UltraScan 1063 English Handbook Rev4

UltraScan 1063
INSTRUCTION HANDBOOK
- Installation, setup, operation -
Beta LaserMike Inc. Beta LaserMike Limited Beta LaserMike Asia Pacific
8001 Technology Blvd. Stirling Road Room 606, Suncome Liauws Plaza
Dayton, OH 45424 Cressex Business Park No. 738 Shangcheng Rd.
USA Buckinghamshire Shanghai 200120,
High Wycombe P.R. China
UK
www.betalasermike.com
Status: Released Issue/Rev: 4
Manual Part Number: MAN/E3600-0408 Revision 4 Copyright February 2005

UltraScan 1063 Instruction handbook
Contents
Proprietary Statement ............................................................................................... 3

European Commission Requirements .................................................................... 4
Introduction................................................................................................................ 5
Safety Information ..................................................................................................... 5
Mechanical Installation ............................................................................................. 6
Mounting gauge directly onto existing trough......................................................... 6
Installing to wall of trough (self-flooded gauge) ................................................ 6
Mounted onto base of trough ............................................................................ 7
Mounted to an end wall of the trough (bulk-head mount) ................................ 7
Installing the Beta LaserMike trough...................................................................... 8
Height stand mounting ...................................................................................... 9
Dimensions of gauge only - mm (inches)............................................................. 13
Dimensions of gauge with base carriage - mm (inches) ...................................... 14
Dimensions of water distribution unit mm [inches]............................................ 15
Standard Distribution Unit ............................................................................... 15
Distribution Unit with Bubble Remover (optional) ........................................... 15
Electrical Installation............................................................................................... 16
Setup......................................................................................................................... 16
Connecting the water purge/fill tubes................................................................... 16
Submerged/self-flooded installation ................................................................ 16
Beta LaserMike trough installation .................................................................. 17
Preparing the water seals for the gauge .............................................................. 18
Removing the seal........................................................................................... 18
Making a hole in the seal for the product ........................................................ 19
Labels indicating position of transducer ............................................................... 19
Maintenance............................................................................................................. 20
Replacing transducers.......................................................................................... 20
Spare parts ........................................................................................................... 20
Diameter Calibration ............................................................................................... 21
Calibration procedure ........................................................................................... 21
Troubleshooting ...................................................................................................... 22
Specification ............................................................................................................ 22
Index ......................................................................................................................... 23
MAN/E3600-0408 Page 2 of 23 Revision 4 (Feb 2005)

Proprietary Statement
Proprietary Statement
Manufacturer/Distributor
Beta LaserMike Limited, Stirling Road, Cressex Business Park, High Wycombe, Buckinghamshire, HP12 3RT, United Kingdom
About This Manual

