NOVOTEST T-UD3 User manual

Combined Hardness Tester

NOVOTEST T-UD3

Operating Manual

2018

NOVOTEST.ED.Т-UD3.000 OM

Operation Manual

Hardness Tester NOVOTEST T-UD3

Page. 2

CONTENT

1 DESCRIPTION AND OPERATION OF THE DEVICE AND ITS COMPONENTS.........................5

1.1 The purpose of the device...............................................................................................................5

1.2 Technical characteristics of the device ...........................................................................................5

1.3 Standard delivery set.......................................................................................................................7

1.4 Purpose of the probes......................................................................................................................7

1.5 Parts.................................................................................................................................................8

1.5.1 Ultrasonic Contact Impedance Probe U1 probe.....................................................................10

1.5.2 Leeb probe..............................................................................................................................10

1.6 Design and functioning.................................................................................................................11

1.6.1 Modes.....................................................................................................................................11

1.6.2 Leeb measurement principle (Leeb) ......................................................................................12

1.6.3 Ultrasonic Contact Impedance method..................................................................................12

1.7 Means of measurement, tools and accessories..............................................................................13

1.8 Marking and sealing......................................................................................................................13

1.9 Packing..........................................................................................................................................13

2 INTENDED USE.................................................................................................................................14

2.1 Operational limitations..................................................................................................................14

2.2 Preparing the device for use..........................................................................................................14

2.2.1 Visual inspection....................................................................................................................14

2.2.2 Installing the batteries............................................................................................................14

2.2.3 Connecting the Probe.............................................................................................................15

2.3 Using the device............................................................................................................................15

2.3.1 Preparing the object of testing ...............................................................................................15

2.3.2 Turning on..............................................................................................................................16

2.3.3 Charging the battery...............................................................................................................17

2.3.4 Measurements using Ultrasonic Contact Impedance Probe U1 probe...................................18

2.3.5 Measurements with the Rebound Leeb Probe........................................................................21

2.3.6 Measurement modes ..............................................................................................................24

2.3.7 Calibration..............................................................................................................................28

2.3.8 Settings...................................................................................................................................34

2.3.9 Archive...................................................................................................................................35

2.3.10 Memory card........................................................................................................................36

2.3.11 Information...........................................................................................................................36

2.3.12 Photo fixation of the measurements.....................................................................................37

2.3.13 Connecting to PC.................................................................................................................39

3 TECHNICAL MAINTENANCE OF THE PRODUCT AND ITS COMPONENTS .........................44

3.1 Security measures .........................................................................................................................44

NOVOTEST.ED.Т-UD3.000 OM

Operation Manual

Hardness Tester NOVOTEST T-UD3

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3.2 Verification ...................................................................................................................................44

3.2.1 Operations and verification means.........................................................................................44

3.2.2 Visual inspection....................................................................................................................45

3.2.3 Testing....................................................................................................................................45

3.2.4 Determination of the basic error of the instrument according to the HRC scale...................45

3.2.5 Determination of the basic error of the instrument on the scale HB......................................46

3.2.6 Determination of the basic error of the instrument on the scale НV .....................................46

3.3 Warranty........................................................................................................................................47

3.3.1 Basic Warranty.......................................................................................................................47

3.3.2 Extended warranty .................................................................................................................47

3.3.3 Warranty for repaired or replaced parts.................................................................................47

All NOVOTEST brand spare parts installed during the warranty repair process are covered by the

NOVOTEST guarantee (until the end of the warranty period).......................................................47

Spare parts replaced during warranty service under warranty are not returned to the owner of the

device..............................................................................................................................................47

3.3.4 Wear parts ..............................................................................................................................47

3.3.5 Duties of the owner................................................................................................................48

3.3.6 Warranty Limitations.............................................................................................................48

3.3.7 Other cases not covered by the warranty...............................................................................49

3.3.8 Guarantees and consumer legislation.....................................................................................49

3.4 Maintenance of the device ............................................................................................................49

4 MAINTENANCE ................................................................................................................................52

5 STORAGE...........................................................................................................................................52

6 TRANSPORTATION..........................................................................................................................52

7 RESYCLING.......................................................................................................................................52

NOVOTEST.ED.Т-UD3.000 OM

Operation Manual

Hardness Tester NOVOTEST T-UD3

Page. 4

Caution!

Please read this manual carefully before using the NOVOTEST T-UD3 hardness tester.

