Mannal

FLO

MFL floor Scanner with STARS Top & Bottom Defect Discrimination

MFLi3000-R

MFL Floor Scanner: Free-scanning with Autostop capability and STARS Top &
Bottom Defect Discrimination

Section 1
MFLi3000-R
Safety Notes and Specification

Silverwing UK Ltd Clos Llyn Cwm, Swansea Enterprise Park, Swansea, SA6 8QY Wales, UK
t: +44 (0) 1792 798711 f: +44 (0) 1792 793481 e: [email protected] w: www.silverwingndt.com

MANUFACTURER:

Silverwing (UK) Ltd.

Clos Llyn Cwm,
Swansea Enterprise Park,
Swansea,
SA6 8QY
Wales, UK
Phone: +44 (0) 1792 798711
Fax: +44 (0) 1792 793481
Email: [email protected]
Web: www.silverwingndt.com

DISTRIBUTOR:

MFLi3000-R Operating Manual Section 1
Manual Version 1.0
MFLi3000-R Safety Notes and Specification

Copyright© 2014 by Silverwing (UK) Ltd

The text, figures and programs have been worked out with the utmost care. However, we cannot
accept either legal responsibility or any liability for any incorrect statements which may remain,
and their consequences. The following documentation is protected by copyright. All rights
reserved. No part of this manual may be reproduced or transmitted in any form or by any means,
electronic or mechanical, including photocopying and recording for any purposed without the
express written permission of Silverwing (UK) Ltd. The rights of reproduction through lectures,
radio and television are also reserved. The software and hardware descriptions referred in this
manual are in many cases registered trademarks and as such are subject to legal requirements.

Silverwing (UK) Ltd reserves the right to continue developing the system and software without
documenting each individual case. Silverwing (UK) Ltd will be happy to determine whether this
manual is up-to-date. Silverwing (UK) Ltd holds no responsibility for any damage or destruction
caused when following instructions within this manual.

This manual is part of the original documentation supplied with the MFLi3000-R system.

MFLi3000-R Operating Manual Rev 1.0 Section 1 - MFLi3000-R Safety Notes and Specification

Table of Contents

1 General Introduction ....................................................................................................................................... 2
1.1 Purpose of this Operating Manual .................................................................................................................2
1.2 How this Operating Manual is Organised .......................................................................................................2
1.3 Basic Safety Directions....................................................................................................................................2
1.4 Safety Warnings & Precautions ......................................................................................................................3
1.5 Recommended Operator Training..................................................................................................................4
1.6 Magnetic Flux Leakage Testing Limitations ....................................................................................................4

2 Service and Maintenance................................................................................................................................. 4
2.1 After Sales and Technical Support..................................................................................................................5
2.2 Return Policy...................................................................................................................................................5
2.3 Warranty and Liability ....................................................................................................................................5
2.4 Legislative requirements ................................................................................................................................6

3 Transportation and Storage ............................................................................................................................. 7
3.1 Receiving and Inspection ................................................................................................................................7
3.2 Unpacking .......................................................................................................................................................7
3.3 Packing and Transportation............................................................................................................................8
3.4 Storage............................................................................................................................................................8

4 MFLi3000-R Specification Sheet ....................................................................................................................... 9
4.1 Detection capability table (MFL and STARS).................................................................................................11

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1 General Introduction

1.1 Purpose of this Operating Manual

This manual has been designed so that a person with a good knowledge of the basics of
magnetic flux leakage (MFL) testing may understand the operation and use of the features
offered by the MFLi3000-R system.

Keep this manual safe and handle with care:
 It must be readily available throughout the use of the system.
 It must be provided to any individuals who assume responsibility for operating the system at a

later date.
 It must include any supplementary material provided by the manufacturer.
 The Manuals are also available on the Sitemaster computer in

Improper use of this instrument or failure to follow these instructions may cause injury or
equipment damage. All individuals responsible for operating this instrument must therefore be
aware of the hazards, and must carefully follow these operating instructions and the safety
precautions detailed within. Contact Silverwing (UK) Ltd if you have any questions on any
part of this operating manual.