This manual contains descriptions, drawings, and specifications for a Beta LaserMike product. Equipment or products made prior to or
subsequent to the publication date of this manual may have parts, features, options, or configurations that are not covered by this
manual. Specifications contained herein are subject to change by Beta LaserMike without prior notice. Beta LaserMike is not responsible
for errors or omissions that may be contained herein or for incidental or consequential damages in connection with the furnishing or use
of this information. Comments or suggestions for possible improvements to the manual are appreciated. Please email us at
manualfeedback@betalasermike.com.
The information contained in this manual is the property of Beta LaserMike. The information disclosed in this document is furnished in
confidence and upon the condition that individual and corporate intellectual rights, whether patented or not, will be respected. If this
document is supplied on removable media (e.g. CD), an electronic copy (stored on-site) and one printout is permitted. If this document is
supplied in printed form, no part of this document may be reproduced or scanned without the prior written consent of Beta LaserMike.
This document may not be distributed or circulated to third parties.
Limited Warranty
Beta LaserMike will correct by repair, or at Beta LaserMikes option, by replacement, F.O.B Beta LaserMikes plant, any defect in
workmanship or material in any equipment manufactured by Beta LaserMike which appears under normal and proper use within twelve
months from the date of shipment (eighteen months for OEMs), provided Beta LaserMike is given reasonable opportunity to inspect the
alleged defective equipment at the place of its use and under conditions of its use.
EXCLUSIONS: This warranty does not cover products which have been modified, altered, or repaired by any other party than Beta
LaserMike or its authorized agents. Furthermore, any product which has been, or is suspected of being damaged as a result of
negligence, misuse, incorrect handling, servicing, or maintenance; or has been damaged as a result of excessive current/voltage or
temperature; or has had its serial number(s), any other markings, or parts thereof altered, defaced, or removed will also be excluded
from this warranty.
WARRANTY SERVICE AT CUSTOMER SITE: Warranty service performed at the customers facility will be free of charge for parts and
labor; however, the customer will be liable for transportation and living expenses of personnel dispatched to effect such repair. A
purchase order or other written confirmation of the acceptance of these charges, signed by an authorized individual, will be required prior
to commencement of repairs. Additional charges may be assessed the customer if: 1) The equipment is not made available on a timely
basis, 2) The equipment is found to be without fault, and/or 3) It is determined the equipment is not under warranty, whether by
expiration of the warranty or any act which voids the warranty.
OTHER THAN AS SET FORTH HEREIN, BETA LASERMIKE MAKES NO WARRANTIES, EXPRESSED OR IMPLIED, OF
MERCHANTABILITY AS TO THE EQUIPMENT MANUFACTURED BY IT, AND THERE ARE NO EXPRESSED OR IMPLIED
WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE THEREOF. Beta LaserMikes obligation to correct
defects in such equipment by repair or replacement in accordance with the foregoing provisions is in lieu of any other warranties,
expressed or implied, and in no event shall Beta LaserMike be liable for incidental or consequential damages. No service of Beta
LaserMikes equipment is permitted during the warranty period without the specific written consent of Beta LaserMike.
Service
Your instrument was carefully inspected electrically and mechanically prior to shipment. It should be free of surface mars and scratches,
and it should be in perfect working order upon receipt. If any indication of damage is found, file a claim with the carrier immediately, prior
to using the instrument. If no damage is apparent, proceed by using this manual to install and setup this instrument.
Save the shipping carton and packing material for future storing or shipment of the instrument. If, at some future time, the instrument
must be returned to the factory for service, include a full description of the instrument failure and the mode of operation the instrument
was in at the time of failure. Also include a contact person to discuss the instrument failure.
When returning the instrument to Beta LaserMike, first contact your local Beta LaserMike Service Department for a Return Material
Authorization (RMA). The RMA number is needed for proper handling of returned equipment. Ship the instrument in the original carton,
or, if the original carton is unavailable, ship in a carton providing sufficient protection. Send the instrument to the Asia, Europe, or USA
office (addresses listed on the outside cover of this manual), whichever is closest to you or to the office indicated by your sales engineer.
Place the RMA number on the outside of the carton, and include a purchase order number and any other information specific to your
instrument. Field warranty service is available, if the customer pays travel expenses by advance purchase order. All service operations
should be performed by skilled electronics technicians, who have been trained by Beta LaserMike.

European Commission Requirements
European Commission Requirements

This equipment is intended for use in a heavy industrial environment. The
equipment generates, uses and can radiate radio frequency energy and, if not
installed and used in accordance with the instructions, may cause harmful
interference to other equipment. There is no guarantee that interference will not
occur in a particular installation. If this equipment does cause harmful
interference to other equipment the user is encouraged to try to correct the
interference by one or more of the following measures:
Re-orientate or relocate the equipment.
Increase the separation between the pieces of equipment.
Connect the pieces of equipment on separate mains circuits.
Ensure that the relevant items of equipment are properly and securely earthed to a
common earth point using adequately sized cable or other means of connection.
Where supplied or specified, shielded interconnection cables must be employed

with this equipment to ensure compliance with the pertinent RF limits. Changes
or modifications not expressly approved by the company could void the users
authority to operate the equipment.
This product was rigorously tested to comply with the European EMC
(Electromagnetic Compatibility) Directive. With regard to this, Beta LaserMike
recommends that any non-Beta LaserMike peripheral equipment is CE marked
for the Heavy Industrial environment (EN50082-2). Beta LaserMike also
recommends that any cables not supplied by Beta LaserMike, but used for
powering Beta LaserMike equipment, be built using good EMC practices (i.e.
cables with braided shield, and connectors with 360 termination of the braid to
a metal/metalised shell connector at both ends). If you have any questions
regarding this, contact the Beta LaserMike Service Department.

