(爬行器英文)使用说明书

Pipeline Crawler System Operating InstructionsModel: DTPXQ-IIIDandong Flaw-Detection Instrument Factory, ChinaTable of Content1.Introduction42.Main Technical Specifications43.System Components44.Operating Principle55.Installation and Operation65.1.Installation 65.2.Operating the Crawler 66.Maintenance and Precautions7er Instructions of the Magnetic Positioning System87.1.Overview 87.2.Working Principle 87.3.System Components 87.4.Settings and Interface of the Emitter Control Panel 97.5.Receiver Sensitivity Adjustment Instructions 107.6.Main Technical Specifications of the Magnetic Positioning System 117.7.Operating Procedures 117.8.Battery Maintenance and Precautions 147.9.Item List 158.Battery Charger User Instructions158.1.Main Features 158.2.Main Technical Specifications 15er Instructions 169.TH-JBQ-3A Field Radiation Alarm User Instructions179.1.Introduction 179.2.Main Features and Applications 179.3.Main Technical Specifications 17er Instructions 179.5.Cautions 189.6.Supplies: 189.7.Warranty for the alarm 1810.Accessories181.INTRODUCTIONThe DPTXQ-III X-ray Pipeline Crawler System is designed for non-destructive test of circumferential butt welds in pipelines such as gas and oil transmission lines. Thanks to its internal circumferential X-ray tube, it can test single circumferential butt welds with just one exposure. Therefore compares to the common outboard testing in the past, the work efficiency increased dramatically, as well as lowered workload of operations.The main features of the system including compact design, low weight, ease of operation, reliable and wide range of applications.2.MAIN TECHNICAL SPECIFICATIONS•Pipeline diameter range: 600-820mm•Thickness of the pipeline: 5-28mm•Max angle of climb: 38°•Travel speed: 15m/min•Travel distance: 0-1000m (Return)•Weight: 200Kg•Power source: DC batteries (120V)3.SYSTEM COMPONENTSThe Pipeline Crawler System consists of the crawler, magnetic positioning system, X-ray generator, DC battery and recharger, radiation alarm.•Crawler: To move the system inside the pipeline.•Magnetic positioning system: Including emitter and receiver, to direct the crawler moving to the precise welding points.•X-ray generator: Generates X-ray which penetrate through the testing area, to acquire an X-ray image.•DC power: A 120V DC battery, to power the whole system.•Recharger: To recharge the battery.•Radiation alarm: Prompting when the crawler is in exposure mode for safety.Figure 1 - Component Illustration 14.OPERATING PRINCIPLEThe crawler can travel inside the pipeline, when remote instructions are received, they will be processed by the CPU to determine whether to move forwards, backwards or stop, and when to start and stop the exposure process. A varies of tasks can be carried out by sending remote instructions to the system.Figure 2 - Component Illustration IIFigure 3 - Component Illustration III5.INSTALLATION AND OPERATION5.1.Installation•Check the package box to see if it’s intact, without cracks and damage.•After unpacking, check the contents according to the package contents list.•Take out the crawler, and then test whether the screws are loosened.•Select the necessary frames and fasten the screws.•Take out the battery cartridge then put it in the crawler.•Connect the X-ray generator to the device, and make sure it’s fastened.•Connect the various plugs.•Mount the Magnetic Positioning Receiver.•Double check the system to make sure the installation is performed correctly before use.5.2.Operating the Crawler(i)Start:Slide the locked switch to the “Power On” position, the crawler will then start moving forward after 3 seconds.(ii)Moving:The crawler will pause 3 seconds after being switched on or exposure is been performed, after that short period, it will start the motor and moving forward until it receives the positioning signal. While it’s on the move, the alarm will beep in every 10 seconds (Moving Beep), each beep lasts for 1 second.