Electromagnetic-Acoustic (EMA) Thickness Gauge NOVOTEST UT-3M-EMA
The NOVOTEST UT-3M-EMA is a portable electromagnetic-acoustic (EMA) thickness gauge designed for non-contact measurement of wall thickness in metal and alloy parts. This device is suitable for testing steel pipes, flat-rolled stock, rods, and other metallic structures without the need for couplant or preliminary surface preparation. Its EMA technology allows for measurements through various gaps, including air, rust, paint coatings, fluids, plastic, and salt deposits, making it highly versatile for diverse industrial applications. The thickness gauge finds utility in engineering, aerospace, metallurgy, metal structure mounting, thermal and nuclear power plants, field laboratories, and vehicle testing.
Function Description
The operating principle of the NOVOTEST UT-3M-EMA is based on measuring the propagation time of an acoustic wave through the test object. This measured time is then converted into a thickness value using a preset ultrasonic wave propagation velocity. The acoustic wave is generated through electromagnetic-acoustic conversion directly on the surface of the test object, eliminating the need for a contact medium between the transducer and the object. This direct conversion ensures that the wave is not distorted in the medium.
A key feature of the device is its specialized data processing algorithm, which enables accurate thickness measurements even in the presence of interfering factors such as metal anisotropy, multiple reflectors, and external noise. This automation minimizes human error, ensuring fully automatic thickness measurements.
The device operates in several modes to accommodate different testing scenarios:
- "MEASUREMENT" Mode: This is the primary mode for thickness measurement and includes sub-modes such as "AUTO," "MANUAL," "B SCAN," "CONTROL," and "CALIBRATION."
- "AUTO" Mode: In this mode, the device automatically analyzes measured signals, selects the appropriate measurement method, sets receiver path parameters, and displays the thickness value. The speed of ultrasound velocity in the test object must be set either through calibration or manually (1000 to 9999 m/s). The device employs a transversal wave, with a propagation speed of 3250 m/s in steel. For materials with high attenuation or large objects, the device can average 2, 4, 8, 16, 32, 64, or 128 signals to reduce noise.
- "MANUAL" Mode: This mode allows for detailed measurement and testing with user-defined settings. Parameters are categorized and can be adjusted by the operator, including amplification (AMP.), start point of the selected gate (START), width of the beam control gate (WIDTH), amplitude processing threshold (THRESHOLD), scanning duration (DUR.), delay of scanning start (DELAY), level (LEVEL), and averaging (AVG.).
- "B SCAN" Mode: This mode displays a B-Scan, which represents the shape of the test object. It is particularly useful for detecting corrosion damage, material reduction, and lamination during scanning. Settings for this mode include minimum (MIN.) and maximum (MAX.) measurement range values, thresholds (THRESHOLD 1 and THRESHOLD 2), and sound signal control (SIGNAL).
- "CONTROL" Mode: Designed for examining products against exact thickness specifications (minimum and maximum), this mode triggers an alarm if the measured thickness exceeds set thresholds, indicating a product rejection. It also allows operators to estimate corrosion damage as a percentage of the reference thickness. Parameters include reference thickness (REF.), thresholds (THRESHOLD 1 and THRESHOLD 2), and sound signal control (SIGNAL).
- "CALIBRATION" Mode: Used to calibrate the device by placing the EMA transducer on a test object. Operators set averaging signals and the reference sample thickness, then initiate calibration. The process involves placing the transducer in the air, confirming, then placing it on the sample, and confirming again. If the measured value deviates significantly from the reference, recalibration is necessary.
- "ARCHIVE" Mode: This mode allows users to view all saved measurement values, sorted by creation date. Selected files can be downloaded for further work with specific settings.
- "SETTINGS" Mode: This section provides access to various device settings, including language (English and Russian), display brightness (10% to 100%), color scheme, sound (ON/OFF), "Median" filter (TYPE F.), SD card clearing (CLEAR. SD), transducer selection (TRANSDUCER), material type (e.g., aluminum, steel, bronze, gold), measurement units (mm, µm), time (24h), and date settings.
- "INFORMATION" Mode: Displays product information such as battery charge, voltage, consumed current, total operation time, measurement time, serial number, firmware version, and chipboard version.
Important Technical Specifications
The NOVOTEST UT-3M-EMA is a portable device housed in a durable and lightweight aluminum casing, containing a chipboard, electronic components, and a lithium-ion battery.
- Measurement Range: 0.6 - 200 mm (depending on the transducer).
- Permissible Error: ± (0.01h + 0.05) mm, where h is the nominal thickness.
- Ultrasound Velocity Range: 100 - 9999 m/s.
- Resolution: 0.01 mm.
- Measurement Modes: Autocorrelation (ACF), Echo, Echo-Echo (dual echo), Pique-Pique.
- Dimensions of Processing Unit (max): 165x90x50 mm.
- Power Type: Built-in lithium-ion battery.
- Worktime without Charging (min): 8 hours.
- Weight of Processing Unit (max): 0.45 kg.
- Display Size: 3.5 inches.
- Operating Temperature Range of Processing Unit: -20 to +50 °C.
- Air Humidity (max): 98% at 35 °C.
The device is controlled via a keyboard, and signals, readings, and device status are displayed on a contrast color LCD/TFT display. Transducers connect via coaxial cables to connectors on the top panel. A mini-USB connector on the bottom is used for PC connection and battery charging.
Usage Features
- Transducer: The device uses an EMA transducer, which includes a permanent magnet. Users must exercise care when moving the device near sharp metal objects to prevent magnetization and potential harm. Placing the transducer near plastic magnet cards can cause card failure. When testing loose or lightweight samples, the operator should hold the sample by hand. It is recommended to place the device on the test object smoothly and hold it, especially since the magnetic field can cause additional acceleration. Initial placement on the test object should be at a 60° angle, then the transducer should be put upright.