Introduction
Introduction
The UltraScan 1063 is used for measuring the wall thickness and concentricity
of extruded pipe and tube products. UltraScan 1063 models differ in the number
of transducers - 4, 6 or 8 transducers and transducer frequency (2.25, 5, 10 or
20MHz). The bubble remover (in the water distribution unit) is optional.
Example for Model naming convention
4
1000 series transducer
model Transducer
type
US 1063-4T-5M-25E
UltraScan 63mm Frequency 25mm [1in]

[2.48in] max 5 MHz element size
product
diameter.
Typical ultrasonics system
Transducer
connections RS232,
(4, 6 or 8) Profibus or
DeviceNet
Host system
UltraScan or controller
UltraScan
DSP
For information of the DSP processing module and PC viewing software or

controller see relevant manuals.
Safety Information
Any electrical connections should be performed by a person

suitably qualified for the country of installation.
If the equipment is used in a manner not specified by the manufacturer the

protection provided by the equipment may be impaired.

Mechanical Installation
For details on installation category, pollution degree and Ingress Protection (IP)
see Specification / Environmental conditions.
Installation types will vary depending on the gauge model and users requirement.
Mounting gauge directly onto existing trough

The existing cooling trough may be suitable for direct installation of the
UltraScan 1063. If the existing trough is not suitable due to trough size
constraints or other reasons, then the Beta LaserMike trough is required. If so,
please refer to section Installing the Beta LaserMike trough.
The gauge must be immersed in water so that there is a liquid medium to carry the
ultrasonic signals. The gauge is either 1) submersible in a flooded section of a
cooling trough (as shown below) or 2) can be self-flooded (by applying the end
seals supplied by Beta LaserMike) for mounting onto a dry trough or spray tank.
The distance of the gauge from the extruder can vary depending upon line speeds,
cooling rates of the material and availability of space along the extrusion line or in
the existing cooling trough.
Installing to wall of trough (self-flooded gauge)
New wall
(not supplied) Trough area for water
spillage
Drainage
Remove base mount carriage first.
Then seat the gauge on top.

Mounted onto base of trough
Base mount carriage is required for this type of installation.
Attach base mount carriage first,

using 4xM8 bolts.
Then seat the gauge on top.
Mounted to an end wall of the trough (bulk-head mount)
Use 4xM8
bolts

Installing the Beta LaserMike trough

If the existing cooling trough is not suitable for direct installation of the
UltraScan 1063, Beta LaserMike can supply a separate trough for mounting and
installation as shown below.
Welded or bolted between sections of the trough:
Trough adapter
plates
Adapter plate seals (gaskets)

(in-between adapter plates and trough
flange)
Welded or bolted to the end of the trough:
Trough adapter plate with adapter

plate seal (gasket)
Free standing:

Height stand mounting
The Beta LaserMike trough can be mounted on a height stand. Any type of
stable height stand (see Specification for weight) can be used, but Beta
LaserMike supplies a stand that is appropriate for the UltraScan 1063 and has
appropriate adapter plates.
Dimensions of Height stand and Beta LaserMike Trough mm [inches]
Top fixing plate:

3 equispaced holes
9.5 [0.37]
[3.5]
Height stand foot:
25.75]
3 holes : 12.5 [0.49]
[7.68] [7.09] [1.1]
[10.04]
[3.94]
[44.25]
[23.5]
[1.08]
[17.91]