(iii)Positioning:Put the positioning emitter on the desired testing area outside the pipeline, when the crawler reaches that point and its onboard positioning receiver pick up the signal, the crawler will stop moving and proceed to the next phase. There are two kinds of positioning:Positioning while moving FORWARD: When the crawler ismoving forward, it will stop immediately when the positioning signalis being received. If the positioning emitter is off in 0~10 seconds,then the crawler will proceed to delayed waiting phase (Alarm willsound at the same time to indicate waiting state), after 20 seconds theX-ray generator will be powered up by high voltage and the crawlerwill proceed to exposure phase. If the positioning emitter is off at11~20 seconds, the crawler will proceed to backward moving state,and start moving backward (Alarm will sound at the same time toindicate backward moving state).Positioning while moving BACKWARD: When the crawler ismoving backward, alarm will beep once every 10 seconds to indicatethe backward moving state, each beep lasts for 1 second; it will stopimmediately when the positioning signal is being received, and thealarm will generate 1Hz (0.5s on, 0.5s off) sound until thepositioning emitter is off, then the motor will start and the crawler willbe moving forward.(iv)Exposure:When the crawler is in exposure phase, the alarm will make 0.5Hz continuous sound until the end of exposure, after that there’s 2 seconds delay and then the motor will start and the crawler will start moving.(v)Errors:There are three kinds of possible errorsLong exposure error:Normally the exposure time should be lessthan 5 minutes, if the exposure time reaches a certain threshold(Exposure time exceed 8 minutes), and there’s still no instructionfrom the emitter to finish exposure, then X-ray generator will beautomatically forced turned off for safety reason; alarm will go off atthe same time and lasts for 2 second, after that crawler will be forcedto move backward.No positioning signal error:If the crawler continues moving formore than 6 minutes without receiving any positioning signal, it willbe considered that the emitter is faulty, the crawler will then soundthe alarm and automatically returns, this is a procedure to prevent theerror of the magnetic positioning system.Water, obstacles blocking, and low battery error:If the crawlerencounters water or other obstacles when it’s on the move, or thevoltage of the battery is lower than a preset value, the crawler will beforced to go back. This is a security measure to protect the safety ofthe crawler.6.MAINTENANCE AND PRECAUTIONS!1. The outer appearance of the crawler and fastening device need to be visuallychecked and make sure they are in working order after each use; When lifting the machine, make sure to apply forces evenly on each side, and do not twist or pull otherwise it may damage the machine.2. Check the battery regularly; do not discharge the battery completely (refer tothe battery requirements section).3. X-ray generator has poor shock absorption; therefore it should be handledcarefully.4. Although the system is very reliable and it comes with alarm, but all fieldpersonnel should still carry a radiation-warning device to prevent accident. Incase the system failed to carry out exposure procedure, the system should bepulled out immediately and checked thoroughly.5. If the crawler failed to work, then it should be pulled out with emergency towdevice.6. Check the battery level and make sure it’s full before each use.7. It is strictly prohibited to use the crawler in the rain or under severe dampenvironment; If the crawler is splashed with water, the power should be turn offimmediately to prevent short circuit, and make sure to dry it off before use itnext time.ER INSTRUCTIONS OF THE MAGNETIC POSITIONING SYSTEM7.1.OverviewThe main features of the systemincludes powerful penetratingability, high positioning accuracy,no harmful radiation, compactdesign and simple operation, it’s amuch better replacement to the oldgeneration of radioactive isotopecesium 137 locator.7.2.Working PrincipleIt adopts the international leadingtechnology of Eddy Current.7.3.System ComponentsThe system consists of two parts including emitter and receiver.The emitter is a battery-powered portable device; the receiver needs stable and independent DC power that provided by the crawler. The emitter is placed on the outside of the pipeline, and the receiver should be mounted on the top of the crawler inside the pipeline.Figure 4 - Positioning Emitter Figure 5 - Positioning Receiver7.4.Settings and Interface of the Emitter Control Panel1. “Penetrating Properties”buttons area: it has three levels, including Thin, Medium and Thick, from weak to strong penetration, select these according to the thickness of the testing material