Bondtracer - GE Measurement & Control
Contents
1. However should service become necessary GE Inspection Technologies has established a number of Factory Trained Service Centers For the location of the nearest facility refer to GE Customer Service 4 Bondtracer User s Manual 5 The Bondtracer The Bondtracer is a pulse echo hand held instrument for inspection of composite parts ranging from 0 070 in to 0 625 in in thickness This instrument enables airport ramp personnel to map size and assess the severity of damage to a composite part and thus determine if more inspection is required The Bondtracer can be used in cramped and darkly lit areas hot and bright sunlight and cold environments In addition it can withstand aircraft fuel oil hydraulic fluids shock vibration RF emissions large temperature changes and both wet and dry climates The Bondtracer package includes e The Bondtracer instrument 022 509 665 e Probe 113 843 660 e Test calibration block 118 540 980 e Probe cable 4 ft 022 509 786 e Couplant 4 oz 118 300 810 e 3 AA batteries 021 010 020 e User s manual 021 002 477 Bondtracer User s Manual 5 Figure 1 on the next page shows the front of the Bondtracer Users operate the Bondtracer through a front keypad with three buttons On Off Cal and Brightness They view indicator LEDs through a clear lens on the front window Four LEDs display instrument readings e Green Pass e Red Fail e Yellow CAL Calibration Coupled2. 44 845 130 3925 E mail geit info ge com 021 002 477 Rev 2 France 68 Chemin des Ormeaux Limonest 69760 France Tel 33 47 217 9216 Germany Robert Bosch Str 50354 Hurth Germany Tel 49 2233 6010 Spain San Maximo 31 Planta 4A Nave 6 Madrid 28041 Spain Tel 34 195 005 990 www geinspectiontechnologies com ISO 9001 REGISTERED COMPANY 2010 General Electric Company All rights reserved Technical content subject to change without notice China 5F Building 1 No 1 Huatuo Road Zhangjiang High Tech Park Shanghai 201203 China Tel toll free 86 800 915 9966 Tel 86 0 21 3877 7888 Japan 7F Medie Corp Bldg 8 2 4 14 Kichijoji Honcho Musashino shi Tokyo 180 0004 Japan Tel 81 442 67 7067
3. e Blue Power On Low Battery To accommodate different lighting conditions the Brightness button enables users to select from three different levels of brightness 6 Bondtracer User s Manual BONDTRACER E Inspection Technologies gt Figure 1 The Bondtracer The Bondtracer runs on three AA batteries for a total of 8 hours of continuous use when the probe is attached and coupled Bondtracer User s Manual 7 6 Starting and Stopping the Bondtracer Before starting the Bondtracer be sure you have installed three AA batteries in the rear of the unit as shown in Figure 2 below and inserted the probe into the LEMO connector at the top of the unit Probe Connector Battery Cover Figure 2 Rear Panel for Battery Insertion 8 Bondtracer User s Manual To power up the Bondtracer press the On Off button The Bondtracer runs an internal self check and lights all the LEDs in a chase pattern After power up the blue LED remains lit as long as the Bondtracer is on Note If the Bondtracer fails the self check the working LEDs blink for 10 seconds and then the Bondtracer will power down To turn off the Bondtracer press the On Off button An Auto Off feature shuts down the Bondtracer after 15 minutes of no use not coupled and no keypad buttons being pressed The power LED will begin to flash
4. when about 30 minutes of run time remain on the batteries The Bondtracer will shut down automatically when the battery level is too low to provide proper operation 7 Calibrating the Bondtracer Once the Bondtracer is powered on it can be calibrated against a known good block of composite material To calibrate couple the attached probe to a known good composite that is similar to the suspected area in thickness coating and other necessary physical characteristics Press the CAL keypad button for one second The Bondtracer stores the Time Of Flight and amplitude of the known good part The Yellow LED is used to indicate calibration and coupling status No calibration is stored when the yellow LED is off A flashing yellow LED indicates that a calibration has been stored and that the probe is currently uncoupled A solid yellow LED indicates a calibration has been stored and the probe is coupled Bondtracer User s Manual 9 Figure 3 Bondtracer Lights IMPORTANT Since the Bondtracer has no internal memory you must recalibrate it each time you power it up 10 Bondtracer User s Manual 8 Testing Suspect Material with the Bondtracer To test a piece of suspect material with the calibrated Bondtracer couple the probe to the suspect material The Bondtracer fires a pulse at 60 Hz and then detects the echo from the material It compares the amplitude and TOF Time Of Flight with the values from the known good material
