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GEInspection Technologies Ultrasonics

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BoltMike IIIOperating Manual

g 2005 General Electric Company. All rights reserved.We reserve the right to technical modifications without prior notice


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BoltMike III

Operation Manual

Ident-Nr. 021-002-168

Revision F2005 GE Inspection Technologies, LP

50 Industrial Park Road

Lewistown, PA 17044

Phone (717)242-0327 or (866) 243-2638

Fax (717) 242-2606

www.geinspect iontechnologies.com


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BoltMike III Operating Manual Page iii

The following information must be read and understood by any user of a GE Inspection Technologies measurementinstrument. Failure to follow these instructions can lead to errors in stress measurements or other test results.Decisions based on erroneous results can, in turn, lead to property damage, personal injury or death. GE InspectionTechnologies assumes no responsibility for the improper or incorrect use of this instrument.

General WarningsProper use of ultrasonic test equipment requires three essentialelements:

Selection of the correct test equipment

Knowledge of the specific test application requirements

Training on the part of the instrument operator

This operating manual provides instruction in the basic set-up and operation of the GE Inspection TechnologiesBoltMike III measurement instrument. There are, however, additional factors which affect the use of ultrasonic testequipment. Specific information regarding these additional factors is beyond the scope of this manual. The operator

should refer to textbooks on the subject of ultrasonic testing for more detailed information.

Operator TrainingRead the information in this manual prior to use of a GE Inspection Technologies instrument. Failure to read andunderstand the following information could cause errors to occur during use of the instrument. Failure to follow theseinstructions can lead to error in stress measurement or other test results. Decisions based on erroneous results can,in turn, lead to property damage, personal injury or death.

Operators must receive adequate training before using ultrasonic test equipment. Operators must be trained in generalultrasonic testing procedures and in the set-up required before conducting a particular test. Operators must under-stand:

Soundwave propagation theory

Effects of the velocity at which sound moves through thetest material Behavior of the sound wave

Which areas are covered by the sound beam

More specific information about operator training, qualification, certification and test specifications is available fromvarious technical societies, industry groups, and government agencies.

Important Notice


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Page iv BoltMike III Operating Manual

Testing Limitations

Information collected as a result of ultrasonic testing represents only the condition of test-piece material that is ex-posed to the sound beam. Operators must exercise great caution in making inferences about the test material not

directly exposed to the instruments sound beam. 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 evaluated areas, should only be attempted by personnel fully trained in applicable techniques of statistical

analysis.

Sound beams reflect from the first interior surface encountered. Operators must take steps to ensure that the entire

thickness of the test material is being examined.

Calibrating the instrument/transducer combination is particularly important when the test piece is being ultrasonically

tested for the first time or in any case where the history of the test piece is unknown.

Transducer Selection

The transducer used in testing must be in good condition without noticeable wear of its contact surface. Badly worn

transducers will have a reduced effective measuring range. The temperature of the material to be tested must be within

the transducers temperature range. If the transducer shows any signs of wear it should be replaced.


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BoltMike III Operating Manual Page v

Chapter 1: General Information ....................................................... 1

1.1 Key Features of the BoltMike III .............................................................. 11.2 BoltMike III Ultrasonic Inspection Kit..................................................... 11.3 Installing Batteries in the BoltMike III ................................................... 2

Chapter 2: Keypad, Display Screens, and Functions .....................5

2.1 Keypad Features .......................................................................................... 52.2 Interpreting Display Screens .................................................................... 62.3 Working With the Function Menu Screen ............................................ 10

2.3.1 Description of BoltMike III Functions ............................................ 10

Chapter 3: Instrument Setup ...........................................................13

3.1 Setting Basic Function Values ................................................................ 133.2 Creating a New Group .............................................................................. 14

3.2.1 Recalling Stored Groups ................................................................... 16

3.3 Connecting a Probe ................................................................................... 173.4 Instrument Zeroing ................................................................................... 173.5 Preventing Adjustments to Instrument Settings

(Lock-Out Control) ................................................................................... 19

Chapter 4: Inspecting Fasteners ....................................................2 1

4.1 Preparing for Inspection ........................................................................... 224.1.1 Adjusting the Displays Zoom Setting ............................................. 234.1.2 Selecting the Ultrasonic Operating Mode (I.P. or M.E.) .................. 254.1.3 Automatic Gain Compensation ........................................................ 274.1.4 Manually Adjusting Gain .................................................................. 274.1.5 Selecting the Displayed Phase .......................................................... 27

4.1.6 Setting High and Low Alarm Limits .................................................. 294.2 Inputting Ambient Temperature ............................................................. 304.3 Recording an L-Ref ................................................................................... 314.4 Measuring Tensioned Fasteners ............................................................. 32

4.4.1 Navigating Within a Group ............................................................... 334.4.2 Clearing (Deleting) Stored Readings from a Group........................... 344.4.3 Printing a Hard Copy of the Display (A-scan or Graphical Bar) ..... 36

Contents


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Page vi BoltMike III Operating Manual

Chapter 5: Working with Groups ....................................................39

5.1 Creating a New Group .............................................................................. 39

5.2 Recalling Stored Groups .......................................................................... 41

5.3 Copying an Existing Group ...................................................................... 42

5.4 Printing Stored Groups ............................................................................ 425.5 Deleting Stored Groups ............................................................................ 44

5.6 Editing Stored Groups .............................................................................. 44

Chapter 6: Calibration Groups ........................................................ 45

6.1 Creating a Calibration Group ................................................................. 46

6.2 Storing Measurements in a Calibration Group .................................... 48

6.3 Using Calibration Group Calculations .................................................. 50

Chapter 7: Specifications and Warranty ........................................51

7.1 Features ...................................................................................................... 51

7.2 Specifications ............................................................................................ 52

7.3 Instrument and Transducer Warranty .................................................... 53

7.4 Service ........................................................................................................ 55

7.5 Returning Goods ....................................................................................... 55

Index .................................................................................................. 57


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BoltMike III Operating Manual Page 1

Chapter 1: General InformationThe GE Inspection Technologies BoltMike III is an easy-to-use, digital, ultrasonic inspection instrument with a graphicwaveform display. It combines versatile fastener-inspection capabilities with a powerful data storage system thatscapable of storing up to 10,000 measurements.