[14.76]
[3.94]
[0.43]
[7.87]
[0.49] [13.54]
[0.35]
[11.81]
[7.4]
[11.81]
[33.62]
[52.13]
[12]

Installing the height stand & Beta LaserMike trough
Before fixing the Beta LaserMike trough to the height stand, ensure the height stand is
firmly bolted or clamped to the floor or other rigid structure.
Secure the height stand to the floor as shown below and lock at the required height using
height stand lever.
Mount the adapter plate as shown below.
Align the mounting holes on the BLM trough with the appropriate holes on the mounting
plate, and secure with washers and bolts. Do not exceed a tightening torque of one Newton
metre.
Trough aperture for

product Beta LaserMike trough
Hole for water tubes
4 M6x25mm [0.98] Caphead bolts

& 4 washers
Adapter plate
3 M8x16mm [0.63] Hex bolts and

3 washers.
Lever for height adjustment
3 M10 bolts (not supplied)


Mounting the gauge into the Beta LaserMike trough
Use bolts/holes as highlighted on photo below to mount the gauge to the trough:

Dimensions of gauge only - mm (inches)


Dimensions of gauge with base carriage - mm (inches)

The base carriage is used for direct mounting to the base of the existing trough.
See illustration under section Mounting gauge directly onto existing trough
above.

Dimensions of water distribution unit mm [inches]
Standard Distribution Unit

O.D.
CUSTOMER
CONNECTION -
WATER IN
Distribution Unit with Bubble Remover (optional)
Water flow on/off. Water purge

(Individual water flow
Horizontal position = on adjustment)
Vertical position = off

Electrical Installation
Electrical Installation
The gauge will have to be connected to the UltraScan DSP processing module.
Four, six or eight transducers (depending on your gauge configuration) should
be connected to the module. See manual(s) for UltraScan DSP module for
further information.
Setup
Connecting the water purge/fill tubes
Both inlets are labelled accordingly on gauge itself.
The water purge system releases a water flow directly across the face of each
transducer. This is to keep the transducer face free of air bubbles and debris.
Connect a water inlet to the supplied water manifold and connect a tube from
the manifold to the water purge connection inlet on the gauge. The water fill
inlet is not required in flooded cooling trough, but is necessary for self-flooding
in a dry trough or spray tank. Note that the water connection inlets should not
be used as a main trough fill.
Submerged/self-flooded installation
Water fill
inlet Water purge
inlet Transducer
cable outlet
For better illustration of water purge/fill inlet locations, see section Dimensions
of gauge above.

Setup
Beta LaserMike trough installation
Water
fill inlet
Water
purge inlet
Transducer
cable outlet
4 pairs of bolts/nuts for

connecting water
Optionally, the water
manifold.
distribution unit can
be supplied with a
bubble remover (not
shown)
For better illustration of water purge/fill inlet locations, see section Dimensions
of gauge above.

Setup
Preparing the water seals for the gauge

Water seals are used for self-flooded installations or with the Beta LaserMike
trough, i.e. in all cases where the trough itself is not suitable to mount or
submerge the gauge.
Note that the rubber water seals are not suitable for guiding the product. If
product guidance is required, then either use proprietary guide rollers or contact
Beta LaserMike for advice.
Removing the seal
Depress outer ring axially and

rotate anticlockwise
(simultaneously)
Unscrew wing screws
Remove seal assembly (shown

below) and replace silicon seal.
Outer ring
Seal M5 Wing nuts -
stainless
Inner ring

Setup
Making a hole in the seal for the product
The default hole in the middle - 7mm [0.28in] should be customised to allow
product to go through. As a nominal value make the hole 0.5mm [0.02in]
smaller than the product to be measured. To create the hole use a stainless
metal pipe (hollow cylinder) and sharpen edges as shown below. Then use a
hammer to drive the pipe through the seal.
Sharpen
edge of pipe
Labels indicating position of transducer

The following labels will be attached to the top of the gauge showing the
number and position of the transducers.
4-transducer model: 6-transducer model: 8-transducer model:
Represents
transducer cable

Maintenance
Maintenance
Replacing transducers
1) Remove the unit from water
2) Remove gauge from base fixing unit (if fitted)
3) Remove seal assembly as described under Preparing the water seals.
4) Remove M6 Caphead screws from both sides.
5) Pull unit apart to gain access to transducer fixing screws (see photo of 4
transducer model below).
Transducer
fixing screws
6) Slacken transducer screws and remove transducer.