1.2 How this Operating Manual is Organised

This operating manual is organised into sections, with each section divided into various chapters.
 Section 1 (this section) refers to the MFLi3000-R safety instructions and specifications.
 Section 2 refers to the mechanical MFLi3000-R setup, hardware and operation.
 Section 3 refers to installation and operation of the MFLi3000-R Data Acquisition software.

1.3 Basic Safety Directions

 Do not operate the MFLi3000-R system without reading, understanding and following this
operating manual, otherwise injury or damage may result.

 Observe all warnings, notes and instructions as marked on the packaging, on the equipment,
and detailed in the operating manual.

 The customer takes responsibility for the compliance to all appropriate safety measures.
 Only responsible and reliable staff should be authorised to work with the equipment.

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 The equipment must not be used for purposes other than those intended. Silverwing (UK) Ltd
assumes no responsibility for any damage resulting from such improper usage.

 The equipment must not be modified. In case of modifications the customer takes all
responsibility for any incidents due to such modifications.

 Ensure the equipment is always in safe operation condition. Qualified staff shall perform
functional tests and checks for damage at regular intervals. Only authorised staff shall do
disassembly, and according to operation instructions only.

 Maintenance of electrical components of the equipment must be performed by a professional
electrician, or under supervision of a professional electrician.

 Ensure, by regular checks, that working site, equipment and environments are kept in a clean
and clearly arranged state.

 Rules and regulations regarding the prevention of accidents that apply to the working site
should be observed.

 If the system does not operate normally, please contact Silverwing (UK) Ltd for assistance.

1.4 Safety Warnings & Precautions

During operation of the MFLi3000-R system, adhere to the following safety warnings and
precautions.

DANGER!

The MFLi3000-R system is designed for a specific use. Using the
MFLi3000-R system outside of its intended use is dangerous. Severe
injury or death could result. Read and understand this operating
manual before use.

CAUTION!

MAGNETIC MATERIAL. Due to magnetic material, consult IATA
documentation before air shipping.

WARNING!

MAGNETIC MATERIAL. The MFLi3000-R contains strong magnets
that produce an extremely strong magnetic field which may cause
failure or permanent damage to items such as watches, memory
devices, CRT monitors, and medical or other electronics devices.

WARNING!

PERSONEL SAFETY. Tools, magnets, and metal objects can cut,
pinch, or entrap hands and fingers. HANDLE WITH CARE. People
with pacemakers or ICD’s must stay at least 2m (79’’) away.

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WARNING!

Damage to the MFLi3000-R and/or cables during or prior to use
may cause explosion or fire.

1.5 Recommended Operator Training

Silverwing recommend all users of the MFLi3000-R attend the MFLi3000-R operator training
course (sold separately). The training course covers the following main points:
 MFLi3000-R Data Acquisition software;
 Magnetic Flux Leakage and STARS technologies;
 The Autostop (stop on defect) principle;
 Scanner components;
 Scanner setup and calibration;
 Scanner maintenance.

1.6 Magnetic Flux Leakage Testing Limitations

Magnetic Flux Leakage (MFL) systems are heavily reliant on the inspection surface on which they
operate. It is important to understand that as the conditions of the inspection surface deteriorates,
so can the effectiveness of any MFL system.
MFL systems interpret a leaking field and any influencing factors that affect this leaking field must
be understood and factored into the inspection process. In order to maintain detection
capabilities, it must be understood that as plate thickness increases, the detection sensitivity
must increase. As the detection sensitivity increases, the likelihood of spurious defects increases
accordingly.

It must also be understood that MFL is one of the many available NDT inspection techniques. To
improve the accuracy and confidence of any inspection it is important to incorporate the use of
other NDT techniques such as Pit Gauging and Ultrasonic Testing (the limitations of these
techniques must also be understood).

2 Service and Maintenance

 The specified calibration and maintenance work should be performed promptly according to
the maintenance schedule.

 After completion of maintenance work test all functions and all safety devices.

