenever in the Channel or Mixer Menus.

2.1.1 FREQUENCY CONTROL

The frequency may be adjusted from 55 Hz to 4 MHz. From the Channel Menu press the F key to select frequency for adjustment. The word Frequency and the value are highlighted to indicate that it has been selected for adjustment.

Press the up or down arrow key to add or subtract one from the most significant digit of the current frequency setting. Press the right or left arrow key to add or subtract one from the second most significant digit of the current frequency setting.

Press the Page Up or Page Down key to multiply or divide the frequency by a factor of ten. Press the Home key to set the frequency to 4 MHz. Press the End key to set the frequency to 55 Hz.

Frequency control is also available in the Setup Menu.

2.1.1.1 FREQUENCY SELECTION RECOMMENDATIONS

It is recommended that Channels 1 and 2 be set in differential mode and mixed in Mixer 1 to eliminate support plates. The output of Mixer 1 will be used to detect small pit and crack defects. Channel 3 should be set in absolute mode and used to detect general wall loss. Channel 4 should be set in differential mode and set to a relatively low frequency. Channel 4 will be used to discriminate between defects and other anonymous indications such as magnetic inclusions.

It is recommended that the frequency of Channel 2 be set to the frequency for which the calculated skin depth is equal to the wall thickness of the tube. This frequency is listed in the table “Tabulated calculation for the Value F” in the Electrical Conductivity of Materials Report published by Eddy Current Technology Incorporated. It is recommended that Channel 1 be set to two times the frequency of Channel 2. It is recommended that Channel 3 be set to a frequency approximately 10% below the frequency for Channel 1 unless the difference between the frequencies of Channel 1 and Channel 2 would be less than 1 kHz. In this case, Channel 3 should be set to a frequency 1 kHz below the frequency of Channel 1. Channel 4 should be set to 1/2, 1/3 or 1/4 of the frequency of Channel 3.

In the Setup Menu, there is an easier way to set all four frequency channels to their optimum settings. After typing Y to select frequency for change, type A to select auto mode. It is then necessary only to set frequency for Channel 1 and the system automatically sets the frequency for Channel 2 to one half the frequency of Channel 1. The frequency of Channel 4 will be set to one quarter of the frequency of Channel 1. The frequency for Channel 3, which is intended to be the Absolute Channel, will be set to two thirds of the frequency of Channel 1.

2.1.1.2 FREQUENCY SELECTION CRITERIA

The ect MAD 8D Multifrequency Eddy Current System uses continuous wave inspection frequencies in which all frequencies are on the probe simultaneously and continuously. The information from the individual frequencies are selected by filtering. This eddy current instrument design concept provides for a higher inspection speed capability and better mixing than can be provided with a design concept that uses time domain switching of frequencies.

All oscillators that generate the inspection frequencies in the ect MAD 8D are phase locked when channels are in a harmonic relationship and the lower channel number has the higher frequency in order to minimize noise. For this reason, it is wisest to select frequencies which are in harmonic relationship. For example, since frequency differences of approximately a factor of 2 work best for mixing out support plates it is recommended that two frequencies used to mix out support plates be set exactly a factor of 2 apart. Such as, using 24 kHz for Channel 1 and 12 kHz for Channel 2 when inspecting a aluminum brass tube with a .049 wall thickness.

Frequencies set close to each other or close to a harmonic relationship will result in excessive noise. For example, the use of 10 kHz and 5.1 kHz or 9.9 kHz will result in excessive noise but frequencies of 5 kHz or 9 kHz would work well when another channel is set to 10 kHz.

No two frequency channels should be set to the same frequency (unless the channels are connected to separate probes or when inspecting ferrous metals). If two frequency channels are set to the same frequency they will be phase locked. It is possible that they will be locked in phase, out of phase, or in any other phase relationship. If locked out of phase there would be no response from either of these frequency channels. If locked in another phase relationship, then the phase and amplitude of signals would vary every time the unit is turned on or any time that any channel frequency is changed.

2.1.2.1 PHASE CONTROL

The phase control is adjustable from 0 to 359 degrees in one degree increments. From the Channel Menu, press the P key to adjust phase. After pressing the P key, the word Phase and its value are highlighted, indicating that Phase has been selected for adjustment.

Use the up or down arrow keys to add or subtract 10 from the current phase setting. Use the right or left arrow keys to add or subtract one from the current phase setting.

Press the Page Up or Page Down key to add or subtract 90 degrees from the phase setting. Press the Home key to set the phase to zero. Press the End key to set the phase to 180.

If you press a key that selects a phase setting above 359 degrees, then 360 degrees is subtracted from the new value. If you press a key that selects a phase setting below 0 degrees, then 360 degrees is added to the new value.

2.1.2.2 PLAYBACK PHASE CONTROL

A playback phase control is available when working with data that has been recalled from disk. The purpose of this control is to allow phase control adjustments for data which may have been stored incorrectly. The playback phase control is only available after recalling data from disk. The playback phase control is adjusted in the same manner as the phase control.

2.1.3.1 GAIN CONTROL

The gain control is adjusted in 256 linear steps from 0 to 255. From the Channel Menu, press the G key to adjust gain. After pressing the G key, the word Gain and the value are highlighted, indicating that gain has been selected for adjustment.

Use the up or down arrow keys to add or subtract 10 from the current gain setting. Use the right or left arrow keys to add or subtract one from the current gain setting.

Press the Page up or Page down key to add or subtract 100 from the gain setting. Press the Home key to set the gain to zero. Press the End key to set the gain to its maximum value.

2.1.3.2 PLAYBACK GAIN CONTROL

A playback gain control is available when working with data that has been recalled from disk. The purpose of this control is to allow gain control adjustments for data which may have been stored incorrectly. The playback gain control is only available after recalling data from disk. The playback gain control is adjusted in the same manner as the phase control.

2.1.4 VOLT/DIV CONTROL

To select the volts per division switches for adjustment, type a D from the Channel Menu. After selecting the volts per division switches for adjustment, use the up arrow key to increase screen sensitivity, or the down arrow key to decrease screen sensitivity. The volts per division switches may be adjusted through the range of 0.063 volts per division (most sensitivity) to 2.0 volts per division (least sensitivity).

To select only the horizontal volt per division switch or only the vertical volt per division switch for adjustment independent of the other volt per division switch, type an “H” or a “V”. After typing the H or V, use the up or down arrow keys to adjust that volt per division switch.

With a single volt per division switch activated, type a D to select both volts per division switches for simultaneous adjustment.

2.1.5 LP FILTER CONTROL

The LP filters for channels which are to be mixed must be set to the same LP filter frequency for good mixing. For this reason normally when an LP filter is changed all four LP filters are set to the same value. This feature can be defeated in the Setup Menu by typing a 4 to toggle on and off all four LP same. When inspecting carbon steel tubes with both high and low frequencies simultaneously, it may be desirable to set all four LP same to Off then the low frequency channels can be set to a low LP filter setting and the high frequency channel can be set to a higher LP filter setting.

The LP filter may be adjusted from 8 Hz to 450 Hz. Press the L key to enable adjustment of the LP filter. After pressing the L key, the word LP Filter and its value are highlighted, indicating that LP filter has been selected for adjustment.

Use the up or down arrow keys to add or subtract 10 from the current setting. Use the right or left arrow keys to add or subtract one from the current setting.

Use the Page up or Page down key to add or subtract 100 from the LP filter setting. Use the End key to set the LP filter to 8. Use the Home key to set the LP filter to 450.

An LP filter setting of 100 Hz is normally considered high enough for inspection speeds up to 14 inch per second using standard probes. The LP filter may be set higher to allow higher inspection speeds. The LP filter may be set lower when using low inspection frequencies, specifically frequencies below 1 kHz.

2.1.6 RESERVED

2.1.7 SCREEN

For control of the screen on which a frequency channel is viewed, please see Section 2.0.0.5, Screen Assignments.

2.1.8 POSITION SPOT CONTROL

The position spot feature allows you to move the spot anywhere, to any position on screen.

To activate this feature, type the “<” or “>” signs. When this feature is activated the “< >” will be yellow in the menu above the word Screen. When this is highlighted, use the up, down, left or right arrow keys to move the spot on the screen. To move the spot faster, hold down the Shift key while using the arrow keys to move the spot. Use the Home key to return the spot to the center of the screen.


2.2 MIXER MENU

From the Main Menu or from the Channel Menu type an X to enter the Mixer Menu.