This operating manual (hereinafter OM) includes general information intended to familiarize the

operating personnel with the operation and operating rules of the NOVOTEST T-UD3 hardness tester

(hereinafter referred to as the device or hardness tester). The document contains technical

characteristics, description of the design and principle of operation, as well as information necessary

for the correct use of the product. Before getting started, it is necessary to familiarize yourself with this

manual, since the operation of the device must be carried out by persons familiar with the principle of

operation and design of the device.

Proper and effective use of the hardness tester requires mandatory availability:

Methods of testing;

Conditions for carrying out the testing, according to the testing procedure;

Trained, and familiar with this OM user.

The enterprise-manufacturer reserves the right to make non-critical changes, without impairing

product specifications. These changes may not be mentioned in the text of this document.

The scope of delivery of the instrument includes the operational documentation including this

operating manual and the instrument passport.

The present OM applies to all modifications of the device: T-UD3, T-U3, T-D3.

Terms used in this manual:

Hardness testers for metals –are used for material hardness testing, without destroying its

structure.

Hardness –property of a material to resist the elastic and plastic deformation, or destruction when

an indenter of another material that is more solid and takes no deformation of its body incorporated

into the surface layer.

Indenter –An element of the device pressed into the material for measuring its hardness. For

manufacturing indenters diamonds, hard alloys, hardened steel are used.

Young's modulus (modulus of longitudinal elasticity) –Physical quantity characterizing the

properties of the material to resist tension, compression under elastic deformation.

Leeb method –To measure the hardness of the material, the elastic rebound method is used (The

ratio of the speed of the impact body before and after the impact is measured).

Ultrasonic Contact Impedance –Consists in measuring the degree of change (damping) of the

vibration frequency of the rod with the indenter at the end when inserted into the surface of the sample.

The softer is the metal the dipper indenter penetrates into it, the bigger the square of the contact and

the less it influences the rod oscillation frequency (ultrasonic).

Kalman filter –An effective recursive filter that estimates the vector of a dynamic system state

using a series of incomplete and noisy measurements.

Median Filter –One type of digital filter, widely used in digital signal processing to reduce noise.

The median filter is non-linear FIR filter. Median filtering is an efficient procedure for processing

signals subject to impulse noise.

NOVOTEST.ED.Т-UD3.000 OM

Operation Manual

Hardness Tester NOVOTEST T-UD3

Page. 5

1 DESCRIPTION AND OPERATION OF THE DEVICE AND ITS COMPONENTS

1.1 The purpose of the device

The device is designed to measure hardness of:

metals and alloys on the Rockwell (HRC), Brinell (HB) and Vickers (HV), Leeb (HL),

Shore (HS) hardness scales and others.;

surface layer of metal subjected to fusing, spraying, mechanical, thermal and other types of

metal surface treatment;

cast iron, stainless steels and non-ferrous alloys, using the calibration mode on non-

standard hardness test blocks;

measuring of the tensile strength (v) for stretching products from carbonaceous steels of

the pearlite class by automatic recalculation from the Brinell hardness scale (HB).

The Hardness Tester allows instant analysis of the hardness of the product directly at the site of

operation or production of the product in workshop, laboratory and field conditions, for example, in

machine building, metallurgy, power engineering, shipbuilding and railway transport, aerospace and

oil and gas industry, repair and installation and service organizations etc.

The objects of measurement can be: pressure vessels for various purposes (reactors, steam

generators, collectors, boiler drums, gas holders, etc.), rotors of turbines and generators, pipelines,

rolls, crankshafts, gears, parts of various vehicles, industrial semi-finished products (castings,

Forgings, sheets), etc. Also, the hardness tester can be used for:

assessing the stability of technological processes (product processing, welding, etc.);

diagnostics of equipment, in order to evaluate its residual safe resource (control of

hardness of pipelines, boilers, etc.);

assessing the quality of performed repairs;

heat treatment quality evaluation.

1.2 Technical characteristics of the device

The NOVOTEST T-UD3 hardness tester is a portable device made in an impact-resistant housing

(with a special protective silicone bumper-case for complicated operating conditions) inside which a

board with electronic components and accumulators are placed. The main characteristics of the device

are presented in Table. 1.1, Table. 1.2 shows the ranges of measurements, and characteristics of probes

in Table. 1.3.