- Operating Environment: The device should be operated in environments free from dust and aggressive media. Radio noise at the operating location should not impair operation. If strong magnetic fields are present, the operating area should be shielded.
- Temperature Acclimatization: If the device is moved from sub-zero temperatures to a room with above-zero temperatures, it should be kept in its package for at least 6 hours to prevent moisture buildup.
- Battery Charging: The battery can be charged by connecting the power unit to the device or by connecting it to a PC. Full charging takes up to 14 hours. It is prohibited to leave the device unattended during charging. For long storage, the battery should be charged every 2 months, even if the device is not in use, to prevent failure.
- Transducer Connection: The transducer should be connected to the sockets on the top of the device using a connection cable. It is crucial to handle connectors by their ribbed part and never pull the cable to avoid damage. The transducer should be connected when the device is off.
- Measurement Process: Before use, ensure the battery is sufficiently charged (indicated by a green battery icon). Connect the EMA transducer, turn on the device, select the operating mode, and calibrate if necessary. Place the EMA transducer on the test object to achieve a stable reading. Measurements can be saved and named using a virtual keyboard.
- Packaging: The processing unit and transducer are supplied in a protective packaging container. To prevent mechanical damage to the cable and sockets, disconnect the transducer before placing the device into the container for transport.
Maintenance Features
- Periodic Inspection: After commissioning, it is recommended to periodically inspect the device for operability, compliance with operating requirements, battery charge level, and absence of damage.
- Charger Safety: When using the charger with a 220V, 50 Hz power supply, operators must adhere to "Safety procedure when operating consumer electronic units."
- Long-Term Storage: For extended periods of non-operation, batteries should be disconnected and removed from the device, following battery storage regulations.
- Qualified Operators: The device should only be used by persons instructed and certified with a II qualification category in safety engineering for measuring devices.
- Warranty: NOVOTEST provides a basic warranty of 3 years for devices purchased from NOVOTEST or authorized dealers, subject to timely annual maintenance. The warranty covers defects in material or manufacturing, with repairs or replacements handled by NOVOTEST or an authorized dealer. The warranty period typically starts from the date of shipment. An extended warranty program of 3 to 5 years is available through a certificate purchase.
- Repaired/Replaced Components Warranty: All NOVOTEST branded parts installed during warranty repair are covered under the NOVOTEST warranty until the end of the original warranty period. Replaced spare parts are not returned to the owner.
- Wearing Parts:
- Parts Replaced During Maintenance: Built-in batteries, gaskets (if removed for adjustment), grease, and operating liquids have limited service lives and are covered by the basic warranty until their first replacement or adjustment, not exceeding the specified operational limits.
- Wearing Parts (12-month warranty): Transducers and their components, and connection cables are covered by a 12-month basic warranty. Parts wearing due to friction (e.g., movable parts of transducers) are not covered unless failure is due to a material or workmanship defect within the warranty period.
- Owner Obligations: Proper operation and maintenance, as outlined in the manual and registration certificate, are crucial to avoid costly repairs and extend device service life. Owners should promptly submit the device for warranty repair if any defect is found, use only branded spare parts and couplants, maintain records of maintenance (receipts, bills, registration certificate stamps), and clean the casing and probe according to NOVOTEST recommendations. Failure to perform timely maintenance may void warranty rights.
- Warranty Exclusions: The warranty does not cover damages from negligent/incorrect operation, natural disasters, water intrusion, misuse, wear and tear, non-observance of NOVOTEST recommendations (maintenance, operation), unauthorized device configuration changes or intrusions, refusal of regular maintenance repairs, external factors (air pollution, hurricanes, shocks, scratches, unsuitable cleaning), or use of unapproved repair methods or third-party spare parts/couplants. All warranty repairs must be performed by an authorized NOVOTEST service center.
- Consumer Law: NOVOTEST's warranty does not affect consumer rights provided by sales agreements and applicable laws.
- Maintenance Types:
- Preventive Maintenance: Performed at least once a quarter, including visual inspection, cleaning, and greasing.
- Regular Maintenance: Mandatory at least once a year by NOVOTEST to maintain warranty validity. Records of regular maintenance, including stamps from the authorized service center, are essential for warranty claims.
- Troubleshooting: A table of possible failures and their elimination methods is provided. For example, if the device does not turn on, check the power supply. If there is no measurement, check for breaks in the electronic circuit. If measurements are wrong, recalibrate the device and eliminate external factors.
- Running Repairs: Due to its design, the device should be repaired by specialized companies or the manufacturer. For warranty service, the registration certificate must be submitted.
- Storage: Store the device in its packaging container at +5 °C to +40 °C (recommended 10 °C – 30 °C) with relative humidity up to 80% at 25 °C. Avoid aggressive media vapors, direct sunlight, rapid shocks, falls, or strong vibrations. For long-term storage, the processing unit, transducer, and power unit should be preserved in separate plastic bags within the transportation case.
- Transportation: Packed devices can be transported by any carrier if they remain in the factory container, are protected from direct moisture, stay within -50 °C to +50 °C temperature, humidity does not exceed 95% at 35 °C, withstand vibrations (10-500 Hz, amplitude up to 0.35 mm, acceleration up to 49 m/s²), and shocks (peak acceleration up to 98 m/s²). Devices must be fastened in the vehicle to prevent falling or mutual bumps. After transportation from sub-zero temperatures, the device should be held in its container for 6 hours at room temperature to prevent moisture buildup.
- Disposal: The device does not contain dangerous or harmful substances. Disposal can be done according to common waste disposal practices, categorized by component type (plastic, metal, fastening). Recycling precious metals from electronic boards and connectors is not expedient due to their low content.
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