The first line of the Mixer Menu indicates whether Mixer 1 or 2 is selected for adjustment by the number 1 or 2 which appears after the word mixer. After the mixer number, on the same line, appears the letter(s) A, B, C, or D or the word “OFF” to indicate whether the selected mixer is viewed on screen A, B, C, or D or currently turned off (not viewed).

Having pressed the X key to enter the Mixer Menu, you will note that all the mixer channel control functions are now highlighted. This indicates that the control functions may be selected for adjustment by pressing the highlighted letter of each control word. From the Mixer Menu, you can press the highlighted letter of any control you wish to set. Listed are In Phase, Out Phase, H Weight, V Weight, H Volt/Div, V Volt/Div, and Screen. Any of the controls (except Screen) are adjusted by pressing the highlighted letter of the word in the menu, followed by using the up and down arrow keys for coarse adjustments, and the left and right arrow keys for fine adjustments.

Page up, Page down, Home, and End are used for courser adjustments. After selecting a control function to adjust, you may adjust that value, or select a different control function to adjust, by pressing the first letter of that control function.

The MAD 8D can have up to two separate mixer channels. To adjust other mixer channels, type an X. After typing an X, type an arrow key to select a different mixer channel, as indicated by the number after the word mixer. At the same time, the numbers for In Phase, Out Phase, H Weight, V Weight, H Volt/Div, V Volt/Div, and Angle Amplifier indicator are changed to indicate the correct values for the selected mixer channel. After the mixer number on the mixer line appears a number which indicates which screen(s) that mixer channel is viewed on. To mark the four screens, A, B, C, and D, on the screen, type an S whenever in the Channel or Mixer Menus.

2.2.0 MIXER OPERATION

There are two mixers in the ect MAD 8D Eddy Current System. Each mixer can be set to mix the signals from any two frequency channels or a frequency channel and mixer. The mixer sources are set in the Setup Menu. It is normal to set up Mixer 1 to mix the signals in Channel 1 and Channel 2. It is normal to set Mixer 2 to mix the signals from Channel 3 and Channel 4. The rest of this section of the manual assumes that Mixer 1 mixes the signals from Channel 1 and Channel 2 and Mixer 2 mixes the signals from Channel 3 and Channel 4. The remainder of this paragraph describes the operation of Mixer 1. The operation of Mixer 2 is identical.

A mixer channel is used to selectively eliminate unwanted signals, such as support plates or dents. This is accomplished by subtracting the signals in Channel 2 from the signals in Channel 1. It is normal to set lower frequency in the frequency channel with the higher number. For a support plate mix it is recommended that Channel 2 be set to one half of the frequency for Channel 1.

In the mixer the signal from Channel 2 is processed through an input phase control and separate horizontal and vertical weight controls before it is subtracted from the high frequency channel, Channel 1. Adjust Channel 2 so the support plate signal appears larger than it does in Channel 1 when the volts/division settings for Channel 1 and Channel 2 are the same.

Record a signal from the support plate using the following procedure. Position the support plate close to but just to one side of the probe in the calibration tube. Press F8 to erase the Random Access Memory, then perform the following three steps quickly:

1. Press F3 to begin recording.
2. Move the support plate past the probe.
3. Press F2 to enter playback mode

The support plate is now being played back repeatedly (make sure that Auto Stop is turned off in the Setup Menu).

Mix the two signals by either of the two procedures listed in Section 2.2.0.1 or 2.2.0.2.

2.2.0.1 MANUAL MIXING

Type X followed by I in order to adjust the input phase control on Mixer 1. Increase the input phase setting by 10 by typing an up arrow key. If the support plate signal as viewed in the mixer channel is larger, type a down arrow key. Repeat this procedure to find the optimum setting for the input phase control.

Type an H followed by an up arrow key to increase the horizontal weight setting by 10. If the support plate signal as viewed in the mixer channel appears larger, type a down arrow key. Repeat this procedure to find the optimum horizontal weight control.

Select the vertical weight control for adjustment by typing a V. Use up and down arrow keys to find the optimum setting.

Type an I to adjust the input phase control and use left or right arrow keys to adjust the input phase control by one to select the optimum input phase control setting.

Type an H to select the horizontal weight control for adjustment and use left and right arrow keys to adjust the horizontal weight control by one to determine the optimum setting.

Type a V to select the vertical weight control for adjustment and use left and right arrow keys to adjust the horizontal weight control by one to determine the optimum setting.

Finally, type an I and adjust the input phase control with left and right arrow keys to find the optimum input phase control setting.

Now continue with step 2.2.0.3.

2.2.0.2 AUTOMATIC CANCELLATION

Before starting the automatic cancellation process, check the settings for the horizontal and vertical weight controls. If any of these are set to 0 or close to 0, the automatic cancel functions will not work properly. In this case set the horizontal and vertical weight controls to values between 40 and 100.

The automatic cancel feature may not work properly if the input phase control is set incorrectly by 180 degrees. If the automatic cancel feature does not appear to work, change the input phase control by 30 degrees and activate automatic cancel a second time.

The automatic cancel function does not work well with dent signals. In this case, it may be best to manually cancel dent signals.

After following the procedure outlined in section 2.2.0, type an X to select Mixer 1 and type a C to select auto Cancel.

The software automatically performs the procedure outlined in section 2.2.0.1 in order to determine the optimum settings for the input phase control and the horizontal and vertical weight controls.

Note that it is important to minimize the length of the recorded signal in order to optimize the speed of the auto cancel feature.

After pressing C for cancel, the word Cancel is replaced with a number that represents the relative size of the residual support plate signal. You will see this number being reduced as the software optimizes the mixer controls.

At any time during the auto cancel feature, you may press a Q if you wish to terminate the auto Cancel function before it has been completed.

Continue with step 2.2.0.3.

2.2.0.3 OUTPUT PHASE ADJUSTMENT

Having completed procedures 2.2.0.1 or 2.2.0.2, adjust the output phase control to set liftoff or dents horizontal.

2.2.1 INPUT PHASE CONTROL

The In phase control is adjustable from 0 to 359 degrees in one degree increments. From the Settings Menu, press the I key to adjust In Phase. After pressing the I key, the words In Phase and its value are highlighted, indicating that In Phase has been selected for adjustment.

Use the up or down arrow keys to add or subtract 10 from the current In Phase setting. Use the right or left arrow keys to add or subtract one from the current In Phase setting.

Press the Page up or Page down key to add or subtract 90 degrees from the In Phase setting. Press the Home key to set the In Phase to 180. Press the End key to set the In Phase to zero.

If you press a key that selects an In Phase setting above 359 degrees, then 360 degrees is subtracted from the new value. If you press a key that selects an In Phase setting below 0 degrees, then 360 degrees is added to the new value.

2.2.2 OUTPUT PHASE CONTROL

The Out Phase control is adjusted in the same manner as the In Phase control in section 2.2.1 above.

2.2.3 H WEIGHT CONTROL

The H weight control is adjustable in 100 linear steps from 0 to 100. From the Mixer Menu, press the H key to adjust H weight. After pressing the H key, the word H Weight and the value are highlighted, indicating that H weight has been selected for adjustment.

Use the up or down arrow keys to add or subtract 10 from the current H weight setting. Use the right or left arrow keys to add or subtract one from the current H weight setting.

Press the Page up or Page down key to add or subtract 100 from the H weight setting. Press the Home key to set the H weight to 100. Press the End key to set the H weight to zero.

2.2.4 V WEIGHT CONTROL

The V weight control is adjusted in the same manner as the H weight control. See section 2.2.3.

2.2.5 VOLTS/DIV CONTROL

The volts per division switches are adjusted in the same manner as described in section 2.1.4 volts/div under Channel Menu above.

Note that in the Mixer Menu, when you type a D to select the volts per division switches for adjustment, the H and V of H Weight and V Weight are no longer highlighted. This is because the keys H and V take on a new meaning for selecting the horizontal or vertical volts per division switches separately once D has been selected. If you wish to select H Weight or V Weight when the volts per division switches are activated, type an I, O or an X followed by an H or a V in order to activate the H Weight or V Weight controls.

2.2.6 MIXER GAIN CONTROL

The mixer gain control is used to adjust the amplitude of signals that result from the mix. The mixer gain control can be adjusted from 50 per cent to 800 per cent. Settings between 100 and 200 are most often used.

2.2.7 SCREEN

For control of the screen on which a mixer channel is viewed, please see section 2.0.0.5.