5. 9 6 Environmental Sealing us needed Aa 12 Bondtracer User s Manual iii 1 Important Notice The following information must be read and understood by any user of GE ultrasonic test equipment Failure to follow these instructions can lead to errors in test results Decisions based on erroneous results can in turn lead to property damage personal injury or death 2 General Warnings Proper use of ultrasonic test equipment requires two essential elements knowledge of the specific test application requirements and training on the part of the instrument operator This operating manual provides instruction in the basic set up and operation of the GE Bondtracer 3 Testing Limitations In ultrasonic testing information is obtained only from within the limits of the sound beam Operators must exercise great caution in making inferences about the test material outside the limits of the sound beam For example when testing large materials it may be impossible or impractical to inspect the entire test piece When a less than complete inspection is to be performed the operator must be shown the specific areas to inspect Inferences about the condition of areas not inspected based on data from the evaluated areas should only be attempted by personnel fully trained in applicable statistical and probability techniques In particular materials subject to erosion or corrosion in which conditions can vary significantly in any given area shou
6. GE Sensing amp Inspection Technologies Bondtracer Operating Manual imagination at work Ultrasonic 021 002 477 Rev 2 February 2010 Bondtracer Composite Checker for Airframes Operating Manual 021 002 477 rev 2 February 2010 26 GESensingInspection com 2010 General Electric Company All rights reserved Technical content subject to change without notice no content intended for this page proceed to next page Contents O 0 JO ul Important Noti a A dia des 1 General Warnings am a A A a dee 1 Testing MAA A A adas 1 3 1 Ultrasonic Test Measurement Critical Operating Procedures o oooooooooooorrr ee teen eens 2 Safety Inform ton ct ia a A sd 3 4l Batteries ua o EN A A A is Greens 3 42 Defects Errors and Exceptional Stresses o o oooooo ene rererere eben eens 3 4 3 SERVICE ne et MA ee eas Ack Seats Ga sdk SAA oe da NG teh heer OOS 4 The Bondttacet iuris 3 ste iii ts its 5 Starting and Stopping the Bondtracer coerente en K eee ene e nent nent eben eens 8 Calibrating the Bondtracer 2 40 2 A its 9 Testing Suspect Material with the Bondtracer 0 0 Leet n een eee ene eee 11 Technical Specific OO sescenti be drid a 12 gE SEs A A A He A A A E 12 IN AAN 12 93 Battery LIfe tit ir A A A Nee et 12 94 Operating Temperature ossa sons nes se A ee nn ee Gu EE ee ee EE a Ee ee be 12 9 5 Storage Temperatures cc a Whee Heer Saeed Sie eee Gt it Shel Hi een A S A 12
7. and delivers a pass or fail result e Ifthe amplitude and TOF of the signal from the area being inspected are within the defined limits the green LED will illuminate indicating a pass e Ifthe amplitude and TOF of the signal from the area being inspected is less than the defined limits the red LED will illuminate indicating a fail e Ifthe amplitude and TOF of the signal from the area being inspected is greater than the defined limits the red LED and yellow LED will blink indicating an above calibrated range The Bondtracer remains in this mode until you press the CAL button or until it is powered down either manually or through auto shutdown Bondtracer User s Manual 11 9 Technical Specifications 9 1 Size 180 mm H x 92 mm W x 46 mm D 9 2 Weight 450 g including batteries 9 3 Battery Life 8 hours of continuous use on three AA alkaline batteries 9 4 Operating Temperature 0 to 55 C 9 5 Storage Temperature 20 to 70 C 9 6 Environmental Sealing Impact resistant dust and splash proof gasket sealed case tested to IP54 12 Bondtracer User s Manual GE Inspection Technologies is an active participant in Europe s Waste Electrical and Electronic Equipment WEEE take back initiative directive 2002 96 EC E The equipment you purchased required the extraction and use of natural resources for its production It may contain hazardous substances that could impact health and the env
8. eloped so that couplant is used and applied in a consistent manner to minimize variations in couplant layer thickness and errors in test results Calibration and actual testing should be performed under similar coupling conditions using a minimum amount of couplant and applying consistent pressure on the transducer 2 Bondtracer User s Manual 4 Safety Information IMPORTANT The Bondtracer is an instrument for materials testing Any use for medical applications or other purposes is not allowed The Bondtracer may only be used in industrial environments The Bondtracer can be operated with batteries 4 1 Batteries For the battery operation of the Bondtracer GE recommends the use of three high quality AA alkaline batteries 4 2 Defects Errors and Exceptional Stresses If you have reason to believe that a safe operation of your Bondtracer is no longer possible you have to disconnect the instrument and secure it against unintentional reconnection Remove the batteries if necessary A safe operation is no longer possible if The instrument shows visible damages The instrument no longer operates perfectly Bondtracer User s Manual 3 e After prolonged storage under adverse conditions like exceptional temperatures and or especially high air humidity or corrosive environmental conditions e Being subjected to heavy stresses during transportation 4 3 Service Every effort has been made to provide you with a reliable GE product