7) Remove and split plastic conduit to remove transducer lead.
8) Follow instructions in reverse order to install new transducer.
Spare parts
Part description BLM part number Quantity per Unit
2.25 MHz transducer 1560103 Can be ordered individually.
5 MHz transducer 1560109 Can be ordered individually.

Seal assembly ASY3600-0402-1/A 2

Diameter Calibration
Diameter Calibration
The calibration jig (purchased option) is only used for outside diameter
calibration. It is not used in wall thickness calibration. Whereas diameter
measurement is not affected by the type of product being measured, wall
measurement is and can consequently only be calibrated on-line for a specific
product. Refer to the host system or controller operator manual for instructions
to calibrate wall thickness measurements.
Calibration procedure
Remove seal from one end of the gauge as described under section Setup.
Fix seal blanking plate onto one side of gauge (simultaneously depress and
rotate clockwise)
Into other side insert small calibration sample and fix into position
(simultaneously depress and rotate clockwise)
Check reading on terminal and adjust as required *
Remove small sample.
Insert large calibration sample, fix into position and check reading on
terminal. Adjust reading as required *.
* Controller or host system manuals may have to be consulted.

Troubleshooting
Troubleshooting
Problem/ Possible Cause Action
Symptom
Product not centred. Centre product in gauge.
No readings Water purge not functioning Check water flow (see section Water supply installation)
and water purity.
Water purge too weak Adjust water flow as described in section
Fine-adjusting the water purge flow.
Transducer(s) not working Replace the transducer(s) as described under section
Maintenance.
Inaccurate Incorrect calibration Consult the Operator Manual of the host system or
readings control for proper calibration procedure
Specification
Environmental Conditions
Environment Indoor use only
Altitude Up to 2000m [6560 ft]
Ambient operating temp. 5-40C [41-104F]
Ambient storage temp. -20 to 50C [-4 to 122F]
Max relative humidity Submersible.
Max immersion time in water 8 hours.
Drying time approx. 16 hours under standard temperature &
humidity.
(Gauge and transducers can be immersed longer than specified
here, but this will reduce the operating life of the transducers)
Installation category Installation category 2
Pollution degree Pollution degree 1 (Equipment has been designed for operation with
a level of pollution of its internal micro-environment, which
corresponds with the definition of Pollution Degree 1 in BSEN 61010-
1)
IP rating Protected to IP68 (as defined in BSEN 60529).
Noise level < 70 dBa
Physical Characteristics
Weight Beta LaserMike trough: approx. 19kg [42lb]
Gaugehead: 5.6kg [12.3lb].
Dimensions Please refer to Gauge dimension drawings in this manual.
Throat size 85mm [3.35]
Number of transducers 4, 6 or 8
per gauge
General
Measurement range (O.D.) 2.54 - 63mm [0.1 - 2.48in]
Transducer frequency 2.25, 5, 10 or 20 MHz
Transducer element 25mm [1in]
Expected life for gauge and Gauge and transducers can last several years if used as specified in
transducers. this Instruction Handbook. Using the UltraScan gauge and
ultrasonic transducers in a manner other than specified in this
Instruction handbook can reduce the expected life.