2.2.8 POSITION SPOT CONTROL

The position spot feature allows you to reposition the spot for a mixer channel anywhere on the screen. This function works the same as described in 2.1.8.


2.3 FILE MENU

The File Menu is used to save and recall all of the eddy current instrument settings that control the frequency channel and mixer channel.

To enter the File Menu, type an F from the Main Menu. From the File Menu, you have options to list the directory, retrieve the settings, or save the settings.

2.3.1 DIRECTORY

To list all available files containing eddy current instrument settings in the logged directory, type the letter D (To change the logged directory see Section 2.5.4).

2.3.2 RETRIEVE SETTINGS AND CALIBRATION TABLE

To retrieve eddy current instrument settings from the disk, type the letter R from the File Menu to enter the Retrieve Menu. From the Retrieve Menu, you see the messages:

Old filename:
ECTLAST (or the last used valid filename)
Enter new name
?
or
old filename

If you wish to retrieve settings stored under the old filename, press the Enter key at this time. If you wish to load the settings of a new filename, enter the filename at this time. A valid filename can be up to eight characters long. The “.ST2” extension is automatically added by the software.

After pressing Enter, you see the message:
Confirm retrieve
filename Y/N?

If you have entered the filename correctly, type a Y. If not, type an N to start over again. After typing a Y to recall the settings from disk, the new settings and calibration tables will be loaded into the MAD 8D. If you have entered a filename which does not exist in the current file services directory, you will see the message:
File filename not found
Hit any key

If this is the case, hit any key and re-enter the filename. If you wish to load a file which is not in the current file services directory, then enter the Setup Menu (see section 2.5, Setup) to change the file services directory.

2.3.3 SAVE SETTINGS AND CALIBRATION TABLE

From the File Menu, type an S to enter the Save Menu. Having entered the Save Menu, you see the

message:
Old filename:
ECTLAST (or the last used valid filename)
Enter new name
?

Type in a valid filename, which is any name with one to eight characters, or press Enter to use the old filename. Do not include the “.ST2” extension, this is added automatically.

Having typed the new filename, press Enter, and you see the message:
Confirm save to
filename Y/N?

If you have correctly entered the filename you wish to use, type a Y. If the filename you have selected already exists in the current directory, you will see the message:
File filename already exists
Overwrite it?
Y/N

If you wish to replace the existing file of the filename you have entered in the current directory, type a Y, and the eddy current instrument stores all of the existing settings and calibration table to the new filename you have typed. If you do not wish to overwrite the existing file, type an N and start over.


2.4 DATA

The Data Menu is used to set the defect detector threshold to detect defect signals, and to track the zone, row, and tube numbers that are used as file names to save and recall data from a disk.

To enter the Data Menu, type a D from the Main Menu. From the Data Menu, you have the options to analyze data, track the tube number, or enter the calibration table editor.

2.4.1 THRESHOLD

Threshold sets the threshold for defect detection. The defect detector works from data in the Mixer 1 channel, which is presumed to be free from support plate signals.Dent signals should be adjusted to be horizontal. The threshold sets the sensitivity for this detection process. A threshold setting of 255 turns off the defect detector. A threshold setting in the range from 3 to 6 is ideal for defect detection. The threshold control is adjusted in 256 linear steps from 0 to 255. From the Data or the Analyze Menu, press the H key to adjust threshold. After pressing the H key, the threshold value is highlighted, indicating that threshold has been selected for adjustment.

Use the up or down arrow keys to add or subtract 10 from the current threshold setting. Use the right or left arrow keys to add or subtract one from the current threshold setting.

Press the Page up or Page down key to add or subtract 100 from the threshold setting. Press the Home key to set the threshold to 255. Press the End key to set the threshold to 0.

2.4.2 ANALYZE

From the Data Menu, type an A to enter the Analyze Menu.

In the Analyze Menu, after the word analyze appears, the word PHASE, MAG or V MAG. This indicates whether the selected calibration table provides phase, magnitude, or vertical magnitude analysis.

From the Analyze Menu, a cursor is available in screen A. The cursor is used to analyze defect depth as indicated in the highlighted line of text on the sixth line from the top. The cursor is a two point cursor marked as a rectangular white box for the origin and a white cross for the end point on the screen. The end point of the cursor can be moved with the up, down, left, and right arrow keys (it is recommended that the numeric lock key is off.) The origin of the cursor can be moved with the four keys W, A, S, and Z, for up, left, right, and down motions of the origin. Movements of the cursor are faster if the above mentioned four keys are used in conjunction with a Shift key.

Information about the cursor is noted on the highlighted line. The first information given is the angle of the cursor. The second information is the magnitude in volts of the distance between the two end points. The third information is the percent throughwall and I.D. or O.D. indication based on a calibration table.

2.4.2.1 THRESHOLD

The threshold may be adjusted from the Data or Analyze Menus in accordance with Section 2.4.1.

2.4.2.2 CHANNEL

To select the channel to be analyzed, type an N, followed by left or right arrow keys. Note that when you change the selected channel, the settings for the selected channel are displayed in the Channel Menu. Also, a hyperlink is available to move directly to the Channel Menu by typing a D. This makes it easy to make quick changes to the frequency channel which was selected for analysis.

It is possible to return to the Analyze Menu from the Channel Menu, using a hyperlink, by typing A.

2.4.2.3 MIXER

To select the mixer to be analyzed, type an X, followed by left or right arrow keys. Note that when you change the selected mixer, the settings for the selected mixer are displayed in the Mixer Menu. Also, a hyperlink is available to move directly to the Mixer Menu by typing a D. This makes it easy to make quick changes to the frequency channel which was selected for analysis.

It is possible to return to the Analyze Menu from the Mixer Menu, using a hyperlink, by typing A.

2.4.2.4 SAVE DEFECT

When a defect is analyzed, the result of the analysis may be saved to a file on disk in ect Report format. This output format can be turned on or off in the Setup Menu and must be initialized in the Report Setup Menu before use.

If the ect Report format is turned on, then after typing the F you will be prompted to enter the support plate number or letter. After entering this value you will be prompted for the defect code.

If your system has the AutoMAD feature then the support plate numbers will be calculated automatically if this feature is tuned on in the AutoMAD Menu.

2.4.2.5 ZONE ROW TUBE

A hyperlink is available to move to the Zone Row Tube Menu by typing a T.

2.4.2.6 VIEW

A hyperlink is provided to move directly to the view graph function so that the calibration data can be viewed graphically on the screen. A hyperlink is provided to move back to the Analyze Menu from the view graph by typing an A.

2.4.2.7 CALIBRATION TABLE

2.4.2.7.1 CHANGE CALIBRATION TABLE

From the Analyze Menu, type a C to enter the Calibration Table Menu.

Having pressed the letter C, the screen is cleared and a calibration table is shown. From this menu you can edit a calibration table.

There are a total of ten major calibration tables, each containing six minor calibration tables. Major calibration tables are selected by pressing the letter L from the Enter Calibration Data Menu, followed by left or right arrow keys to subtract or add one to the calibration table number. Whenever you change the major calibration table number, the new tables are listed in the calibration table shown in the center of the screen. Having selected the calibration table you wish to edit or view, press any key except L or arrow keys in order to return to the edit mode.

2.4.2.7.2 EDIT CALIBRATION TABLE

To edit a calibration table, use the left, right, up, and down arrow keys to position the question mark (?) cursor over the value to be edited. Then type the one, two, or three digit new value to be entered, followed by the Enter key (or an arrow key to move to another cell). The new value is now installed in the table.

The first column of the lookup table, which is labeled % Wall, is for the percent through wall for a given defect. Values indicating thousandths of an inch of wall loss may be used instead of percent values in the first column.

The second column, which is labeled I.D./O.D., indicates whether the defect originates from the inside diameter or outside diameter. To change a listed value to I.D., type a 1 in the appropriate cell position. To set a value to O.D., type a 0 (zero, not the letter “O”) in the appropriate cell position. Having entered a 1, I.D. is shown in that column. Having entered a 0 (zero, not the letter “O”), O.D. is shown in that column. These I.D. and O.D. indicators will be used when defects are analyzed with the vector analyzer or automated data analyzer.

Calibration defects must be listed from 0% I.D. increasing to 100% I.D. The 100% reading must be listed as O.D. for proper operation of the vector analyzer and automatic analyzer. The outside defects are listed from 100% decreasing to 0% O.D. from top to bottom in the table.