1.1 Key Features of the BoltMike III

Lightweight 2.5 lbs (1.1 Kg)

Large A-scan VGA Display

30 hours life with 5 AA alkaline batteries

Easy-to-use, single-level menu system

Multiple display-screen languages Real-time temperature measurement

1.2 BoltMike III Ultrasonic Inspection Kit

BoltMike III Kit (062-900-063)

BoltMike III Instrument

AC Power Supply Temperature Probe

(2) Transducer Cables, Lemo to MD, 10 feet


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Page 2 BoltMike III Operating Manual

Hard-shell Transport Case

Ultrasonic Couplant

(5) AA Alkaline Batteries

Upgrade Utility CD

Serial PC Cable

Printer Cable

Soft-shell Carrying Bag

Operation Manual

Guide to Ultrasonic Inspection of Fasteners

Quick-Reference Operators Card

Certificate of Calibration Stressware, PC Software

1.3 Installing Batteries in the Boltmike III The instrument is powered by five AA size batteries.

It will accept Alkaline, NiCAD, or NiMH (nickel metalhydride) battery types.

Alkaline batteries, which are recommended, will provideapproximately 30 hours of service life.

When rechargeable batteries are used, they must beremoved from the instrument for charging.


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NOTE: It is recommended that the

instrument be stored with batteries installed.

Figure 1-1INSTALLING BATTERIES


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Chapter 2: Keypad, Display Screens, and FunctionsThe BoltMike IIIs displays, keypad, and functional commands are easy to interpret and use. In this chapter youll find a

brief explanation of all display and keypad features. Youll also find references to manual sections where more detailed

information is available.

2.1 Keypad Features

The keypad includes function (yellow), navigation (orange), group calibration (green), gain (red), and screen-display

(blue) keys. Each keys function is described below.

2.2 Interpreting Display Screens

Figure 2-1Keypad


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Figure 2-2A-SCAN DISPLAY SCREENDisplays A-scan, gates, active data-file

locations, length measurements, and those functions assigned to function keys.

2.2 Interpreting Display Screens

This section of your manual describes the layout of the BoltMike IIIs four display screens. The screens are:

A-scan Display Screen (Figure 2-2)

Graphical Limit Display Screen (Figure 2-3)

Function Menu Screen (Figure 2-4)

Group Navigation and Creation Screens (Figure 2-5)


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Figure 2-3GRAPHICAL LIMIT DISPLAY SCREENDisplays graphical

representation of load, elongation, or stress reading, along with

user-input maximum and minimum limits. Active data-file location,

length measurements, and function keys are also displayed. Note

that this display is obtained by setting RF DISPLAY to OFF in the

Function Menu screen (no A-scan is shown) and that this display is

not available unless values for High and Low Limits are specified

(see Section 4.1.6 to input limits).


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Figure 2-4FUNCTION MENU SCREENDisplays all functionalsettings and allows adjustment of function settings. See Section 2.3

to change function settings.


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Figure 2-5GROUP DISPLAY SCREENSCreates and displays group names,

parameters, and contents. See Section 3.2 to create and select groups and Chapter 5


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2.3 Working With the Function Menu Screen

The function menu screen is accessed by pressing . With this screen displayed, you can adjust most BoltMike III

settings.

Figure 2-6FUNCTION MENU SCREENUse this display screen to adjust all function


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DATEInputs the actual date

TIMEInputs the actual time

BATTERY TYPESelect the installed battery type to ensure accurate remaining battery-life indication. Choose fromAlkaline, NiMH, or NiCAD. (See Section 1.3 to install batteries)

POWER DOWNSelects the battery-life saving AUTO OFF, which powers down the instrument if no key presses ormeasurement occur for four minutes, or the ALWAYS ON setting, which will only power down the instrument when

is pressed.


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Chapter 3: Instrument SetupPrior to measuring fasteners, you must create at least one group in your instrument. The information stored in a groupdefines the type of fastener youre measuring, certain instrument settings, and measurement data from the fastener(s)inspected.

In preparation for measuring fasteners, this chapter explains how to Adjust function settings (Section 3.1)

Create a new group (Section 3.2)

Select an already created group (Section 3.2.1)

Connect a probe (Section 3.3)

Zero the instrument and connected probe (Section 3.4)

Disable instrument controls (Section 3.5)

3.1 Setting Basic Function Values

Prior to creating the first group in your instrument, the following functions must be set to the correct value:

LanguageSet the displayed language to English, German,French, Spanish, Italian, or Russian

DecimalSelect a period (.) or comma (,) to be used as adecimal point

UnitsSet the unit of measurement to inches or millimeters

Date FormatChoose the date format as Month/Day/Year,Year-Month-Day, or Day.Month.Year

Time FormatChoose from 12 or 24 hour clocks


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DateInput the actual date

TimeInput the actual time

Battery TypeSelect from Alkaline, NiCAD, or NiMH

Temperature (must be manually set unless the temperatureprobe is connected)Set to current ambient temperature

Each of these functions is set the same way:

Step 1: Press to access the Function Menu display(shown in Figure 2-4).

Step 2: Press , , , or to select each function you would like to modify.

Step 3: When the desired function is selected, press to activate it. The functions value will appear in the box atthe bottom of the display screen.

Step 4: Press or to adjust the files value.

Step 5: Press when the function is set to the desired value.

Step 6: Continue selecting other functions for modification as outlined in Steps 2 through 5. When complete with all

modifications, press to return to the A-scan display.

NOTE: The settings for the time, date, and temperature functions,

at the time a group is created, are permanently stored as part of the groups data.


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3.2 Creating a New Group

Prior to performing fastener measurements, at least one group must be stored in your instrument. This stored boltgroup will contain information about the type of fastener youre measuring and certain instrument settings. This group isalso where youll store measurement data from the bolt(s) inspected.

the connected probe must be zeroed. To zero the instrument, follow the instructions in Figure 3-3 and on your

instruments display screen.

Figure 3-1CREATING NEW GROUPS


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3.2.1 Recalling Stored Groups

Stored groups can be recalled and modified at any time. To recall a group:

1 Press to open the Group Display Screen

2 Activate the group selection function by pressing below the SELECT function. A group list will appear in theupper-left corner of the display.