Table 1.1 - The main characteristics of the device

Overall dimensions, mm

180х80х35

each 1,2 V

Power supply current, not more than, mA

100

Time of continuous operation, not less than, h

Weight of electronic unit with batteries, not more than, g

250

Operating temperature range, ° С

from -20 to + 40

Humidity, not more,%

from 30 to 80

NOVOTEST.ED.Т-UD3.000 OM

Operation Manual

Hardness Tester NOVOTEST T-UD3

Page. 6

Table 1.2 - Measurement range and limits of the basic permissible error

Hardness scale

Measurement range

Measurement error

Leeb

Rockwell, HRC

From 20 to 70

±2

Brinell, HB

from 90 to 150

±10

Brinell, HB

from 150 to 650

±15

Vickers, HV

from 240 to 500

±15

Vickers, HV

from 500 to 940

±20

Leeb, HL

from 300 to 800

–

±15

Shore, HS

from 30 to 100

Is determined when markup

Strength limit σv (reference), Мpa

from 370 to 1500

Is determined when markup

Table 1.3 - Characteristics of probes

Probe Type

U1 (98 N)

U1 (50 N)

U1 (10 N)

Leeb

Overall dimensions, mm

Ø30х140

Ø20х145

Weight, g, not more than

250

130

Roughness of the measured surface, Ra

2,5

3,2

Radius of curvature of the measured

surface, mm

Weight of the controlled product, not less

than, kg

0,1

Thickness of the controlled product, not

less than, mm

Load, kgf

The device corresponds to: ASTM A956 “Standard Test Method for Leeb Hardness Testing of

Steel Products”; ASTM A 1038 “Standard Test Method for Portable Hardness Testing by the

Ultrasonic Contact Impedance Method”.

MTBF

Mean time between failures of the device without taking into account the reliability factor of the

probes is not less than 6000 h.

Service time

The total average service life of the device is not less than 10 years.

The criteria of decommissioning of the device - economicinexpediency of restoring the operable state

of the components of the instrument by repairing.

NOVOTEST.ED.Т-UD3.000 OM

Operation Manual

Hardness Tester NOVOTEST T-UD3

Page. 7

1.3 Standard delivery set

Electronic Unit ........................................................................................................................1 pc.

Rebound Leeb Probe.............................................................Availability - according to the order

Ultrasonic Contact Impedance Probe U1 (98 N) ..................Availability - according to the order

Ultrasonic Contact Impedance Probe U1 (50 N) ..................Availability - according to the order

Ultrasonic Contact Impedance Probe U1 (10 N) ..................Availability - according to the order

Rechargeable battery...............................................................................................................3 pc.

Charger....................................................................................................................................1 pc.

USB cable for PC....................................................................................................................1 pc.

Case.........................................................................................................................................1 pc.

Operating manual NOVOTEST.T-UD3.000 OM...................................................................1 pc.

Passport NOVOTEST.T-UD3.000 PS ...................................................................................1 pc.

Additional equipment:

Hardness test blocks (HRC, HB, HV, HLD, etc.) .................................................. If ordered

Cordless grinder...................................................................................................... If ordered

* At the request of the customer, the delivery kit can be expanded with additional equipment or

parts. The exact information about the delivery set is indicated in the passport of the device.

1.4 Purpose of the probes

The Rebound Leeb Probe (Figure 1.1, Rebound Leeb Probe) –purposed for hardness

measurement by dynamic method. It is intended for measuring hardness of large-sized objects, and

also coarse-grained materials.

The Ultrasonic Contact Impedance Probe U1 (Figure 1.1, Contact Impedance Probe U1) -

Measurement of hardness by Ultrasonic Contact Impedance method. The use of a diamond indenter

allows the probe to be mounted precisely at any tiny point, and leaves a small-size imprint, making the

measurement of the U1 the least destructive.

The probe is perfectly suited for the following tasks: measuring the hardness of complex shapes,

fine-grained materials, heat-treated materials, thin layers and coatings, surface hardened parts, thin-

walled pipes, small parts, etc.

Table 1.4 shows the characteristics of the UCI U1 type probes.

Figure 1.1 - Types of probes

NOVOTEST.ED.Т-UD3.000 OM

Operation Manual

Hardness Tester NOVOTEST T-UD3

Page. 8

Table 1.4 - Features and applications of UCI U1 probe type

Model

Load

Features

Main applications

UCI U1

(98 N)

98 N

(10 kgf)

The main type of probe for

solving most problems of

hardness measurement. 10 kg

load is to be applied for

measurement (set automatically

by the probe). Low requirements

for surface cleanliness.