Although it is not normally possible to measure angle indications for 0% I.D. or 0% O.D. defects, these values must be filled in. It is recommended that these 0% values be linearly extrapolated from the two shallowest I.D. and two shallowest O.D. defects. For example, if the 40% O.D. defect is 126 degrees, and the 20% O.D. defect is 135 degrees, then set the 0% O.D. defect to 144 degrees. When extrapolating for the 0% I.D. defect, you should not expect that the extrapolated value would be 0 degrees, even though a dent has been set horizontal. 0% I.D. defects should have a small positive angle with lift off set to 0 degrees.

The third, fourth, fifth, and sixth columns, which are labeled Degrees C1, C2, C3, and C4, are the angles of defects for frequency Channels 1, 2, 3, and 4. The last two columns labeled Degrees M1 and M2 are the actual angles of defects measured in the Channels Mixer 1 and Mixer 2.

2.4.2.7.3 PARAMETER

Parameter selects whether a specific calibration table is used for phase analysis, volts-peak to peak analysis or vertical volts analysis. Type the letter P to toggle through these three selections.

2.4.2.7.4 VIEW GRAPH

At any time while editing or viewing calibration tables, it is possible to view the tabulated data graphically. Type the letter V.

Having typed the letter V, the data is graphically represented on the screen.

Phase angle in degrees is shown on the horizontal axis from 0 to 180 degrees. Percent of wall loss (or thousandths of wall loss) is shown on the vertical axis from 0 to 100.

To exit the View Graph Menu and return to the Edit Table Menu, type any key (except keys reserved for hyperlinks).

2.4.2.7.5 CALIBRATION TABLE SELECTION NUMBER

The calibration table used for defect analysis can be selected from the Analyze Menu. Type an L, followed by left or right arrow keys to select the desired calibration table number.

All ten calibration tables are automatically saved to disk whenever control settings are saved through the File Save Menu, available from the Main Menu.

2.4.3 ZONE ROW TUBE NUMBER

From the Data Menu, type a Z, R, or T to enter the Zone Row Tube Menu. In the Zone Row Tube Menu you have the ability to set the zone, row, and tube numbers, which are used for subsequent save and recall of data to and from the disk.

Zone, row, and tube numbers are now listed in the Zone Row Tube Menu. Other functions that are available in this menu include Previous Next, Index, and Analyze.

2.4.3.1 CHANGING A ZONE ROW TUBE NUMBER

To change a row number, type the letter R followed by right or left arrow keys to add or subtract one, up or down arrow keys to add or subtract 10, and Page up or Page down keys to add or subtract one hundred.

To change the tube or zone number in the same manner, type a T or a Z followed by left, right, up, down, Page up or Page down keys.

2.4.3.2 PREVIOUS NEXT

The ect MAD 8D can follow a predetermined list of tubes to be inspected. By typing an N, the next tube in a prearranged list of tubes to be inspected or analyzed is taken from the list file on the hard disk. By typing P the previous tube in the rearranged list of tubes inspected is taken from the list on the hard disk.

When using the previous and next functions the current tube being inspected is listed in the left hand column of numbers. These are the zone, row, and tube numbers which will be used when saving eddy current data to disk or saving defect data to disk. The column of numbers to the right of this are the next tube on the list. This is the tube which should be entered by the probe after completion of taking data from a current tube.

The filename for the list of tubes is set in the Setup Menu. Information about how to prepare a tube list is provided in Section 4.0.2, TUBELIST.WK1.

If no filename has been entered in Setup (the filename is blank) then previous next function works differently.In this case, when you type N for Next the software searches the data disk for the next available tube number. This makes it easy to retrieve all of the stored tube data sequentially while analyzing data that was previously stored on disk without having knowledge of the tube numbers which were inspected and without having a list of the tubes that were inspected on disk.

2.4.3.3 PN INDEX

The PN Index is a pointer into the predetermined list of tubes. By typing an I followed by arrow keys, it is possible to change the index number to make it possible to start at a position in the list other than the first entry.

2.4.3.4 ANALYZE

A hyperlink is provided from the Zone Row Tube Menu to the Analyze Menu. Type an A to move directly from the Zone Row Tube Menu to the Analyze Menu.


2.5 SETUP

From the Main Menu, type a U to enter the Setup Menu. You can also enter Setup directly from several other menus, including the Channel Menu, Mixer Menu, Zone Row Tube Menu and Analyze Menu. If you enter Setup from any of these menus, then when you quit Setup you return to the menu from which you entered Setup. The Setup Menu is shown in Figure 2.5.

The Setup Menu is a convenient way to view all information about the operation of the ect MAD 8D.

As The top line shows the current settings filename.

Next are listed Channels 1, 2, 3, and 4, and the headings to indicate the control settings for each of these channels. Listed are: Frequency, Phase, Gain, Vertical Volts Per Division, Horizontal Volts Per Division, Angle Amplifier, LP Filter, HP Filter, Balance X, Balance Y and Screen.

Below in the channels is displayed information on Mixers 1 and 2. All the settings are shown under the headings Horizontal Weight, Vertical Weight, Input Phase, Output Phase, Vertical Volts Per Division, Horizontal Volts Per Division, Angle Amplifier, and HP Filter. The current zone, row, and tube numbers are shown to the right of this.

Below the mixer information is shown general information about the ect MAD 8D eddy current instrument. everal functions can be controlled directly from the Setup Menu.

Type an “>” to enable the angle amplifier for change. Use the right arrow key to turn on the angle amplifier. Use the left arrow key to turn off the angle amplifier.

The angle amplifier can be used to increase the angle of a throughwall hole from its normal position of 45 degrees to a position of 90 degrees while leaving lift off horizontal. This spreads the angles of I.D. defects from 0 to 90 degrees on the screen, while compressing O.D. defects between 90 and 180 degrees.

Figure 2.5, Setup Menu

Figure 2.5, Setup Menu

2.5.1 LOCK

The settings lock provides a convenient means of locking the critical settings of the channel and mixer functions. Type an L to toggle the lock on or off. With the lock on, it is not possible to adjust the settings for Frequency, Phase, or Gain in a channel. With the lock on, it is not possible to adjust the Horizontal Weight, Vertical Weight, Input Phase, and Output Phase in the mixer. Horizontal and Vertical Volts Per Division, and the Angle Amplifiers are adjustable with the lock on.

Setting the lock on prevents accidental adjustment of critical performance settings that would seriously affect recorded data, while allowing convenient control of screen sensitivity (Horizontal and Vertical Volts Per Division and the Angle Amplifier) as these are functions that do not affect recorded data.

2.5.2 AUTO STOP

The Auto Stop feature is used to automatically stop the recording or playback function after a predetermined period of time. Auto Stop is adjusted in the Setup Menu.

There are two modes of operation. The Auto Stop feature can be set to stop automatically after one complete strip chart display is full. This makes the record or playback time period dependent upon the chart speed. To select this mode for Auto Stop, type A followed by the HOME key. This will set the Auto Stop time to 999.9 seconds. Press Enter and Auto Stop will indicate as being On.

There may be situations during data acquisition in which it is desirable to control the number of recording seconds more accurately, as this can conserve disk space. To do so, type A and enter the number of seconds and tenths of seconds that the Record feature is to operate. Press Enter. The number of seconds will then be indicated.

Auto Stop can be set Off by typing A followed by the END key and then the Auto Stop time will indicate 0.0 seconds. Press the Enter key and Auto Stop will indicate On.

During calibration of the eddy current system, it is recommended that Auto Stop be Off. During data acquisition it is recommended that Auto Stop be set to a number of seconds a little bit longer than it takes to inspect a tube. This will keep data files to a minimum to conserve disk space. During data analysis, it is recommended that Auto Stop be set Off.

2.5.3 DATA DIRECTORY

The data directory lists the drive and directory which eddy current data would be saved to or recalled from when using the function keys. The data directory shows the complete DOS path to the data. The first part of the data directory is the drive specifier, and can be:

A: To select floppy disk drive A:
B: To select floppy disk drive B:
C: To select the internal hard disk
D: To select the optical disk drive if installed

The second section of the data directory follows the first section, without any spaces, and specifies the directory on the specified drive. Use a “\” to indicate the root directory. This would be convenient when performing large inspections that would occupy nearly all of one optical disk or more than one optical disk, or when writing files to the floppy disk.

You may also enter your own directory name after the backslash.