3 Press to select the group to recall, then press .

NOTE: The instructions for creating a new group, as explained in this section, assume that your inspection application involves a

standard fastener type. Properties for standard material types B7, B16, 8.8, 9.8, 10.9, 11.9, 12.9, 304SS, 316SS, 1020S, Monel, and

A490 are stored in your instrument and cannot be modified.To adjust any of these preloaded material properties, select MATERIAL

on the NEW GROUP creation screen, and then press for CUSTOM material. Once selected, the custom material type must

be named using the on-screen keyboard. Then press to complete naming. Now all material properties can be

adjusted.Custom material names can only be changed by first pressing to select the material name (on the Group Display

screen) then pressing to edit. The new custom material type is added to the material selection list. Up to a total of 10 custom

types can be added and are then available for selection whenever a group is created or edited. When more than 10 custom materials

are added, the oldest materials are overwritten by the newest ones. During instrument reset, all custom material types will be deleted.

Be sure to store (in StressWare) groups containing custom material types you wish to retain prior to resetting the instrument.

NOTE: To create a new group containing group-parameter values (and fastener reference lengths if you choose) that match those of


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Figure 3-2CONNECTING A PROBE CABLE

3.3 Connecting a Probe

Prior to inspecting a fastener, you must connect a probe to the instrument and perform the zeroing procedure. The

BoltMike III supports single-element probe types (see Chapter 7 for specifications).

NOTE:When operating in the I.P. mode, probe zeroing compensates for the effects of probe-contact-surface

wear, couplant thickness, and other factors. Note that the External Zero procedure also compensates for tem-

perature changes. Internal Zero does not.


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Figure 3-4THE EXTERNAL INSTRUMENT ZEROING PROCEDURE ALLOWS THE USER TO

ZERO USING A KNOWN THICKNESS STANDARD. NOTE THAT THE EXTERNAL ZERO

Figure 3-3INSTRUMENT ZEROING PROCEDURE


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3.5 Preventing Adjustments to Instrument Settings

(Lock-Out Control)

The Lock-Out display, to which access is controlled by a password, allows certain of the instrument functions to be

disabled.

As shown in Figure 3-5, the Lock-Out display is accessed by simultaneously pressing and . The user must

then input a password (the default is set to STRESS) before being able to adjust the Lock-Out settings. Locking the

individual functions has the following effects:

GROUPS Locked is disabled

GROUP CAL Locked is disabled

INST ZERO Locked is disabled

MENU Locked is disabled

L-REFS Locked Stored L-Ref readings cannot be cleared

NOTE: This display allows you to change the password setting. Simply select the

PASSWORD options, then press to activate the on-screen keyboard and modify

the password itself.


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Figure 3-5SEVERAL INSTRUMENT FUNCTIONS CAN BE DISABLED OR LOCKED-OUT USING THIS


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Chapter 4: Inspecting FastenersThis chapter explains how to use your instrument to inspect fasteners and how to view the results of these inspections in

various ways. In this chapter, youll learn how to:

Prepare for inspection by setting operating parameters tomatch the fastener you are inspecting (Section 4.1)

Configure the instrument to signal when minimum and

maximum tension limits are met (Section 4.1.6)

Input the current ambient temperature (Section 4.2)

Measure and store a reference fastener length (L-Ref)

(Section 4.3)

Inspect tensioned bolts and store the resulting data in a

group (Section 4.4)

View an assortment of calculated values related to the

tensioned fastener, including load, elongation, stress, and

time of flight (TOF) (Section 4.4.1)

Delete one or more stored values from the contents of a

group (Section 4.4.2)

Print a hard copy of the display and certain instrumentsettings (Section 4.4.3)

Once your instrument contains at least one group and has been configured with the correct function settings (as outlined in

Chapter 3), you may begin inspecting fasteners and storing the results of these inspections in a group.


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4.1 Preparing for Inspection

Prior to inspecting fasteners and storing the results in your newly created group, several parameters specific to thetype of fastener being tested must be set. These settings are listed below and described in more detail in the sectionsthat follow.

Its important to note that the preparations listed below must be completed prior to recording the reference length (L-Ref) for a specific fastener. Several of the five adjustments listed below may not be altered after an L-Ref has beenrecorded. To prepare for fastener inspection:

Adjust the display screens zoom setting Select the ultrasonic operating mode (Initial Pulse or Multi-

Echo) that best suits the specific fasteners geometry

Apply Automatic Gain Compensation (AGC)

Manually adjust gain (if required)

Select the measured phase

NOTE: Following the instructions in this chapter will allow you to

satisfy most typical fastener inspection requirements. For inspection of

non-standard fastener types that require the creation of a Calibration

Group and calculation of material properties, see Chapter 6.

NOTE: Decisions related to operating modeselection, phase selection, AGCactivation, and manual gainadjust-

ments should only be made by individuals who fully understand the impact these changes will have on fastener-inspection results. An explanation of these effects is beyond the scope of this operators manual. If additional informa-

tion is required, refer to GE Inspection Technologies Guide to Ultrasonic Inspection of Fasteners.


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4.1.1 Adjusting the Displays Zoom

Setting

The Zoom control allows an A-scan to be viewed at different magnification levels for different reasons (Figure 4-1). Each

zoom level represents a different range setting. In this case range refers to the amount of time represented on thedisplays horizontal axis. The BoltMike III has four zoom levels, each useful for a different aspect of A-scan evaluation:

ZOOM LEVEL 1used to confirm that the desired

packet of echoes is being evaluated

ZOOM LEVELS 2 through 4used to confirm that the

same peak is triggering the measurement gate for corre-

sponding reference (L-Ref) and fastener measurements

Note that the displayed view in zoom levels 2 through 4 is simultaneously enlarged and shifted to maintain the trigger-ing position in the center of the display window.

Youll need to adjust zoom levels while determining the optimal gain, phase, and operating mode settings for the type

of fastener you are inspecting. Note that the primary reason for adjusting zoom settings is to confirm which echo is

triggering the gate (when L-Ref is recorded, for instance), and therefore ensure that like echoes are compared when

calculating fastener loading and elongation.


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Figure 4-1FOUR ZOOM LEVELS. Youll use the zoom feature to closely examine the A-scan gate crossing

and ensure that like echoes are triggering the gate.


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4.1.2 Selecting the Ultrasonic Operating Mode (I.P. or M.E.)After a new group is created and before the first reference length

(L-Ref) is recorded, you must select an operating mode. You must select an operating mode each time you store an L-

Ref value. However, after an L-Ref is recorded, you may not change the operating mode while inspecting that fastener.