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2.1 After Sales and Technical Support

Silverwing (UK) Ltd provides after sales and technical support and is available from Monday to
Friday from 9:00 AM to 5:00 PM GMT (excluding UK public holidays). Contact us either by:

Phone: +44 (0) 1792 798711
Fax: +44 (0) 1792 793481
Email: [email protected]

Please provide the following information when contacting Silverwing:
 Your name and your company name.
 The technical point of contact (name, phone number, email).
 System serial number, equipment type and any software versions.
 A detailed description of the issue.

2.2 Return Policy

If the MFLi3000-R system has been diagnosed as being faulty, or if it is in need of repair, it can
be returned to Silverwing (UK) Ltd. A Return Material Authorisation (RMA) number must be
obtained from Silverwing (UK) Ltd before it can be returned. To return the system:
1. Pack the system safely in the original transit case and ensure the product is shipped fully

insured (for a guide on how to pack the system, please refer to Section 2 – Hardware, Setup
and Operation).
2. Include the following:

a. The RMA number supplied by Silverwing (UK) Ltd. Clearly mark this on the outside of
the box.

b. A return address where the system can be shipped.
c. A contact telephone number / email address to be reached during work hours.
d. A detailed description of the problem.
3. Ship the unit prepaid to the address specified by Silverwing (UK) Ltd.

2.3 Warranty and Liability

All warranty and liability claims in case of damage to persons or material are excluded, if they are
caused by one or more causes stated below:

 Usage of equipment other than that according to the intended purpose.
 Work on equipment by persons other than those authorised to work with the equipment.
 Improper transport, storage, assembly, commissioning, operation or maintenance of

equipment.

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 Operation of equipment containing faulty safety devices, or safety devices not fitted
properly, or safety and protection devices that are out of function.

 Disregarding instructions regarding safety, transport, storage, assembly, operation,
maintenance and setting-up, as stated by the operations manual.

 Modification of equipment not authorised by the Silverwing (UK) Ltd.
 Insufficient monitoring of equipment parts which are subject to wear.
 Repairs executed improperly, use of spare parts from other suppliers.
 Catastrophic impacts, e.g. by external matters or force majeure risks.

2.4 Legislative requirements

The MFLi3000-R system is designed to meet the safety requirements in accordance with
electrical safety and electromagnetic compatibility. It has been tested and has left the
factory in a condition in which it is safe to operate. The equipment is in conformity with the
statutory requirements of the EC directive and complies with the following provisions of
Low Voltage Directive 2006/95/EC and the Electromagnetic Compatibility Directive
2004/108/EC.

The Waste Electrical and Electronic Equipment Directive (WEEE Directive) aims to
minimise the impact of electrical and electronic goods on the environment by increasing
re-use and recycling and by reducing the amount of WEEE going to landfill. It seeks to
achieve this by making producers responsible for financing the collection, treatment, and
recovery of waste electrical equipment, and by obliging distributors to allow consumers to
return their waste equipment free of charge.

Silverwing (UK) Ltd offers its customers the possibility of returning unused and obsolete
equipment for correct disposal and recycling. The Dustbin Symbol indicates that when the
last user wishes to discard this product, it must be sent to appropriate facilities for
recovery and recycling. By not discarding this product along with other household-type
waste, the volume of waste sent to incinerators or landfills will be reduced and natural
resources will be conserved.

The European Union’s RoHS (“Restriction of the use of certain Hazardous Substances”)
Directive (2002/95/EC) came into effect on July 1, 2006. All of the systems manufactured
by Silverwing (UK) Ltd fall under Category 9, Measurement and Control Equipment.
Currently this category is exempt from RoHS compliance until at least 2018, when it and
other exemptions will be reviewed. Regardless of this, all products manufactured by
Silverwing (UK) Ltd are compliant with the RoHS Directive.

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3 Transportation and Storage

3.1 Receiving and Inspection

For transport purposes the MFLi3000-R system is supplied within a black transit case strapped to
a non-wooden pallet. Any transport work may only be carried out by appropriately trained
personnel. Transportation instructions on the packaging must be followed (refer to Section 2 –
Hardware, Setup and Operation).