A “\” is required after your directory name, but if you do not insert it, the MAD 8D will do that for you.

To enter a new data directory name, type a D followed by your disk drive specifier, “\”, directory name, and final “\”. Having typed the desired directory name, press the Enter key. The ect MAD 8D checks for the existence of this directory, and sets the data directory if you have entered a valid directory.

If you have entered an invalid drive and directory name, you may see any of the following messages:

“Insert diskette for drive X: and strike any key when ready.”, which may mean that the drive does not exist, or there is no disk in the drive.
“Path not found. Hit any key.”, which may indicate that the directory has not been created on the disk.

You can only enter directory names for directories that already exist. If you wish to create a new directory name, then quit to System and use the DOS command md (make directory) to create the desired directory. See your DOS manual for additional information.

2.5.4 FILE SERVICES DIRECTORY

The file services directory specifies the directory that the ect MAD 8D will use for most save and recall of eddy current instrument settings.

This function is controlled in the same manner as the Data Directory in Section 2.5.3 above.

When the MAD 8D is turned on, and when you quit to System from the Main Menu, the default settings, ECTLAST, are read from or saved to the filename ECTLAST in the default directory, the directory in which the main MAD 8D software exists.

2.5.5 ZONE ROW TUBE FILENAME

To enter a zone row tube filename, type the letter Z. You may modify or delete the existing filename by using the backspace and delete key. Then, enter the filename you wish to use.

The zone row tube filename is the file which is used for the list of tubes followed by the previous/next feature in the Data Menu.

If no zone row tube filename has been entered, then when the key N is typed in the Zone Row Tube Menu to obtain the next zone row tube number, the software searches the Data Directory to find the next available zone row tube filename for which a data file exists.

2.5.6 NUMBER OF SAVED CHANNELS

To change the number of saved channels type the number symbol “#”, then use the arrow keys to set the number of saved channels to a number between 1 and 4 inclusive.

When the number of saved channels is 4, then data from all 4 eddy current channels will be saved to disk whenever data is saved to disk. If the number of saved channels is set below 4; then a correspondingly smaller number of channels is saved to disk. This will save disk space. The amount of disk space required to save a given number of seconds of data at a given sample rate will be directly proportional to the number of saved channels.

2.5.7 DATA COMPRESSION

Type N to toggle data compression on and off. It is recommended that normally data compression be left in the “ON” position.

Data compression occurs when the data compression is on and data is saved from RAM to a disk using the F7 key. When recalling the data using the F6 key, the data is expanded to its original size.

Data is collected from the individual eddy current channels in a 12 bit format. Each 12 bit word is stored in extended RAM, occupying 16 bits (two 8 bit words, leaving 4 bits not used). When data is stored to disk with data compression on, the data is packed so that there are no unused bits. This compresses the data into a file 3/4 the size of the data that was stored in RAM.

With data compression off, the saved file size is the same as the size of the data in RAM. It is recommended to normally use data compression to minimize file size.

One may desire to set data compression off, as this will result in files which are easier to read by other software programs.

When the data is read from the disk it is automatically expanded if necessary. If the stored data is not compressed, no expansion takes place. The data format when data is not compressed is explained in Section 5.2.

When data compression is on; then the eddy current instruments settings are saved with the data. When data compression is off; then the eddy current instruments settings are not saved with the data.

2.5.8 USE SETTINGS

The use settings function controls whether or not eddy current instrument settings are loaded from data files when data files are recalled.

Whenever the ect MAD 8D saves eddy current data files to disk in compressed format, it includes information about all of the channel and mixer settings. This is done so that it is possible to determine exactly how the eddy current instrument was set at the time the data was recorded.

Type a U to toggle the use settings to “ON” or “OFF”.

It is recommended that use settings normally be set “OFF”. These settings should only be set “ON” when it is specifically desired to recall the settings that were saved with the data.

2.5.9 SAMPLE RATE

The sample rate may be adjusted from 125 Hz to 8 kHz. Type an S and use the arrow keys to set the desired sample rate.

ect recommends a sample rate of 1 kHz for an inspection speed of 1 foot per second. It is generally considered by others (Including the ASME Code) that a sample rate of 500 Hz is more than adequate for inspecting, with an inspection speed up to 14 inches per second. ect recommends a sample rate of 4 kHz for a probe speed of two meters per second.

2.5.10 AUTOERASE TIME

The autoerase timer automatically erases all X-Y screens after a predetermined number of seconds.

Press the E key to activate the number of seconds for change. Use arrow keys to set the number of seconds for the autoerase time. To turn off autoerase, set the erase time to 0 seconds.

The autoerase time can be turned on or off while in the eddy current mode. Hold down the Shift key while typing the # key on the main keyboard. When the autoerase feature is on and you are in the eddy current mode, the word Erase will be written in yellow on line 28 in the Main Menu.

2.5.11 ect REPORT SETUP MENU

The ect Report Setup Menu allows the user to turn on or off the generation of a disk file of defects in the ect report format.

To enter the ect Report Setup Menu, type an R.

2.5.11.1 REPORT OUTPUT ON/OFF

To turn the report output on or off, type an R.

2.5.11.2 REPORT FILE NAME

Type a letter F and then enter a valid filename for the report output. The extension .ECA is automatically appended to your file name. The file will be in the ECTDATA subdirectory of drive C.

2.5.11.3 MAP FILE NAME

The map filename is information which is passed to ect Report so that ect Report can automatically recall the correct map that is associated with the.ECA data file.

Type the letter M and then enter a valid filename for the map. The extension .ECM is automatically appended to your filename.

2.5.11.9 QUIT

To quit the Report Setup Menu and return to the Setup Menu, type the letter Q. After you type the letter Q, the software first checks for the existence of the report filename that you have entered. If the filename does not exist on disk, the filename is created.

2.5.12 ISIS SETUP MENU

ISIS output is an optional feature. ISIS is an output of defect data lists, which are used by the ISIS software package for heat exchanger data management.

To enter the ISIS Menu, type an I.

2.5.12.1 ISIS OUTPUT ON/OFF

To toggle the ISIS output “ON” or “OFF”, type the letter S.

2.5.12.2 ENTER COMPONENT NUMBER

The component number forms part of the output data. To enter this character, type a C. You will be prompted for the component number. Type any alpha or numeric character and press the Enter key.

2.5.12.3 ENTER ISIS FILENAME

To enter the ISIS filename, type an F. You will then be prompted for the filename. Type any valid DOS filename and press the Enter key. The extension .DAT is automatically appended to your filename.

2.5.12.4 QUIT

To quit the ISIS Setup Menu and return to the Setup Menu, type the letter Q. After you type the letter Q, the software first checks for the existence of the ISIS filename that you have entered. If the filename does not exist on disk, the filename is created. The ISIS file will always be in the directory C:\ECTDATA.

2.5.13 KARTA OUTPUT

Karta output is an optional feature. Output for the Karta Technology Tubestat heat exchanger database management software can be turned “ON” or “OFF” by typing a K.

2.5.14 DON’T ANALYZE LESS THAN % O.D., % I.D., VOLTS

This feature makes it possible to request the data analyzer to bypass defects shallower than a predetermined depth.

Type a “%” (Shift 5) followed by an O or an I to select O.D. or I.D., then use arrow keys to set the minimum percent wall loss that will be analyzed.

Type a V to select volts for change. Use the arrow keys to set the desired voltage. A value of approximately 0.10 may be a good value for this setting.

This is a convenient way to ask the data analyzer to skip shallow defects in order to decrease the time it takes the analyst to analyze defects by decreasing the number of defects drawn to his attention

2.5.15 PRINTER SELECTION

The ect MAD 8D Eddy Current System’s software supports a print screen capability available on four major classifications of printers. Specifically, an Epson LQ (Canon Bubble Jet BJ-200), 24-pin Toshiba dot matrix, LaserJet, PaintJet, and DeskJet printer. To select any one of these types of printer, press a “P” to enable printer selection, then press Q, T, L, P or D to select the desired printer. The selected printer is highlighted in yellow.

The 24-pin dot matrix selection is intended for a Toshiba dot matrix printer.

The LaserJet setting is for a Hewlett Packard LaserJet Series II or Series III printer. The PaintJet setting is for a Hewlett Packard PaintJet printer. The DeskJet setting is for a Hewlett Packard DeskJet printer.