to meet different field testing requirement. Choose “Thin” for small pipeline with thickness of 10mm; choose “Medium” for t h i c k n e s s l e s s t h a n 20mm; choose “Thick” for thickness more than 20mm.2. “+15V +5V -15V” Indicator LED: Indicating the working condition of the emitter’s internal circuit, all three should be o n u n d e r n o r m a l operating conditions.3. “Strength Adjustment” button area: to adjust thepower of the transmission.Greater value indicates strongermagnetic field emission. Theoretical values on the display ranges from 0 to 255, however the real figures are generally smaller, for example “thin” level is usually less than 50, “medium” is usually less than 100, and “thick” is usually less than 150. More magnetic emission power means greater power consumption, therefore it’s not recommended to continuously working under the maximum power for that penetrating setting (It’s when the power wouldn’t increase any more after keeping press the up arrow button).4. “Up” and “Down” buttons in the strength adjustment area: Press “Up” arrow to increase the power, press “Down” arrow to decrease the power.5. “Rapid/Fine Tune”button: To adjust the increase/decrease speed of the strength adjustment. The LED indicator lights up when it’s in “Fine Tune” mode. The default mode is “Rapid Tune”, press the button to switch between these two modes.6. “Voltage Alarm”button: LED for this button does not light normally, but when the voltage is too low (around 27V), the LED will light up and the buzzer will sound immediately to remind the user to recharge the battery of the emitter. The battery should last 10~30 minutes depends on different power settings. Press the button to turn off the alarm state, and the LED indicator will go off.Figure 6 - Emitter Control Panel7. “V/I Monitor”button: press to switch monitoring between voltage andcurrent; If the LED lights up then it’s in the “Current Mode”, the figures showing on the display is the power of the transmission, you can only adjust the power strength in this mode. Press it again to switch to Voltage mode, the LED goes off and you cannot change the power strength in this mode.8. “Set/Lock” button: to lock or unlock settings. You need to press this keyfirst to unlock the settings, and then adjust the penetrating level followed by power strength, after that you may press this button again to lock the settings, the display will flash 2~5 seconds to indicate the system is saving the new settings.9. “Power Saving” switch: it’s close to the handle on the upper side, switchthis off the system will then proceed to power saving mode, and all the settings should be saved; switch this on and the system will power up, ready to work without the need of setting the parameters again. You don’t need to use this switch for a short period of operating time.10. “Power” Switch with lock: The system will boot up after switch it on,and then preform self-test which lasts for around 5 seconds, the figures showing on the display becomes stable. After switch off the system, the power will be cut off completely; all settings will be saved without the need of setting the parameters again.11. Charging Sockets7.5.Receiver Sensitivity Adjustment Instructions1. Two small switches at the bottom of the receiver (in some models theseswitches are at the back of the receiver) which can set 4 different level of sensitivity, showing on the figure below.2. From level 1 to level 4, thesensitivity goes from weak to strongaccordingly. In coordination withdifferent penetration level on theemitter (thin, medium and thick), tosuit a wide range of pipeline withvaries thickness.3. If the transmission cannotpenetrate the pipeline with themaximum power setting on theemitter, you may increase thesensitivity of the receiver.Figure 7 - Sensitivity Settings4. It is recommended to use level 2sensitivity for pipe with thickness less than10mm, and diameter less than 300mm; level 3 sensitivity is used morefrequently for thickness less than 20mm; You may use level 4 sensitivity for thickness more than 20mm; for thickness more than 30mm you should always use level 4sensitivity.5. Note: If there’s serious magnetic interference nearby (from high-voltagewires, transformer substation etc.), You may lower one level of sensitivity on the receiver, and increase the penetrating power on the emitter. Any kind of motor operating