With a probe connected to the instrument and coupled to the fastener you wish to inspect, press to view the

difference between the two operating modes. In addition to the visual display changing, you will probably see some

small change in the measured length when switching from one operating mode to the other. The effect of ultrasonic

operating mode selection on the A-scan may differ when load is applied to the fastener. Because of this, the best

ultrasonic operating mode for a specific fastener type can only be determined from previous experience or by ultrasoni-

cally examining the fastener in both its loaded and unloaded states. Only by evaluating the fastener when tensioned

can you determine which ultrasonic operating mode is best suited to the fasteners geometry.

The BoltMike III can operate in one of two ultrasonic operating modes:

Initial Pulse (I.P.)All calculations are based on the

time to the zero crossing in the first A-scan packet.

Multi-Echo (M.E.)All calculations are based on the

time between zero crossings in the first and second

packets.

Fastener geometry is usually the determining factor to be considered when selecting between operating modes. Figure

4-2 shows the way in which these modes differ.

As multi-echo mode compares two adjacent gate crossings, this operating mode eliminates errors caused by varia-tions in couplant, zeroing techniques, probe characteristics, and operator factors such as the force with which the

probe is applied.


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To select an ultrasonic operating mode, the A-scan display screen must be active. Prior to recording the first L-Ref,

press to choosebetween I.P. (initial pulse) and M.E. (multi-echo). Remember that after an L-Ref reading is stored,

the operating mode for that bolt may not be changed and the operating mode selection will no longer be visible on the

display screen.

Figure 4-2INITIAL PULSE AND MULTI-ECHO ULTRASONIC

OPERATING MODES

NOTE: Operating mode selection will affect the phase settings

available as described in Section 4.1.5.


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4.1.3 Automatic Gain Compensation

The Automatic Gain Compensation (AGC) feature, when applied by pressing , adjusts the instrument gain so that

the gate-triggering echo is positioned between 80% and 100% of full-screen height (FSH). At any time, you may manu-

ally adjust the gain setting as required. However, pressing will reapply the AGC-determined gain level.

4.1.4 Manually Adjusting Gain

Instrument gain level affects the instrument sensitivity and A-scan height. To manually adjust gain when in I.P. operating

mode, press to activate the GAIN CONTROL feature. Notice that the GAIN designation on the display screen will

become highlighted. Then press or to change the gain setting. When complete, press again. This will

deactivate the GAIN CONTROL feature.

When in M.E. (multi-echo) operating mode, there are two GAIN CONTROL settings, one for each display screen.

Simply adjust the first gain setting (as described above), press once, and adjust the second gain setting. When

the second gain setting has been adjusted, press for a third time to deactivate the GAIN

CONTROL feature.


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Figure 4-3NEGATIVE (A) AND POSITIVE (B) HEADING PHASE SETTINGS WHEN IN I.P. MODE. IN

M.E. MODE VARIOUS COMBINATIONS OF POSITIVE AND NEGATIVE PHASE SETTINGS ARE


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4.1.5 Selecting the Displayed Phase

The BoltMike III measures linear position based on the first zero crossing point after the gate threshold has been trig-

gered. Figure 4-3 identifies the zero level (which is approximately equal to a horizontal line drawn through the center of

the A-scan display), threshold gate,

and threshold triggering point when operating in I.P. mode. Note that once an L-Ref is recorded, the phase orientation for

that fastener cannot be changed unless the stored L-Ref is deleted.

The instruments Phase Setting (adjusted by pressing prior to recording an L-Ref) allows the user to position the

threshold above or below the displays zero level. When operating in M.E. mode, the two gates can be independently

positioned above or below the displays zero level, allowing for a total of four phase settings. When the gate is placed

above the display zero, as shown in Figure 4-3A, the next zero crossing after the threshold trigger will occur on a nega-

tive-heading portion of the signal. Conversely, when the gate is placed below the display zero (Figure 4-3B), the next zero

crossing after the threshold trigger will occur on a positive-heading portion of the signal.

The effect of phase setting on the A-scan may differ when load is applied to the fastener. Because of this, the best

phase selection for a specific fastener type can only be determined from previous experience or by ultrasoni-

cally examining the fastener in its loaded and unloaded state. Only by evaluating the fastener under load can you

determine which phase setting is best suited to the fasteners geometry.

NOTE: Decisions related to operating modeselection, phase selection, AGCactivation, and manual

gainadjustments should only be made by individuals who fully understand the impact these changes will

have on fastener-inspection results. An explanation of these effects is beyond the scope of this operatorsmanual. If additional information is required, refer to GE Inspection Technologies Guide to Ultrasonic

Inspection of Fasteners.


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Figure 4-4SELECTING LIMIT TYPE AND SETTING THE HIGH

AND LOW LIMIT VALUES

4.1.6 Setting High and Low Alarm Limits

The BoltMike IIIs display panel indicates when a High or Low limit is violated. The type of limit (Load, Stress, Elonga-

tion, or Off) is selected. Then the Group Display screen is accessed, as shown in Figure 4-4, to set the High and Low

Limit values. To signal whether or not a limit is violated, one of the following icons appears in the upper-left corner of the

display:

The High Limit has been violated

Within the limits

The Low Limit has been violated


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4.2 Inputting Ambient Temperature

Current temperature is displayed in two locations (top-left and top-right corners) on the A-scan display panel. TheBoltMike III allows temperature data to be input in one of two ways:

The user may manually enter an ambient temperature byaccessing the Function Control Menu, activating the

TEMPERATURE function, and adjusting the value by

pressing or .

When the external temperature probe is connected (see

Figure 3-2 to connect the temperature probe), it automati-

cally supplies an updated temperature to the instrument.

NOTE:When ambient temperature is entered manually, the

temperature value shown in the upper left corner of the A-scan display screen will be enclosed by a box. The box will not

be visable when the temperature probe is connected. The

manual temperature setting capability is disabled when the

external temperature probe is connected to the instrument.

In operating environments where temperatureschange during the measurement process, thedisplayed temperature at the time an

L-Ref or fastener measurement is recorded will bestored along with the ultrasonic reading and utilizedin fastener calculations. These stored temperaturevalues can be viewed from the group display screen

as shown in Figure 4-5.Figure 4-5TEMPERATURE DATA


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4.3 Recording an L-Ref

The BoltMike determines fastener loading by comparing tensioned and unloaded measurements taken from the same

fastener. A reference length (L-Ref) must be recorded for a fastener prior to recording the fasteners as-installedtensioned measurement.