To print the screen, hold down the Shift key while pressing the P key or hold down the alt key while pressing the P key. The print screen function can be placed in a macro string. To do so hold down the alt key while typing a P while editing the macro string.

2.5.16 C-SCAN SETUP

C-Scan is an optional display feature for use with rotating probes. The rotating probe system must provide a synchronization pulse for each rotation of the probe. The synchronization pulse must be a negative going TTL pulse applied to Pin 4 of the 15-pin connector on the Channel 1 printed circuit board.

To enter the C-Scan setup mode, type a C. H Step and V Step are now highlighted. To adjust the Horizontal Step, type an H, followed by arrow keys to change the number. To adjust the Vertical Step, type a V, followed by arrow keys to change the number. To exit the C-Scan Setup mode, type any other letter.

The V Step sets the number of raster lines between subsequent Horizontal C-Scan traces. The higher the V Step number, the faster the screen will be filled in the vertical direction.

The H Step adjusts the number of pixels that the C-Scan moves to the right for each sample of data. The higher the H Step number, the faster the horizontal scan line. When using a high speed rotating probe, use a high H Step number. When using a low speed scanning probe, use a lower H Step number.

2.5.17 MACRO STRING

The macro string allows a user defined set of instructions to be followed by the ect MAD 8D after typing a single keystroke.

Two macro strings are available. To edit macro string one, type M1 from the setup screen and then edit the macro string as in the following paragraph. To edit macro string two, type M2 and edit the macro string two as indicated in the paragraph below.

After selecting the macro string you wish to edit enter up to 17 keystrokes you want in the macro string. The Backspace key may be used to delete the last character of the string. The delete key may be used to delete the entire string. Function keys and arrow keys appear in the macro string as a two character code with the first character being a space. A list of these codes appear below for your information. When you have entered your complete macro string, press .

The macro key is the key with the “~”. On most keyboards this is the upper left hand key of the main keyboard. Type this key to execute macro string one. To execute macro string two, hold down the shift key and type the macro key.

If you wish to insert a print to printer command in the macro string, hold down the control key and type a P. The symbol “” will appear in the macro string.

If you enter an F2, which appears as a ” <” in the macro string, then the MAD 8D will not execute the character in the macro string after the F2 immediately. Instead, the MAD 8D begins playback of any signals saved in memory. When the autostop function occurs after one strip chart has filled the screen, then the next character in the macro string is executed. This function makes it possible to prepare a macro string with an F2 playback followed by a control P to print in order to playback signals to the screen followed by a print command in the macro.

The Enter key cannot be placed in a macro string. The macro string cannot be used when entering text strings, such as when entering a filename or a defect code.

You may execute macro string two by holding down the shift key while typing the macro key (the “~” key), or by using the foot switch Labeled “Number 2”.

F1 ( ;) 	F6 ( @) 	  ↑( H)
F2 ( <) 	F7 ( A)	          ↓( P)
F3 ( =) 	F8 ( B) 	  →( M)
F4 ( >) 	F9 ( C) 	  ←( K)
F5 ( ?) 	F10 ( D) 	  Home ( G)
End ( O) 	Page Up ( I) 	  Page Down ( Q)

Table 2.5.17, Function Key Codes

One example of macro use appears below:

2.5.17.1 SINGLE KEYSTROKE DATA ACQUISITION

In the Setup Menu, type an M followed by a 1 in order to start editing the macro string 1 and press to delete the old macro string, now enter the macro string as follows:

Tube, , F3, F7, Yes. Then press as the macro string is now complete. The macro string will appear as (T_M_=_AY).

Make sure that auto stop is “ON”. Then quit to the Main Menu and set the mode to one which includes a strip chart, such as 2 XY, 2 SC. Set the chart speed to some convenient value, such as 42 (in a real inspection you will want to set the chart speed number to a lower value so you can record longer tubes. The value of 42 is being used only for this demonstration.)

Type Data Tube to move to the Zone Row Tube Menu. Set the Zone, Row, Tube number to the tube number before the first tube you intend to inspect. For example, if your first tube is Zone 1, Row 1, Tube 1, then set the Zone, Row, Tube number to Zone 1, Row 1, Tube 0. Position the probe in the tube to be inspected. Press the Macro key and begin pulling the probe through the tube. When the strip chart is full, data is saved to disk automatically, and the system waits until you are ready to inspect the next tube.

2.5.17.2 MACRO STRING PCB SELECTION

The macro string can be implemented by a foot switch, which is normally connected to the 15 Pin connector of the Channel 1 printed circuit board. It is possible to connect the foot switch to any one of the printed circuit boards and then set the software to respond to that board.

To set the macro PCB number, type the semicolon “;” key and then use the arrow keys to select the correct PCB.

2.5.18 FLAW GATES

There is a separate flaw gate for each eddy current channel. Type a G to enter the setup mode. Once in the flaw gate setup mode, type a 1,2,3, or 4 to select a specific channel for setup; then, use arrow keys, Page up, End, and Home to select the desired value between -8 and +8 vertical volts.

The flaw gate will be triggered whenever the vertical voltage in a specific eddy current channel exceeds the vertical volt value set in the Flaw Gate Menu. When this value has been exceeded, then a negative going TTL pulse will be present on pin 7 of the 15 pin connector. For each sample the vertical voltage is in excess of the setting.

Type Q to exit the Flaw Gate Setup Menu.

2.5.19 HP FILTER

To turn the HP Filter “ON” or “OFF” in any of the channels, type the letter H to select HP filter for change.

After typing H, type the numbers 1, 2, 3, or 4 to toggle on or off the HP filter in frequency Channels 1-4.

To toggle “ON” or “OFF” the HP filter in Mixer Channel 1 or 2, type a 5 or a 6.

The HP filter is implemented in software by differentiating the horizontal and vertical channel in the selected frequency or mixer channel.

2.5.20 COLORS

The Screen Colors Menu allows you to change the screen colors used on the eddy current screen and menus.

To enter the Colors Menu, type an O from the Setup Menu.

Once in the Colors Menu, use the left and right arrow keys to select a screen color for change. Once a screen color has been selected for change, type an R, G, or B to select a primary color: Red, Green, or Blue. After selecting a primary color for change, use left and right arrow keys to change the primary color quantity by one. Use up and down arrow keys to change the primary color quantity by ten. After selecting the correct amount of the primary color, you may press R, G, or B and select another primary color for change. After setting all three primary colors to the desired level, press Enter and select another screen color for change.

You may return to the original default colors by typing the letter D.

After setting all the screen colors as desired, type Q to quit to the Setup Menu.

2.5.21 1/5 DIVISIONS INDICATOR

1/5 division indicators may be turned on or off in the XY screens by typing a “/” key.

When the 1/5 division is on, the XY screens will appear as in Figure 2.5.21.

Figure 2.5.21, 1/5 Divisions Indicator

Figure 2.5.21, 1/5 Divisions Indicator

2.5.22 AUTOMAD (AUTOMATIC ANALYZE)

AutoMAD is a software option for high speed fully automatic or semi automatic data analysis. If your system includes AutoMAD, then it will be listed as an option in the Copyright Menu.

To enter the AutoMAD Menu, type a T from the Setup Menu. The AutoMAD Menu appears in Figure 2.5.22.

Figure 2.5.22, AutoMAD Menu

Figure 2.5.22, AutoMAD Menu

2.5.22.1 MASTER

All AutoMAD features can be turned on or off with the master switch. To toggle the master switch on and off, type the letter M. Whenever the MAD 8D is started, the master switch is automatically set off.

2.5.22.2 AUTOMAD

AutoMAD can be toggled on and off by typing the letter T.

2.5.22.3 SP NUMBER

The number of the first support plate encountered can be set by typing the letter I and using the arrow keys to set the number.

Automatic support plate numbering can be toggled on and off by typing the letter S.

The support plate test number can be set to 0 to 7 by typing the letter P and using the arrow keys to change the number. A setting of 3 is recommended. For the support plate detector to work, Mixer 1 must be adjusted to eliminate support plate signals. The Mixer 1 horizontal signal is compared to a channel selected by the support plate test number. This channel should be the horizontal signal from the lower of the two frequencies which were mixed to eliminate the support plate signal. Normally, Channel 2 horizontal is the desired setting. To obtain this, set the SP test number to 3.

2.5.22.4 TEN DEEPEST DEFECTS

Automatic tracking of the ten deepest defects can be toggled on and off by typing the letter D.