9. ent and on human health For proper recycling you can return this product or the batteries or accumulators it contains to your supplier or to a designated collection point Some batteries or accumulators contain toxic metals that pose serious risks to human health and to the environment When required the product marking includes chemical symbols that indicate the presence toxic metals Pb for lead Hg for mercury and Cd for cadmium Cadmium poisoning can result in cancer of the lungs and prostate gland Chronic effects include kidney damage pulmonary emphysema and bone diseases such as osteomalcia and osteoporosis Cadmium may also cause anemia discoloration of the teeth and loss of smell anosmia Lead is poisonous in all forms It accumulates in the body so each exposure is significant Ingestion and inhalation of lead can cause severe damage to human health Risks include brain damage convulsions malnutrition and sterility Mercury creates hazardous vapors at room temperature Exposure to high concentrations of mercury vapor can cause a variety of severe symptoms Risks include chronic inflammation of mouth and gums personality change nervousness fever and rashes Bondtracer User s Manual 15 Customer Support Centers North South America 50 Industrial Park Road Lewistown PA 17044 U S A Tel 866 243 2638 toll free 717 242 0327 United Kingdom Ireland 892 Charter Avenue Canley Coventry CV4 8AF England Tel
10. ironment In order to avoid the dissemination of those substances in our environment and to diminish the pressure on the natural resources we encourage you to use the appropriate take back systems If you need more information on the collection reuse and recycling systems please contact your local or regional waste administration Visit http www geinspectiontechnologies com en aboutus ehs index html for take back instructions and more information about this initiative Bondtracer User s Manual 13 This product contains a battery that cannot be disposed of as unsorted municipal waste in the European Union See the product documentation for specific battery information The battery is marked with this symbol which may include lettering to indicate cadmium Cd lead Pb or mercury Hg For proper recycling return the battery to your supplier or to a designated collection point What do the markings mean Batteries and accumulators must be marked either on the battery or accumulator or on its packaging depending on size with the separate collection symbol In addition the marking must include the chemical symbols of specific levels of toxic metals as follows e Cadmium Cd over 0 002 e Lead Pb over 0 004 e Mercury Hg over 0 0005 14 Bondtracer User s Manual The risks and your role in reducing them Your participation is an important part of the effort to minimize the impact of batteries and accumulators on the environm
11. ld only be evaluated by fully trained and experienced operators Bondtracer User s Manual 1 Sound beams reflect from the first interior surface encountered Because of part geometry and over lapped flaws or overlapped surfaces thickness gauges may measure the distance to an internal flaw rather than to the back wall of the material Operators must take steps to ensure that the entire thickness of the test material is being examined 3 1 Ultrasonic Test Measurement Critical Operating Procedures The following operating procedures must be observed by all users of ultrasonic test equipment in order to minimize errors in test results 1 Effects of Temperature on Calibration Temperature variations change the sound velocity of materials and transducer delay lines and therefore calibrations All calibrations should be performed on site and with test blocks at the same temperature as the test piece to minimize errors due to temperature variations 2 Transducer Selection The transducer used in testing must be in good condition without noticeable wear of the front surface Badly worn transducers will have a reduced effective measuring range The specified range of the transducer must include the complete range of thicknesses to be tested The temperature of the material to be tested must be within the transducer s temperature range 3 Use of Couplants Operators must be familiar with the use of ultrasonic couplants Testing skills must be dev
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