around the testing site should be kept away to avoid the direct interference.7.6.Main Technical Specifications of the Magnetic Positioning SystemEmitter:•Input Voltage: DC32V±8V•Rated Power: ≤50W•Penetrating Power: ≤30mm•Weight: 4.7kg•Operating Temperature: -40℃ ~ 80℃•Working Time: more than 8 hours•Size: 225 x110 x 195mmReceiver:•Input Voltage: DC12V/24V±3V•Rated Power: ≤4.8W•Crawler Speed: ≤30m/min (Recommend constant speed: ≤20m/min)•Weight: 0.5kg•Operating Temperature: -40℃ ~ 80℃•Receiver Sensitivity: 4 levels adjustable•Distance between the receiver and the top (inside) of the pipe: 5~10cm (If crawler has large deviation of track, then 10~20cm is recommended)•Accuracy of positioning: ±5mm•Size: 100 x 110 x 27mmAluminum Protective Case: 400 x 315 x 350mmBattery Charger: 220AC/DC16.8V/1.0A Standard Charger7.7.Operating Procedures(i)Transmission Level Setting:Power level on the emitter and sensitivity level on the receiver shouldbe set according to the pipe’s diameter and thickness.(ii)Correct wiring for the receiver:Wiring:Color of power cord: Red (+), White (-)Color of signal cord: Orange, GreyTechnical Standard for the receiver:Power Supply: DC 24VOutput Signal Type: Passive switch(iii)Setting up the devices1. Mount the receiver: Mount the receiver to the front part of thecrawler (away from the motor side), the distance between receiver and the top of the pipe wall should be appropriate. Connect the cable between the receiver and the crawler (Correct wiring needed, otherwise it may damage the receiver or fail to receive the signals), and then tighten up the connectors. Put the crawler into the opening of the pipeline, make sure the receiver is about 1m into the pipeline so that it’s possible to observe the receiver’s LED status.2. Switch off the power of the motor on the crawler, or lift up thewheels, to make sure the crawler doesn’t move while adjusting the signal strength.3. Placing and starting the emitter: Put the emitter on the outer wall ofthe pipe, control panel facing the user, and ensure the emitter is basically in the same vertical line to the receiver. Use the key to switch on the emitter, and then turn on the power saving mode (If the power saving switch is being turned on beforehand, then the emitter will not boot up normally). It may take a few seconds for the emitter to do the self-test, reload the settings from last time. Remember you need to turn off power saving mode before switch off the emitter, and use the key to lock the power switch after that. Continuous power up interval should be more than 5 seconds.4. Adjusting the transmission power: If the blue indicator LED on thereceiver doesn’t light up, increase the emitter’s power by press the up arrow button in the “Penetrating Strength” area, when the blue LED lights up and become stable (not flashing), increase the power a few more steps to ensure a good reception (the emitter can only send signal to the receiver when the blue LED is on), then lock the setting by press the “Set/Lock” button. While adjusting the transmission power, the red LED on the receiver lights up first, and then blue LED lights up. You may also adjust the position of the receiver horizontally so that it’s in the same vertical line to the emitter.If the blue LED on the receiver already lit up without any adjustment, there’s two ways to re-ensure that the transmission power is sufficient. One way to do this is that you may lower the power on the emitter, up to a point where the blue LED on the receiver turns off,and then you may re-adjust again by increase the emitter’s power using the method above; Another way to make sure the transmission power is sufficient, is that you may simply just increase the power a couple of more steps, however this may cause the receiver picks up the signal earlier than desired, and making the crawler stops prematurely, thus to make the whole positioning process inaccurate.5. Do a test run on the crawler first in a short pipeline, and determinethe appropriate distance between the welds and where you should place the emitter.