On receipt of the system, carefully check it for any damage that may have occurred during
shipping. The transport company is responsible for damage that occurs during transport. If there
appears to be damage, carefully inspect the system components for any further damage and
check that all components correspond to the packing list. In the event of damage, notify the
transport company immediately and keep the packaging as evidence. A full report describing the
damage in detail must be submitted to the transport company and serves as the basis for the
damage claim.
Damage or loss of goods delivered must be reported immediately to Silverwing (UK) Ltd and
confirmed by a copy of the above-mentioned report. If the operating manual is removed, do not
lose or misplace.

3.2 Unpacking

The MFLi3000-R system is packaged in a black transit case. Care should be taken when
unpacking the MFLi3000-R system, any markings or warnings shown on the packaging should be
observed prior to opening. The following steps should then be taken:
 Unpack the MFLi3000-R system in a dry area.
 If a knife is used to remove packaging, care should be taken not to damage the MFLi3000-R

system or cables.
 Check the contents of the MFLi3000-R system against the packing list supplied and any

missing items are to be reported immediately.
 The package and contents of the MFLi3000-R system should be checked for signs of damage

during transport and any problems reported immediately.
 Silverwing (UK) Ltd accepts no responsibility for damage or injury caused during the

unpacking of the system supplied.

CAUTION!

FOUR MAN LIFT. Lift the MFLi3000-R transit cases at its four handles
with the aid of 4 people. Alternatively a forklift can be used.

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3.3 Packing and Transportation

Before packing the MFLi3000-R system into the transit cases, ensure:
 Each component of the system is clean and dry;
 The small case carrying the Sitemaster computer is firmly secure using the supplied straps.

Each component of the MFLi3000-R system must be correctly packed into the correct transit
case. Refer to the supplied packing list.
The large black transit case is designed to hold the MFLi3000-R system and mounted to the base
of the transit case is a keep plate. When packing the MFLi3000-R scanner the magnetic bridge
must be in contact with the keep plate.

CAUTION!

FINGER CRUSH. The magnetic bridge contains strong
magnets that produce an extremely strong magnetic
field which could cause entrapment of hands and
fingers. HANDLE WITH CARE.

If the MFLi3000-R system is to be shipped elsewhere, the original packaging and transport
protection inserts MUST be used.

CAUTION!

MAGNETIC MATERIAL. Due to magnetic material,
consult IATA documentation before air shipping.

3.4 Storage

If storage of the MFLi3000-R system is required then all components must be packed correctly.
The MFLi3000-R should be stored;
 In a clean, dry and secure location.
 Away from water and harsh environment conditions.
 In such a way as to avoid damage to the system.

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4 MFLi3000-R Specification Sheet

Physical Characteristics

Operating Principal Magnetic Flux Leakage & Magnetic Field Reluctance
Scan width
Variable up to 12” (300mm)
MFLi3000-R weight 126lbs (57.5 kg)

Physical dimensions Height: 38.7” (985mm) - Width: 20”* (510mm*) - Length:
27.1” (690mm)
Minimum man-way
size 19.7” (500mm) diameter man-way for MFLi3000-R entry

Transit case Meets IATA requirements for transporting magnetisable
material

Operating Conditions

Power requirements 1 x 12V, 42 amp-hour sealed lead acid battery (x2 supplied)
with 2 chargers for continuous use
Typical battery
operational time Up to 6 hours

Operating -22⁰F to 131⁰F (-30⁰C to 55⁰C)
temperature -31⁰F to 167⁰F (-35⁰C to 75⁰C)
Storage temperature
10-95% RH
Humidity