The tube sheet threshold (TS threshold) can be adjusted by typing the letter H and adjusting the number over the range of 0 to +9 volts. A setting between +6 and +7 is recommended. The tube sheet detector scans Channel 1 horizontal. Channel 1 horizontal should be adjusted so that the tube sheet expansion transition zone signal saturates the horizontal channel. This triggers the tube sheet detector. If Channel 1 is properly adjusted as indicated above, then a tube sheet threshold setting of +9 Volts should be used. If the tube sheet expansion transition zone does not saturate the horizontal channel, then the TS Threshold should be set to a lower value, so that the tube sheet detector will trigger. When the tube sheet detector is triggered, a dark horizontal line is drawn in the strip chart at the location where the tube sheet was detected.

2.5.22.5 TUBE SHEET THRESHOLD

When using an AutoMAD mode for data analysis, the software determines whether or not the probe is in an unexpanded portion of the tube and only analyzes signals from that portion of the tube that is inside the roll expansions in the tube sheets at either end of the tube.

The software determines whether or not the probe is inside the unexpanded portion of the tube by examining the signal in Channel 3, the Absolute Channel, and comparing this to the tube sheet threshold value. The tube sheet threshold value is in volts. A value of approximately seven works well. When the tube sheet threshold is set to seven, this is the number of volts from the center point of the screen in Channel 3 that the signal must be within in order for the software to consider the probe as being in an unexpanded portion of the tube.

It is necessary to set the gain of Channel 3 low enough so that the signal from the 20 per cent I.D. groove in an ASME calibration tube is lower in magnitude than the tube sheet threshold value. It is recommended to adjust the gain control in Channel 3 so that the magnitude of the signal from the 20 per cent I.D. groove in the ASME calibration tube is less than six volts. It may be necessary to install the 5X ATTN cable between the 9-pin Channel 3 connector from the MAD8D amplifier and the Channel 3 connector.

The intended probe speed should be set in the AutoMAD Menu. Type the “/” key, and adjust the probe speed number. This information is used when information about the distance between a defect and the last encountered support plate information is stored to disk for report software.

It is recommended that the phase O.D. / VERT MAG I.D. feature normally be left in the OFF position. When in the ON position in analysis mode, the software will perform phase analysis on O.D. defects. Defects with a phase angle lower than the angle in the calibration tube for a through wall hole will be analyzed by the next higher calibration table number, which should have a valid vertical magnitude calibration data for performing vertical magnitude I.D. analysis. It is recommended the operators wishing to use this feature obtain factory training.

The maximum number of defects which are saved to disk for any one tube can be set to a number between 1 and 10. Type the letter F, and adjust this number using the arrow keys. Note that if this is set to a high number and a lower number of defects that meet the save less than percent criteria, then the smaller number of defects encountered only will be saved.

The BEEP sound when defects are encountered can be turned ON or OFF. Type the letter E to toggle this feature ON or OFF.

2.5.22.6 SEMIAUTOMATIC OPERATION

In the AutoMAD Menu set AutoMAD off. It is recommended to set the support plate numbering on.

Set the first support plate number. It is recommended that this be set to 0, if the probe will be in the far tube sheet when recording is commenced. In this case the tube sheet will be numbered 0 during the inspection and the first support plate encountered after that will be number 1. If only part length tubes are being inspected, then set the 1st support plate number to the number of the support plate which will be first encounter after recording has commenced.

Set find deepest defect on.

Set SP Test to 3. Set TS Threshold to 9.

Enter the Report Setup Menu and prepare this menu as described in this manual.

In the Setup Menu, turn off ISIS and turn off KARTA (if you have these options).

Set the file directory to the name of the directory in which the data to be analyzed exists.

Set “Don’t Analyze Less than” as required. It is recommended that macro string 1 be set to Tube, Next, Recall (F6), Yes, Analyze, Playback (F2). (TN @YA <)

Quit to the Main Menu and type DT in order to enter the Zone Row Tube Menu. Set the zone row tube numbers to 0. Type the macro key. After typing the macro key, the MAD 8D software searches the specified data directory for the next available zone row tube number, and recalls that tube (If more than one scan of a given zone row tube number is saved on disk, then the highest scan number is the one which will be recalled.) After recalling the data tube to RAM, the software will switch into analysis mode and play back the signal to screen. After the entire length of tube has been played back to screen, then the ten deepest defects that were encountered in the data are listed in the menu in order. The deepest defect is redrawn in the impedance plain screen, and the software waits for operator input.

The operator may save information about the deepest defect to disk by typing the letter F and following the procedure as described in this manual. If the operator wishes to view the next deepest defect, type the TAB key. By typing the TAB key several times, each of the individual defects can be viewed. If the operator wishes to go back to a deeper defect, hold the SHIFT key while typing the TAB key. The operator must save defect data for all the defects he considers to be significant.

After all significant defect data on this tube has been saved to disk, type the MACRO key, which will initiate the software to search for the next tube on disk and begin the analysis process again.

2.5.22.7 AUTOMATIC OPERATION

Prepare the ect MAD 8D as outlined above except turn on AutoMAD (press “T”) in the AutoMAD Menu.

Quit to the Main Menu and set the zone row tube number to 0 in the Zone Row Tube Menu. Type the MACRO key. As in semi-automatic operation, the software recalls the first tube, displays it on the screen, and lists the 10 deepest defects. At this point, the software does not wait for operator intervention. Instead, the software saves information about all defects encountered up to a maximum of 10 defects on the disk for the report software. Then the software automatically scans the disk to find the next available tube and repeats the process. This process repeats until all tubes have been analyzed.

If the operator wishes to interrupt this operation, type the letter U. This will result in the software moving to the Setup Menu. Type the letter T, and then once in the AutoMAD Menu, type the letter T to turn off AutoMAD.

2.5.23 DON’T ANALYZE LESS THAN

The don’t analyze less than feature in the Setup Menu is an adjustment for the automatic analysis function, which allows the analyst to adjust the system so that small defects will be ignored. It is possible to adjust internal and external thresholds separately in terms of percent wall loss and to adjust a minimum magnitude of signal below which all defects will be ignored.

The percent O.D. and I.D. calculation is performed in the channel which is selected for analysis at the time the analysis is performed. It is recommended that the mixer channel be selected in order to avoid erroneous readings from support plate signals.

It is recommended that the values for O.D. and I.D. be set with one of the following criteria:

a. Set the value to 20% since normally defects less than 20% of wall are considered not to be reportable. This setting is most desirable when the tubes are relatively new and free from defects.

b. Set the threshold setting approximately 20% below the plugging criteria. This is recommended when inspecting old tubes with many defects.

The minimum volts setting is used to prevent low level noise from being analyzed as severe defects. A setting as low as .05 may work well in new tubes. A higher setting of several tenths of a volts may be desirable in older tubes.

To activate the Don’t analyze less than feature type the % key.

2.5.23.1 DON’T ANALYZE LESS THAN % O.D.

After typing the % sign type “O” to select O.D. for adjustment. Use the arrow keys to set the desired value.

2.5.23.2 DON’T ANALYZE LESS THAN % I.D.

This value is adjusted the same as % O.D. above, except that an “I” is used to select % I.D. for analysis.

2.5.23.3 DON’T ANALYZE LESS THAN VOLTS

In the Setup Menu type the letter V in order to select “Don’t analyze less than volts” for adjustment. The left and right arrow keys adjust this value by .01 volts. The up and down arrow keys adjust this value by .1 volts. The page up and page down keys adjust this value by 1 volt.

2.5.24 MIXER SOURCE

Mixers 1 and 2 are implemented in software. Each mixer has two input channels. It is normally recommended that Mixer 1 source be Channel 1 and Channel 2 and that Mixer 2 source be Channel 3 and Channel 4. If other settings are required, it is possible to set the mixer source to any desired channel.

2.5.24.1 MIXER 1 SOURCE

Type a 1 to select Mixer 1 source for adjustment. After typing the number 1, the first channel will be highlighted for change. Use the left and right arrow keys to adjust the highlighted number to the desired channel. Note that Channels 1 through 4 are frequency channels and that Channels 5 and 6 refer to Mixers 1 and 2. After setting the desired channel for the first source, press the Enter key. The second source will be highlighted for change and is adjusted in the same manner as the first source. When source 2 is correctly set, press the Enter key.

2.5.24.2 MIXER 2 SOURCE

Mixer 2 source is adjusted in the same manner as Mixer 1 source in the above paragraph.