Heat-treated and cemented details.

Measuring in grooves, on teeth, on

radius surfaces.

Measurement on the blades, on the

internal surface of the pipes,

openings.

UCI U1

(50 N)

50 N

(5 kgf)

The main probe type for the most

tasks of hardness measurement. 5

kg. load is to be applied for

measurement (automatically

controled by the probe). Average

surface cleannes requirements.

Heat-treated and cemented parts, for

example, shafts, turbines, gears,

teeth, welds, heat affected zones.

Measuring in grooves, on teeth, in

grooves, on radius surfaces.

Measurement on the blades, on the

internal surface of the pipes,

openings.

UCI U1

(10 N)

10 N

(1 kgf)

The reduced load probe is

designed to measure the hardness

of material with increased

requirements to the print size

(polished surfaces), to measure

the hardness of surface hardened

layers. 1 kg. load is to be applied

for measurement (automatically

controled by the probe).

More sensible to the surface

cleanliness, in comparison with

U1 (50 N).

Nitrided and cemented surface

layers of molds, stamps, stamps,

thin-walled parts.

Bearings, lateral surfaces of saws

teeth.

Measurement of hardness of

hardening coatings.

Measurement on the blades, on the

inner surface of the pipes, inside the

holes.

1.5 Parts

The device consists of an electronic unit made of impact-resistant ABS plastic and placed into a

protective silicone bumper, as well as connected probes. The detachable connection is located on the

upper end surface of the housing; there is also a mini USB connector, which is used to connect the

device to PC or to charge the batteries. The control keyboard is located on the front panel, which also

houses a contrasting color LCD / TFT display. In the lower rear part of the device under the cover,

fixed with the threaded connection with the help of two screws, there is a battery compartment in

which the batteries are installed (Figure 1.2.). In Fig. 1.3, it shows the control keyboard of the device.

NOVOTEST.ED.Т-UD3.000 OM

Operation Manual

Hardness Tester NOVOTEST T-UD3

Page. 9

1–bumper; 2 –LCD/TFT color contrast display; 3 –NiMH battery; 4 –control keyboard; 5 –battery

compartment; 6 –electronic unit; 7 –probe socket; 8 –flash light; 9 –photo camera; 10 –mini USB

socket; 11 –cover; 12 –cover securing with threaded connections.

Figure 1.2 - Hardness meter NOVOTEST T-UD3

Figure 1.3 - Control buttons and their functional purpose

On/Off button

Material selection

Mode selection

Navigation keys

Back

Scale mode selection

Enter

Backspace (back /delete one

position)

NOVOTEST.ED.Т-UD3.000 OM

Operation Manual

Hardness Tester NOVOTEST T-UD3

Page. 10

1.5.1 Ultrasonic Contact Impedance Probe U1 probe

The construction of the probe is shown in Fig. 1.4. The probe has a special removable collapsible

head with a double-sided thrust washer. The thrust washer provides the convenience of positioning the

probe onto the product and pressing during the measurement.

1 –housing; 2 –removable collapsible nozzle; 1 –housing; 2 –removable collapsible nozzle;

3 –removable double sided thrust washer; 3 –removable double sided thrust washer;

4 –support platform. 4 –centering pipe; 5 –diamond tip.

Figure 1.4 - Appearance of the Ultrasonic Contact Impedance Probe U1

One side of the washer is flat; the other has prismatic grooves designed for the convenience of

measuring hardness on cylindrical products of different diameters. The probe with the removed washer

is used for carrying out of measurement of hardness in narrow and hardly accessible places.

To measure hardness on flat surfaces, the washer on the probe head should be installed flat to the

surface of the product, and to measure the hardness on the cylindrical surfaces, the washer on the

probe head should be installed with a side with prismatic grooves to the product.

Caution!

To ensure a better smoothness of the collapsible detachable nozzles, they are individually grounded to

each probe. Replacement of probe tips is not allowed.

1.5.2 Leeb probe

The Leeb probe has a built-in mechanism for charging the spring, which is the most ergonomic

and convenient to work with. Spring charging is provided by moving the upper part of the probe

housing downwards, after which the probe can be installed on the controlled object and measurement

can be done.

Caution!

It is forbidden to discharge the trigger of the Leeb probe “in the air”.

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