Index
Index
Measurement range, 22
Beta LaserMike trough Mechanical installation, 6
Dimension drawing, 9
Installation, 8 Operation, 16
Mounting gauge into trough, 12 Outline drawing
Mounting onto height stand, 11 Gauge only, 13
Gauge with base carriage, 14
Calibration, 21
Parts, 20
Dimensions
Gauge only, 13 Safety information, 5
Gauge with base carriage, 14 Seals
Height stand, 9 Customising the hole for product, 19
Trough, 9 Removing, 18
Water distribution unit, 15 Setup, 16
DSP module, 5 Spare parts, 20
Specification, 22
Electrical installation, 16
Environmental conditions, 22 Temperature, 22
Transducers
Height stand Labels, 19
Dimensions, 9 Replacing, 20
Installation, 11 Specification, 22
Troubleshooting, 22
Installation
Electrical, 16 Ultrasonics system layout, 5
Mechanical, 6
Interference, 4 Water distribution unit, 15
Introduction, 5 Water purge/fill
connections, 16
Maintenance, 20 Weight, 22

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UltraScan 1063

Manual Part Number: MAN/E3600-0408 Revision 4 Copyright February 2005

Proprietary Statement ............................................................................................... 3

MAN/E3600-0408 Page 2 of 23 Revision 4 (Feb 2005)

About This Manual

MAN/E3600-0408 Page 3 of 23 Revision 4 (Feb 2005)

European Commission Requirements

Where supplied or specified, shielded interconnection cables must be employed

MAN/E3600-0408 Page 4 of 23 Revision 4 (Feb 2005)

Example for Model naming convention

UltraScan 63mm Frequency 25mm [1in]

Typical ultrasonics system

For information of the DSP processing module and PC viewing software or

Any electrical connections should be performed by a person

If the equipment is used in a manner not specified by the manufacturer the

MAN/E3600-0408 Page 5 of 23 Revision 4 (Feb 2005)

Mounting gauge directly onto existing trough

Installing to wall of trough (self-flooded gauge)

MAN/E3600-0408 Page 6 of 23 Revision 4 (Feb 2005)

Mounted onto base of trough

Base mount carriage is required for this type of installation.

Attach base mount carriage first,

Mounted to an end wall of the trough (bulk-head mount)

MAN/E3600-0408 Page 7 of 23 Revision 4 (Feb 2005)

Installing the Beta LaserMike trough

Welded or bolted between sections of the trough:

Adapter plate seals (gaskets)

Welded or bolted to the end of the trough:

Trough adapter plate with adapter

MAN/E3600-0408 Page 8 of 23 Revision 4 (Feb 2005)

Height stand mounting

Dimensions of Height stand and Beta LaserMike Trough mm [inches]

Top fixing plate:

Height stand foot:

[7.68] [7.09] [1.1]

MAN/E3600-0408 Page 9 of 23 Revision 4 (Feb 2005)

MAN/E3600-0408 Page 10 of 23 Revision 4 (Feb 2005)

Installing the height stand & Beta LaserMike trough

Mount the adapter plate as shown below.

Trough aperture for

Hole for water tubes

4 M6x25mm [0.98] Caphead bolts

3 M8x16mm [0.63] Hex bolts and

Lever for height adjustment

3 M10 bolts (not supplied)

MAN/E3600-0408 Page 11 of 23 Revision 4 (Feb 2005)

Mounting the gauge into the Beta LaserMike trough

MAN/E3600-0408 Page 12 of 23 Revision 4 (Feb 2005)

Dimensions of gauge only - mm (inches)

MAN/E3600-0408 Page 13 of 23 Revision 4 (Feb 2005)

Dimensions of gauge with base carriage - mm (inches)

MAN/E3600-0408 Page 14 of 23 Revision 4 (Feb 2005)

Dimensions of water distribution unit mm [inches]

Standard Distribution Unit

Distribution Unit with Bubble Remover (optional)

Water flow on/off. Water purge

MAN/E3600-0408 Page 15 of 23 Revision 4 (Feb 2005)

MAN/E3600-0408 Page 16 of 23 Revision 4 (Feb 2005)

Beta LaserMike trough installation

4 pairs of bolts/nuts for

MAN/E3600-0408 Page 17 of 23 Revision 4 (Feb 2005)

Preparing the water seals for the gauge

Removing the seal

Depress outer ring axially and