The unstressed measurement, known as the reference length or L-Ref, is typically recorded for each fastener in a

group prior to field installation. During this process the operator will identify each fastener with a number correspond-

ing to its group name and number. After a fastener is installed, a tensioned reading is stored for each fastener.

Couple the probe to the head of an unstressed fastener (see GE Inspection Technologies Guide to Ultrasonic

Inspection of Fastenersto properly prepare a fastener for inspection). Prior to recording an L-Ref, be sure youve

completed the steps outlined above, including:

Adjusted the displays zoom setting

Adjusted gain (if required)

Figure 4-6A REFERENCE LENGTH (L-REF) MUST


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NOTE:Tensioned-fastener measurements may not be recorded for a specific fastener until a non-tensioned reference

length (L-Ref) has been recorded for that fastener. See the previous manual section to record an L-Ref measurement.

4.4 Measuring Tensioned Fasteners

Tensioned fastener measurements for a specific fastener must be stored in the same group, and the same fastener-

number position, as the L-Ref for that fastener. With the desired group and fastener number active, follow the proce-

dures in Figure 4-7 to store tensioned-fastener measurements of LOAD, STRESS, and ELONGATION.

Figure 4-7RECORDING A MEASUREMENT FOR A TENSIONED FASTENER


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4.4.1 Navigating Within

a Group

There are three ways to navigate from one

fastener to another within the active group. First,

if the A-scan screen is displayed and more than

one fastener is stored in the active group, it is

possible to navigate through the fastener posi-

tions (and tightening stages, if applicable) as

shown in Figure 4-8.

Alternatively, pressing allows you to

search the active group for a specific fastenername, or scroll through all fasteners in the group

as shown in Figure 4-9.

4.4.2 Clearing (Deleting)

Stored Readings

from a Group

To delete a single stored (tensioned) readingfrom a group:

Step 1: Navigate to the fastener and stage

number as shown in Figure 4-8.

Figure 4-8VIEW FUNCTION AND NAVIGATING WITHIN


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Step 2: Provided there is a measurement stored in the active fastener, the CLEAR function will appear at the bottomof the A-scan display. Press and hold to clear the reading.

To delete a stored L-Ref reading from a group:

Step 1: Navigate to the fastener and stage number as shown in Figure 4-8.

Step 2: Now make the L-Ref reading active (by pressing if required), then press and hold to activate theCLEAR function.

Step 3: Deleting a fasteners L-Ref reading will cause the instrument to automaticallydelete all tensioned readings f

Figure 4-9PRESS TO ACCESS THIS SCREEN AND SEARCH FOR A SPECIFIC FASTENER NAME OR

SCROLL THROUGH ALL FASTENERS IN THE GROUP. THIS SCREEN ALSO ALLOWS YOU TO EDIT FASTENER

NAMES.


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4.4.3 Printing a Hard Copy of the Display

(A-scan or Graphical Bar)

The BoltMike III can be connected directly to a printer to output a hard copy print of the A-Scan or Graphical Bardisplay screen. The printed hard copy will also include a listing of some instrument settings and measured values. (To

print the contents of a stored group which will not include a hard copy of the display screen refer to Section 5.4.)Before printing an A-scan hardcopy, you must do the following:

Step 1: Connect the printer to the instrument using the correct printer cable.

Step 2: Press to access the Function Menu Screen

Step 3: Press and until the PRINTER function is selected. Press and use to specify the type ofprinter attached. Printer options are:

EPSON IJETEPSON (dot matrix)

DPU-414DPU-411HP LASERHP IJET-S (ink-jet serial)HP IJET

Step 4: Press until the BAUD RATE function is selected. Press and use or to input the connectedprinters rate.

Once the instrument is configured for the connected printer, you can continue with the A-scan hard copy printingprocess. The printed hard copy will include:

Date

The entire display screen Measurement mode

Gain setting


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Units of measurement

Probe coupled status

Group parameter values

Current fasteners reference length Display-screen listing of measured load, stress, and

elongation

Material type (or custom-material name)

Input or standard material properties

Stress ratio and offset corrections

Step 5: Access the A-scan or Graphical Bar Display Screen. A probe should be connected and coupled, and the A-

scan image should appear as desired before printing. Do not store the measured load as this will cause the PRINTcommand to be replaced by the CLEAR command.

Step 6: Press to print a hardcopy of the A-scan. All settings and values listed above will be included in the

printed hard copy.


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Chapter 5: Working with Groups

Fastener measurements taken with the BoltMike III are stored in groups. In addition to fastener reference (unstressed)

and tensioned lengths, the stored bolt group contains information about the type of fastener youre measuring and

certain instrument settings. Before measuring fasteners, at least one group must be stored in your instrument. In

this chapter youll learn how to

Create a new group (Section 5.1)

Recall a stored group (Section 5.2)

Copy an existing group (Section 5.3)

Print the contents of a group (Section 5.4)

Delete an existing group (Section 5.5)

Edit an existing group (Section 5.6)

5.1 Creating a New Group

To create a new group, you must only specify a group name. In most cases, however, youll wish to enter additional

information. Most often youll indicate the material type and physical characteristics of the fastener being tested, the

number of fasteners youre testing, and the number of tensioning stages after which you wish to measure fastener

loading. You may also enter comments related to the bolt group and a specific name for the type of fastener being

tested.

Follow Steps1 through 9 in Figure 5-1 to create a new group:


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Page 40 Operation Manual BoltMike III

NOTE: The instructions for creating a new group, explained in this section, assume that your inspection application involves a

standard fastener type. Material properties for types B7, B16, 8.8, 9.8, 10.9, 11.9, 12.9, 304SS, 316SS, 1020S, Monel, and

A490 are stored in your instrument and cannot be modified.To adjust any of these pre-loaded material properties, select

MATERIAL on the NEW GROUP creation screen, and then press for CUSTOM material. Once selected, the custom

material type must be named using the on-screen keyboard. Then press to complete naming. Now all

material properties can be adjusted.Custom material names can only be changed by first pressing to select the

material name (on the Group Display screen) then pressing to edit. The new custom material type is added to the

material selection list. Up to a total of 10 custom types can be added and are then available for selection whenever a group is

created or edited. When more than 10 custom materials are added, the oldest materials are overwritten by the newest ones.During instrument reset, all custom material types will be deleted. Be sure to store (in StressWare) groups containing custom

material types you wish to retain prior to resetting the instrument.