Scanning Capabilities

Method of detection 256 Hall Effect sensors, 64 channels
Minimum defect
0.08” (2mm) diameter pipe type 50% deep **
detection sensitivity
Stop-On-Defect MFLi3000-R automatically stops (Autostop) at specified signal
option output. Autostop is optional with variable threshold
Defect verification
tools Reporting threshold (primary indicator) and MFLi threshold
Test through (secondary indicator)
coatings
Maximum coating Yes, if non magnetic
thickness for
detection ** See ‘Detection capability table for defects created with 0.86” (22mm)
Top and bottom ball end cutter (using MFL and STARS)’
discrimination table below in Section 4.1

Un-scanned area Yes, using STARS technology

Real time analysis 0.4” (10mm) (from plate weld, 6.3 x 6.3” (160 x
160mm) corner dead zone)
Detection modes Defect size, x / y position, plate view, top/bottom, MFL, MFLi,

Noise differentiation STARS
MFL, MFLi and STARS

Yes, compared to defect signals

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Drive Capabilities

Method of propulsion DC motor, anti-static drive wheels
Rollers Heavy duty, multi compound rollers
Speed Variable from approx. 0.4 m/s to 1.0 m/s
±0.04% = ±3/32” over 26ft (±3mm over 8 metres)
Positional accuracy
Scan coverage 354”²/minute (9m² / minute)
Maximum single
scan length 1,260” (32 metres)

Reverse capability Yes, during defect analysis

Software and Computing Specifications

Computer system Sitemaster ruggedised touchscreen computer
IP rating IP 65

Operating system Microsoft Windows 10 64-bit
Processor Intel® Core™ i5
Memory 8GB DDR 3
Display
Storage 12.1” (307mm) XGA touchscreen LED

Power supply 120GB SATA internal SSD with anti-shock protection
Uninterruptable 9-36V DC
power supply (UPS)
Internal battery for up to 30 minutes of power (10 minutes with
Interfaces default settings)

4x USB 2.0, 1x Ethernet 10/100/1000, 1x RS232,

Data Acquisition 1x pre-installed version on MFLi3000-Runit (Field updatable)
System Software***

* = Removing the detachable handle can reduce this value to 405mm (16”).

** = This value is based on a clean ferrous inspection surface.
*** = Operating system requirement – Microsoft Windows Vista, 7 or 8.

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4.1 Detection capability table (MFL and STARS)

Plate Thickness

Coating 6mm 8mm 10mm 12mm 16mm
Thickness (0.24”) (0.31”) (0.4”) (0.47”) (0.63”)
  40%+
No Coating        40%+
0.5mm   40%+
1mm        60%+
2mm   60%+
3mm        60%+
4mm   80%+
5mm        80%+
6mm  
7mm  40%+      40%+ 
8mm  40%+ 
9mm  40%+    40%+  40%+ 
10mm
   40%+  60%+

   40%+  60%+

   60%+  60%+

 40%+  60%+  80%+

 40%+  60%+  80%+

 40%+  60%+ 

Top
Bottom

Top
Bottom

Top
Bottom

Top
Bottom

Top
Bottom

 = 20%+

This table was generated from inspection surfaces comprised of 0.86’’ (22mm) ball cutter
defects.

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Silverwing UK Ltd - (Head Office) Silverwing Middle East LLC Silverwing Africa (PTY) Ltd Silverwing USA Inc
Clos Llyn Cwm P. O. Box 75950 Private Bag X1
Swansea Enterprise Park Dubai Postnet Suite 419 Suite 120
Swansea United Arab Emirates Melkbosstrand
SA6 8QY t: + 971 4 360 6751 7437 2911 South Shore Blvd
Wales, UK f: + 971 4 360 6124 League City
t: +44 (0) 1792 798711 e: [email protected] St:o+u1t2h7A2f1ri5ca57 5740
f: +44 (0) 1792 793481 w: www.silverwingme.com Texas
e: [email protected] f: + 27 21 557 4354
w: www.silverwingndt.com e: [email protected] 77573
w: www.silverwingafrica.com DUSoAc Ref: OM-FM3Di-S0
Rt:e+v1:48.032 531 0092
eD: asateleos@f Rsielvlerawsien:g3n0d/t0.5co/2m014

w: www.silverwingndt.com