2.5.25 ALL 4 LP SAME

The system can be set so that the LP filters in all four frequency channels are always the same or it can be set so they can be adjusted independently. Normally, (and specifically when mixers are being used), it is desirable to have all LP filters set to the same value. In specialized testing applications, such as when using very low frequencies and very high frequencies simultaneously to inspect carbon steel materials, it would be desirable to set the LP filter to a low value in the low frequency channel and to a higher value in the high frequency channel.

In order to enable the setting of each frequency channels LP filter separately, type the number 4. This toggles all 4 LP same to “OFF” then adjust the LP separately in the Channel Menus. To lock all 4 LP filters to the same value, type the number 4. This toggles this function “ON”.

2.5.26 FREQUENCY

It is possible to adjust frequencies for each of the four frequency channels in the Setup Menu. Type the letter Y to enable this function the numbers 1, 2, 3, and 4 and will be highlighted. To adjust frequency Channel 1, type a 1 and then use the arrow keys to adjust the frequency as described in Section 2.1.1, Frequency Control. When you have finished adjusting a frequency channel, you may press one of the other highlighted numbers in order to adjust a different frequency channel. When all frequency channels have been adjusted correctly, press the Enter key.

2.5.27 ANGLE AMPLIFIER

Type a greater than “>” symbol to enable the angle amplifier for change. After typing the “>” symbol, the channel numbers 1 through 4 will be highlighted. To select a frequency channel for change, type the number 1, 2, 3, or 4. To select a mixer channel for change, type the number 5 or 6. After selecting a channel for change use the right arrow key to turn on the angle amplifier. Use the left arrow key to turn off the angle amplifier.

The angle amplifier can be used to increase the angle of a throughwall hole from its normal position of 45 degrees to a position of 90 degrees while leaving lift off horizontal. This spreads the angles of I.D. defects from 0 to 90 degrees on the screen, while compressing O.D. defects between 90 and 180 degrees.

2.5.99 QUITTING SETUP MENU

You may quit to any previous menu by typing a Q.


2.6 RECORD/PLAYBACK

The function keys F1 through F12 are used for record and playback functions.

Keys F1 through F4 are used to control the recording and playback of data to and from the computer’s RAM (Random Access Memory).

The function keys F6 through F8 are used to recall data from disk the computer RAM or to permanently save the data on a disk.

The function key F10 is used to set the playback mode to play back in the reverse or forward direction.

2.6.1 F1 ~ STOP

This key is used to momentarily stop playback from RAM to the screen. It can also be used to momentarily stop the recording of data to RAM. Pressing the Stop key once puts the MAD 8D in the stop mode, as indicated by the word Stop in the upper right hand corner of the screen. Pressing the Stop key a second time brings the MAD 8D out of stop mode into record or playback mode.

2.6.2 F2 ~ PLAYBACK

The F2 key is pressed to put the MAD 8D in the playback mode. In the playback mode, data previously stored in RAM is displayed on the screen. You may temporarily halt the playback mode by pressing the F1 key to enter the stop mode. If you press the F2 key while already in playback, then playback begins again from the beginning of memory.

2.6.2.1 PLAYBACK BACKWARDS

Pressing the F10 backward key puts the playback mode in the reverse direction. Pressing F10 a second time puts the playback mode in forward.

2.6.2.2 PLAYBACK SPEED

Use the “-” or “+” keys to decrease or increase the playback speed. Playback speed is indicated on the second line of the Main Menu. When playback speed is 1, then playback speed is the same speed as the speed it was recorded. When playback speed is 2, then playback speed is one half the speed as it was recorded. When playback speed is 4, then playback speed is at 1/4 of the speed the signal was recorded. The slowest playback speed is 1/128 of the record speed. When the playback speed indicated is 0, then the signals are played back to the screen as fast as the computer is capable.

2.6.3 F3 ~ RECORD

Press F3 (the record key) to record eddy current inspection data into the computer RAM. To stop recording, press F2 the Playback key to immediately enter the playback mode, or press F1 the Stop key to momentarily stop recording. Note that when entering the record mode from the playback mode RAM is erased. Therefore, it is necessary to save data from RAM to disk before re-entering the record mode if it is necessary to save the data permanently.

2.6.4 F4 ~ STOP

F4 Reset sets the RAM pointer to zero, the beginning of RAM memory. The Reset key does not erase the contents of the RAM.

2.6.5 F5 ~ SAVE IMAGE

The F5 key is used to save an image file on disk.

To evoke this feature, type F5 and type “Y” in response to “Save Image to Disk? Y/N”. The image will be saved on the disk with a file name based on the zone, row, and tube number. For example; if you are saving an image for zone 1, row 2, tube 3, the file name will be 0102030X.ECI.

To retrieve an image saved on disk, use the IMAGE.EXE utility described in Section 4.0.3, IMAGE. EXE.

2.6.6 F6 ~ RECALL

To recall data from a disk drive to the RAM, press the F6 key. You are prompted to confirm that you wish to recall data from the disk with the current zone, row, and tube number. Type Y if you wish to recall that data from disk to RAM. If necessary, type an N and enter the Zone Row Tube Menu to set the correct tube number for recall.

Note that when recalling data from disk the previous contents of the RAM are erased.

The ect MAD 8D Eddy Current System’s software provides for saving on disk up to 16 scans of the same zone, row, and tube number. When recalling data, you are prompted to confirm recall from disk. The highest scan number is shown. Scan numbers range from 0 to 15, allowing for 16 possible scans of the same tube. The system’s software automatically seeks the highest scan number. If you wish to recall a different scan number, then use the left and right arrow keys to change the scan number before pressing Y to execute the function.

2.6.7 F7 ~ SAVE

The F7 key is used to save data from RAM to the disk. When you press the F7 key, you are prompted to confirm that you wish to save the data to disk and given the current zone, row, and tube number, which is being tracked from the Zone Row Tube Menu.

Having pressed the Save key, if you are prompted for the wrong zone, row, and tube number, then type “N” and enter the Zone Row Tube Menu to correct the number before saving the data. If you are prompted for the correct zone, row, and tube number, press Y to confirm that you wish to save the data to the hard disk. The computer then stores the data to the hard disk using a filename based on the zone, row, and tube number, so that this information can later be recalled with F6, Recall.

See Section 2.5.3, Data Directory to make sure the correct data directory has been selected before saving or recalling data from disk.

2.6.8 F8 ~ ERASE

Pressing the F8 key erases the contents of RAM. It is recommended to press the Erase key to erase random access memory before beginning a record cycle. Erasing RAM also erases the screen.

2.6.9 F9 ~ NOT USED

2.6.10 F10 ~ BACKWARDS

The F10, Backwards key is used during the playback mode to play backwards through RAM at slow speed. To enter the Backwards Mode, press the F10 key when in the playback mode. To change to forward playback, press the F10 key a second time. Note that recording is always in the forward direction.

2.6.11 F11 ~ RECALL CALIBRATION SIGNAL

To recall a calibration signal, press the F11 key. At the prompt type a “Y” if you wish to recall the calibration signal filename that was last used. If not type an “F” and edit the filename to the filename you wish to use, then press to retrieve the calibration signal.

The previously saved calibration signal will be superimposed over the existing screen in black so that the signal can be compared to the current signals on screen.

2.6.12 F12 ~ SAVE CALIBRATION SIGNAL

To save a calibration signal on screen to disk, press the F12 key. Type “F” and edit the filename, then press to save the image to disk under that filename.

The file will be saved in the C:\ECTDATA directory with the filename entered and the extension “.CA2”. The file size will be 30,720K.

Nine Pin Probe Connector

Pin     Function

 1      Coil Drive
 2      Coil Drive
 3      Ground
 4      Power Ground
 5      +10Vdc
 6      Coil Input
 7      Coil Input
 8      Ground
 9      +5Vdc

Fifteen Pin System Connector

Pin     Function

 1      TTL Input Bit 4
 2      TTL Input Bit 5
 3      TTL Input Bit 6
 4      TTL Input Bit 7 (MSB)
 5      TTL Output Bit 7 (MSB)
 6      TTL Output Bit 6
 7      TTL Output Bit 5
 8      TTL Output Bit 4
 9      Analog Ground
10      V Output
11      H Output
12      Input - Vertical
13      Input - Horizontal
14      Not Used
15      Digital Ground

OPERATION MANUAL

The operation portion of this manual provides recommended procedures for the efficient operation of the ect MAD 8D Eddy Current System.