Figure 5-1CREATING A NEW GROUP


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5.2 Recalling Stored Groups

Stored groups can be recalled and modified at any time. To recall a group:

Step 1: Press to open the Group Display Screen

Step 2: Activate the group selection function by pressing below the SELECT function. A group list will appear in

the upper-left corner of the display.

NOTE:To create a new group containing group-parameter values that match those of any stored group (including

number of fasteners, material type and properties, comments, and number of stages but not the fasteners refer-

ence lengths), simply make the group whose parameter values you wish to copy active at the time you create a new

group. The newly created group will have, as its default parameter values, the settings of the active group at the time

the new group was created. Of course any or all of these parameter values can be modified during the group creationprocess. To copy group-parameter values andfastener reference lengths see Section 5.3.

NOTE: The user assigned APPROXIMATE LENGTH sets the triggering gates position and width. When the user

enters an approximate length that is less than 10 inches, the gate width is automatically set to 2 inches and its

starting point is placed at a location thats 1/8 inch shorter than the approximate length. When the user enters an

approximate length that is greater than or equal to 10 inches, the gates width is set to 10% of the entered length (with

a minimum width of 2 inches). In this case the gate is positioned so that it is centered about the user entered approxi-

mate length.


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5.3 Copying an Existing Group

Group parameter values (including number of fasteners, material type and properties, comments, and number of

stages) and fastener referencelengths of any stored groups can be copied to a new group. To copy a group, it must

first be recalled (as described above). To copy the active group:

Step 1: Press to open the Group Display Screen.

Step 2: Activate the group copy function by pressing below the word COPY. The on-screen keyboard will

appear on the right side of the display.

Step 3: Enter the new groups name (as shown in Step 2 of Figure 5-1), and then press when the name has

been entered. The newly created file will now be active.

5.4 Printing Stored Groups

Before sending a groups contents to a printer, you must do the following:

Step 1: Connect the printer to the instrument using the correct printer cable.

Step 2: Press to access the Function Menu Screen

NOTE:To create a new group containing group-parameter values that match those of any stored group (including

number of fasteners, material type and properties, comments, and number of stages but not the fasteners refer-

ence lengths), simply make the group whose parameter values you wish to copy active at the time you create a new

group. The newly created group will have, as its default parameter values, the settings of the active group at the time

the new group was created. Of course any or all of these parameter values can be modified during the group creation

process.


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Step 3: Press and until the PRINTER function is selected. Press and use to specify the type of

printer attached. Printer options are:

EPSON IJET

EPSON (dot matrix)

DPU-414

DPU-411

HP LASER

HP IJET-S (ink-jet serial)

HP IJET

Step 4: Press .

Step 5: Press until the BAUD RATE function is selected. Press and use or to input the connected

printers rate.

Step 6: Press .

Once the instrument is configured for the connected printer, you can continue with the group printing process. A printed

group will include:

All reference and tensioned length measurements stored in

NOTE: The following procedure explains how to print the contents

of a stored group. To print the active A-scan display (as well as a

limited listing of instrument settings and measured values), refer

to section 4.4.3

the group

Groups material type, material properties, comments, limitsand other information which was input when the group wascreated

Step 7: Press to access the Group Display Screen.

Step 8: Press to send the selected group to the printer. All features listed above will be included in the printedoutput.

Step 9: Follow the on-screen instructions to select the group to be printed. Then press .


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Step 3: Press to select the stored group you wish to recall, and then press .

5.5 Deleting Stored Groups

Stored groups can be deleted at any time. Once deleted, the contents of a group may not be restored. Note that section4.4.2 explains how to CLEAR (delete) individual values within a group without deleting the entire group. To delete anentire group:

Step 1: Press to open the Group Display Screen

Step 2: Activate the group selection function by pressing below the SELECT function. A group list will appear inthe upper-left corner of the display.

Step 3: Press to select the stored group you wish to delete, press to make the group active, and then pressbelow the DELETE function.

Step 4: As prompted on the display screen, press and hold for three seconds to confirm the command to

DELETE the group.


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5.6 Editing Stored Groups

After a group is created, the value of those group parameters listed below may be edited. Note that when the change ingroup-parameter value effects the calculation of load, stress, or elongation, editing the parameter value will cause theinstrument to automatically modify these calculated outputs.

Approximate Length Effective LengthX-Sectional Area Stress RatioStress Offset Bolt NameStage Name Reference TemperatureMeasured Temperature Limit TypeLow Limit High LimitBolt Comment Group Comment

Material Type Custom Material Properties


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When material-property constants are not known or when a high level of accuracy is desired, calibration groups areused. A calibration group can be created using a single fastener or as many as nine fasteners. To create a calibrationgroup, known tensile loads are applied to a fastener while the fasteners response is measured. The known tensileloads, corresponding to each tensioned fastener measurement, are inputted into the BoltMike III. The instrument thenuses the calibration data to calculate Stress Offset and/or Stress Ratio values.

In this chapter, youll learn how to

Create a new calibration group (Section 6.1)

Store measurements in a calibration group (Section 6.2)

Apply the corrections calculated by the calibration group toconventional groups (Section 6.3)

The BoltMike III relies on ultrasonic inspection techniques to determine fastener loading, elongation, and other values.The accuracy of load and elongation calculations depends on many factors. Two major influences on the accuracy ofthese calculations are the material-property constants used and the fastener systems physical characteristics.

While the material-property constants (including elasticity, acoustic velocity, and yield strength) are considered to bestandard values, actual material properties vary widely. This variation is even found among fasteners produced in thesame manufacturers lot. When recording measurements in a conventional BoltMike III group, the accuracy of load andelongation calculations depends partly on the difference between the fasteners actual material properties and thoseproperties represented by the standard material constants. Similarly, variations in fastening systems physical charac-teristics (such as thread geometry) affect the accuracy of load and elongation

calculations.

When BoltMike III users desire to calculate load, elongation, stress, or TOF (time of flight) values within 5% (or less) of

the actual value, they generally choose to create calibration groups.

Chapter 6: Calibration Groups


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6.1 Creating a Calibration Group

To create a new calibration group, you must first specify a group name, the material type and physical characteristics

of the fastener being tested, the number of fasteners youre testing, and the number of LOAD levels at which youll

record fastener reaction (to a maximum of nine fasteners and nine loads each). You may also enter comments related

to the calibration group and a specific name for the type of fastener being tested. Refer to Figure 6-1 and follow Steps1

through 8 below to create a new Calibration Group:

Step 1: Press to open the NEW CAL GROUP Display Screen shown in Figure 6-1(A).

Step 2: Use the on-screen keyboard to input a Calibration Group name. Note that Cal Group names always begin

with the character *. Press (DONE) to store the group name.

variations in fastening systems physical characteristics (such as thread geometry) affect the accuracy of load andelongationcalculations.

When BoltMike III users desire to calculate load, elongation, stress, or TOF (time of flight) values within 5% (or less) of

the actual value, they generally choose to create calibration groups.

NOTE: Decisions related to the creation of a calibration group should only be made with

full understanding of their impact on the accuracy of fastener inspections. If additional

information is required, refer to GE Inspectiion Technologies Guide to Ultrasonic Inspection

of Fasteners.


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Figure 6-1CREATING CALIBRATION GROUPS

Step 3: Press or to select each group param-

eter you wish to adjust, and then press to activate the

highlighted parameter. Note that when creating a calibration

group you must specify the number of fasteners youll test

during the calibration process, and the number of known

loads youll apply to each fastener. Figure 6-1(B)

Steps 4, 5, 6: Follow the on-screen instructions tochange the value of the highlighted feature. Figure 6-1(B)

Step 7: If you wish to input material-property constantsother than the standard values stored in your instrument,select the Cal Group feature tit led MATERIAL, and thenpress to input a CUSTOM material type. This CUS-TOM function requires that you name the new material type

by pressing and allows you to adjust the value of eachmaterial constant. See Section 5.1 for more instructions onnaming, editing, and deleting custom material types.

Step 8: Press to CREATE the Cal Group. Figure 6-1(B)

Reference and tensioned fastener data must be stored priorto calculating the Calibration Groups Stress Offset and/orStress Ratio. Refer to Section 6.2 to store measurements in

the calibration group and calculate these parameters.


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NOTE:To create a new cal group containing group-parameter values that match those of any stored group(including number of fasteners, material type and properties, and comments, but not the fasteners refer-

ence lengths), simply make the cal group whose parameter values you wish to copy active at the time you

create a new group. The newly created cal group will have, as its default parameter values, the settings of the

active group at the time the new group was created. Of course any or all of these parameter values can be

modified during the cal group creation process.

Step 8: Press to CREATE the Cal Group. Figure 6-1(B)

Reference and tensioned fastener data must be stored prior to calculating the Calibration Groups Stress Offset and/or

Stress Ratio. Refer to Section 6.2 to store measurements in the calibration group and calculate these parameters.

6.2 Storing Measurements in aCalibration Group

Once a new calibration group is created, reference (non-tensioned) and tensioned measurements must be stored for

each fastener in the group. Calibration groups are selected for activation just like any other group by pressing ,

then pressing and scrolling through the list of available groups. Remember, calibration group names are preceded

with the character *.

L-Ref (non-tensioned) and tensioned measurements must be recorded for each fastener in the calibration group before

the Stress Offset and/or Stress Ratio calculations can be made. To store these values, a source of known tensile load

must be available. Refer to GE Inspection Technologies Guide to Ultrasonic Inspection of Fastenersfor detailed

information related to collecting loaded-fastener calibration data.


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NOTE:Prior to calculating the correction factor(s), the instrument will prompt you to choose between a

REGRESSION (calculates Stress Offset and Ratio) or VECTOR calculation. If you require additional informa-

tion when choosing the calculation method, then refer to GE Inspection Technologies Guide to UltrasonicInspection of Fasteners.

Figure 6-2 (Part 1)STORING MEASUREMENTS IN A CAL GROUP

Refer to Figure 6-2 (Parts 1 and 2) and follow Steps1through 10to store fastener measurements in a Calibration

Group.


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Figure 6-2 (Part 2)STORING

6.3 Using Calibration Group Calculations

The procedures listed in Sections 6.1 and 6.2 allow a cal group to be created and Stress Offset and/or Stress Ratio to

be calculated. There are two ways to apply the resulting correction factors to other groups. First, create a conven-

tional group (Section 5.1). While creating the conventional group, input the Stress Offset and/or Stress Ratio valuesfrom the cal group. Alternatively, copy the contents of the cal group and adjust the number of fasteners to satisfy

requirements.

(Section 5.3)


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Chapter 7: Specifications and WarrantyThe following lists the features and specifications of your BoltMike III. This chapter concludes with warranty information

for your BoltMike III.

7.1 Features

The BoltMike III offers many standard features including:

A-Scan display of waveform with automatic gainadjustment

Alternative LARGE DIGIT and bar-graph display feature

Operator-controlled zoom

User initiated probe / instrument zeroing

Calibration for non-standard fastener and material types

Unlimited input of special material types and properties

Sufficient memory to store up to 512 Groups and 10000

bolts

Printed reports that can be sent directly to various types ofprinters

STRESSWARE (Windowsbased) software allows fortwo-way communication between instrument and PC.Report, group parameters, and measurements can betransmitted to and from the instrument.

Software upgrades can be accomplished by operators


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International (Multi-Language, Date and Time Formats)user interface that offers the following languages:

English

French

German

Spanish

Italian

Russian

Japanese (availability will be based on demand)

7.2 Specifications

Bolt Measurement Range: 0.75 inch to 2 50 inches

Measurement Resolution: 0.0001 inch

Load measurement accuracy: 2%

Operating temperature range: 10C to +50C

Temperature measurement: External temperature transducer provides automatic updating (manual input is also possible)

Display Type: Graphic Waveform LCD (1/4 VGA)

Display (w x h): 3.8 x 2.8 inches (320 x240 pixels)

Display update: 4 Hz

Display Adjustments: Contrast, backlight, and four-stage zoom


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Memory: 512 bolt groups; 10000 bolts

Power Supply: 5 AA batteries (alkaline, NiCad, NiMH) or external AC to DC power convertersupply.

Battery Life: Up to 30 hours

Measurement Methods: Ultrasonic Single Echo and Multiple-Echo

Operational Adjustments: Phase Selection, Automatic Gain Compensation, and Manual Gain Adjustment

Dimensions (w x h x d): 7.5 x 5.5 x 2.2 inches

Weight: 2.5 lbs.

Probe: Single Element Magnetic

CE Compliance This instrument was evaluated and found to be within compliance of thefollowing test specifications:

EN 55011:1991 Group 2 Class AEN 61000-4-3:199780-1000MHz, 1.4 GHz - 2GHz

10 V/m, Criteria AEN 61000-4-4:1995 Criteria AEN 61000-4-5:1995 Criteria BEN 61000-4-6:1995 Criteria A


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To any parts of an instrument or transducer, which, under normal usage, would not or are not expected tolast the warranty period, i.e. wear items (i.e. batteries and cables).

To any instrument or transducer, which have not been subject to proper care and maintenance.

GE Inspection Technologies shall not be liable for any damages, whether direct or indirect, economic,commercial, incidental, or consequential, and whether arising from GE Inspection Technologies

negli gence, breach of contract, product liability, warranty or any other reason.

To any instruments or transducer not manufactured by GE Inspection Technologies. For equipmentfurnished, but not manufactured by GE Inspection Technologies, GE Inspection Technologies

assigns to the Buyer any warranty and/or claim it may have against the manufacturer or

supplier of the equipment.

THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY OTHER WARRANTIES, EXPRESSED OR IMPLIED INCLUDING

ANY IMPLIED OR EXPRESSED WARRANTY OF MERCHANTABILITY, SUITABILITY OR FITNESS FOR A PARTICU-

LAR PURPOSE and GE Inspection Technologies neither assumes nor authorizes another to assume any liability inconnection with such equipment, except as provided above.

7.4 Service

Every effort has been made to provide you with a reliable product. However, should service become necessary contact:

SERVICE DEPARTMENT

GE Inspection Technologies, LP

50 Industrial Park RoadLewistown, PA 17044

Telephone (717) 242-0327 or (866) 243-2638

Fax (717) 242-2606


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7.5 Returning Goods

Please return any materials or goods for repair directly to GE Inspection Technologies Service Department at 50

Industrial Park Road, Lewistown, PA 17044. An RMA number is not needed. Items returned shall be shipped in an

appropriate manner. Customers shipping from outside the USA should send instruments returned for repair via UPS if

possible. Shipping charges and duties/customs fees are the responsibility of the customer.


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IndexA

A-scan Display ........................... ............................... ............................... .......................... 6

AGC ..................... .............................. .............................. .............................. .................... 27

Alarm Limits ..................................................................................................................... 30

Alarm Lamp .............................. .............................. .............................. ......................... . 30

ALWAYS ON ................... .............................. .............................. .............................. .......... 11

Ambient Temperature ................................................................................................. 31

APPROXIMATE LENGTH ............................ ............................... .............................. ........ 41

AUTO OFF ..................................... .............................. .............................. ......................... 11

Automatic Gain Compensation .................................................................................. 27

B

BACKLIGHT ............................. .............................. .............................. .............................. 11

Batteries ........................... ............................. .............................. .............................. ........ 2

BATTERY TYPE ........ .............................. .............................. .............................. ............... 11

Battery Type .............................. .............................. .............................. .......................... 14

BAUD RATE ........ .............................. .............................. .............................. ..................... 43

C

Calibration Group Calculations ........................... ............................... ........................ 50

CalibrationGroups ............................ ............................... .............................. ................ 45

Clearing (Deleting) Stored Readings from a Group .............................................. 34

CONTRAST ............................ .............................. .............................. .............................. .. 11

Copying an Existing Group ........................... ............................... .............................. .. 42

Creating a Calibration Group ............................ .............................. ............................ 46

Creating a New Group ............................. ............................ ............................ ............. 39

D

Date Format .............................. .............................. .............................. ......................... . 13


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F

Function Menu ................................................................................................................. 10

G

gates posit ion and width .............................................................................................. 41

Groups ............................................................................................................................... 39

H

High Limit .......................................................................................................................... 30

IInitial Pulse (I.P.) ........................... .............................. .............................. ........................ 25

Instrument Zeroing ....................................................................................................... 17

K

Keypad Features .............................................................................................................. 5

L

L-Ref ................................................................................................................................... 32

Language .............................. .............................. .............................. .............................. ... 13

LIMIT TYPE .......................... .............................. .............................. .............................. .... 30

LOAD .............................. .............................. .............................. .............................. ........... 33Lock-Out ............................................................................................................................ 19

Decimal ............................... ............................... .............................. .......................... ...... 13

delete a single stored (tensioned) reading from a .............................................. 34

Deleting Stored Groups ............................ ............................. .............................. ........ 44

E

edit fastener names ........................................................................................35

Editing Stored Groups .....................................................................................44ELONGATION ....................................................................................................33


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Low limit ............................... ............................... .............................. ............................... . 30

M

Measuring Tensioned Fasteners ................................................................................ 33

Multi-Echo (M.E.) .............................................................................................................. 25

N

Navigating Within a Group ............................. ............................... .............................. .... 34new calibration group ................................................................................................... 46

new group ......................................................................................................................... 16

O

Operating Mode ........................... .............................. .............................. ........................ 25

P

PASSWORD ........................... ............................... ............................... ............................... . 19

Phase ................................................................................................................................. 28

POWER DOWN .............................. .............................. .............................. ........................... 11


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PRINT................................................................................................... 10PRINTER ............................................................................................... 43printing an A-Scan hardcopy .............................................................. 36Printing Stored Groups ....................................................................... 42Probe .................................................................................................... 17

R

Recalling Stored Groups............................................................. 16, 41reference length .................................................................................. 32REGRESSION ...................................................................................... 49RF DISPLA............................................................................................ 11

S

search for a specific fastener name ................................................... 35STRESS ............................................................................................... 33Stress Offset ........................................................................................ 50Stress Ratio .......................................................................................... 50TTEMPERATURE................................................................................... 31temperature probe .............................................................................. 31Tensioned fastener .............................................................................. 33threshold trigger .................................................................................. 29Time Format ....................................................................................... 13

U

Units ...................................................................................................... 13

V

VECTOR ................................................................................................ 49

W

Warranty.............................................................................................. 53


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Z

zero crossing........................................................................................ 29Zeroing ................................................................................................ 17Zoom .................................................................................................................................. 23

Documents

Manual operare BoltMike III.pdf