(iv)Operating1. Switch on the crawler, put the emitter close to the outer surface ofthe pipeline, then move it away slowly following the pipeline to send out the signal, the crawler should start working.2. When the crawler starts working, place the emitter on the upperwall of the pipeline close to the weld point, make sure it’s in the same vertical line to the receiver (otherwise it may cause positioning inaccurate).3. After the positioning process finish, take the emitter and move it tothe next testing (welds) point. While moving emitter, the head of the emitter (the side with the locked switch) should be kept facing the same way, and user should also observe the power value on the control panel display, it’s normal if the value changes up or down 1 level.(v)Attention while in operating1. The settings for the emitter (including penetrating level andtransmission strength) should be re-adjusted for pipe with different diameter and/or wall.2. The variation of the distance between the emitter and pipelineshould not exceed 2mm, otherwise you may re-adjust the transmission power (especially for the repositioning when the crawler re-enter the pipeline).3. If necessary, use the power saving switch close to the handle whilecarrying it from one weld point to another, remember to turn it back on upon reaching the next point.4. The receiver is only designed to work inside the pipeline, when it’sout in the open and exposed to the magnetic field for too long, it may damage the receiver.5. The sensitivity level on the receiver cannot be changed while thepower is on, to change it you need to turn off the power first, and thenturn it back on after the new sensitivity level is being set.6. The speed of the crawler may change due to power consumption,and this may affect the positioning accuracy. It is recommended to usethe Magnetic Positioning System on a crawler with steady speedability.7. Try not to set the speed of the crawler too fast, and make sure it’smoving in a straight line, otherwise it may affect the positioningaccuracy.8. The inside and outside surface of the pipeline may be painted withsome special anti-corrosion, anti-static and anti-magnetic materials,when this affects the penetrating ability of the emitter, adjust thepenetrating power of the emitter as well as the sensitivity of thereceiver accordingly.9. After positioning, the crawler proceeds to exposure phase, duringthis period, some electrical parts inside the crawler may generate mildinterference to the receiver, however the signal can be shielded bysetting up certain program during exposure phase.7.8.Battery Maintenance and Precautions1. Battery should not be charged continuously for over 24 hours, or it mayaffect the lifespan of the battery.2. When the battery is not being used for more than a month, you needperform a discharge and recharge to protect the battery.3. If the display on the control panel showing 28 or less when pressing the“V/I” button, it’s not in a good state for long time use; when the low-voltage alarm beeps, you should recharge the battery as soon as possible orthe emitter may turn off automatically.4. When the emitter is in Power-Saving mode(The main locked switch is still on), because thepower is not completely turned off, therefore itwill still drain the battery slowly. Remember toturn off the locked power switch and put it inthe storage case after use.5. To charge the battery, plug the two chargingcables into the two sockets separately. Whenthe LED indicator turns from red to blue, itmeans the charging completed.Figure 7 - Charging Sockets7.9.Item List•Magnetic Positioning Emitter•Magnetic Positioning Receiver•33V/4.8AH High Capacity Rechargeable Battery (pre-installed in the emitter)•Accessories: Battery Charger x2, DC16.8V/1.0A Standard Charger•Accessories: Protective Storage Case•Accessories: Protective Storage Case Key x2, (silver color)•Accessories: Emitter power switch keys x2 (with black handle)8.BATTERY CHARGER USER INSTRUCTIONS8.1.Main FeaturesFigure 9 - Battery Charger•Wide input voltage range•Output voltage value can be adjusted continuously from 120~150V•Output current value can be adjusted continuously from 0.5~5A•To increase the output current, more units can be set in parallel without the need of current process•Input: over-current, over-voltage, under-voltage protection; Output: short circuit, over-current, over-voltage protection; Overheating protection•Intelligent temperature-controlled fan cooling8.2.Main Technical Specifications•Environmental ConditionsOperating Temperature: -20~50℃;Storage Temperature: -40~70℃;Relative Humidity: 90% (40±2℃);Atmospheric Pressure: 70~106 kPa•Dimensions and Weight: 250mm x 210mm x 68mm 3.2Kg•Input Voltage: AC180~264V Frequency: 50Hz±10%•Output Voltage: DC120~150V (factory setting 5A)•Efficiency >90%•Power Factor >0.85•Load Regulation <1%•Voltage Regular <0.1%•Ripple Voltage <1%•ProtectionInput: over-current, over-voltage, under-voltage protection;Output: short circuit, over-current, over-voltage protection;Overheating protection•Thermal Protection Threshold: 80~85℃•Insulation Resistance ≥20MΩ•MTBF ≥50000her Instructions1. Check before connecting the power: observe to see if there’s any damagedue to transportation, such as loosen screws, strange appearance etc.Proper measures should be taken if any problems are being found.2. Connection: connect the safety ground wire and power cord; make surethe connection is correct and firmly tightened.3. Select charging conditions: turn the “Charging Current Selection” knobto 2A; charging time is 10 hours, increase the current appropriately to speed up the charging. Charging voltage should be selected as 135V.4. No-load power up: turn on the power switch, and then output voltageshould be appeared on the voltmeter. Use a small screwdriver to adjust the output voltage setting on the panel to a desired value, turn it clockwise to increase the voltage, counterclockwise to reduce the voltage.5. Connect the output cable: turn off the power, connect the cable to thecharger and rechargeable battery according to the marks on the panel, red wire to the (+) terminal on the charger, green wire to the (-) terminal. Make sure the connection is correct and then connect the 5-pin plug to the battery. Extra caution should be taken as wrongly connection to the terminals may damage the device. All connectors should be connected firmly.6. Adjust charging current: turn on the power, use a small screwdriver toadjust the output current setting on the panel to a desired value (adjustment can only work when there’s input current), turn it clockwise to increase the current, counterclockwise to reduce the current.7. Cooling fan is temperature-controlled, when the internal temperatureexceeds certain point, the cooling fan will be triggered to start, fan speedvaries with different output voltage and current settings, this is normal; When it’s working, do not block the ventilation of the fan.8. When the internal temperature of the device reaches the auto-shutdown threshold, the device will automatically stop working to protect it from being damaged; when the temperature dropped the device will restart and work again.9.Warning: do not charge the battery until you’ve checked the charger is in working order.9.TH-JBQ-3A FIELD RADIATION ALARM USER INSTRUCTIONS9.1.IntroductionThis product is designed according to the special requirement of industrial X-ray testing site, it features a new looking, and wirelessly radiation detection, small size and low weight, high output power, alarm with sound and flashlight, easy to carry.9.2.Main Features and Applications•Alarm with sound and flashlight, 360°sound field •It is widely used in the field of X-ray and γ-ray testing, γ source transportation and indoor monitoring system.9.3.Main Technical Specifications•Sound Pressure: ≥80dB •Sound Frequency: 900Hz •Intermittent Frequency: 1.5Hz •X-ray detection range: 20 meters (open area)•Power Consumption: ≤25W •Size: Φ200mm , Height 225mm •Weight: 3.5kg •Battery Life: 8 Hourser Instructions1. Turn on the alarm by pushing the switch to the “Working” mode, and then place it on a suitable surface.Figure 10 - Radiation Alarm2. Adjust the volume by rotate the control knob to an appropriate level.3. When X-ray is being detected, siren will sound with flashlights.4. Siren will continue to sound for 6 more seconds after X-ray detection isgone, due to the internal data refresh rate.5. Turn the switch back to “Charging” mode when finish.6. The alarm needs to be recharged after working for 8 hours, make sure theswitch is on “Recharge” mode, and then connect the battery charger plug to the alarm, the LED showing green light, the battery should be fully recharged approximately 15 hours.9.5.Cautions1. Only use the supplied charger to charge the battery.2. Handle with care.3. The LED also doubles as a low-power indicator, it will show red lightwhen the battery is really low, and alarm will stop working and should be recharged as soon as possible.9.6.Supplies:Charging Power Adaptor x19.7.Warranty for the alarmManufacturer can repair it for 6 months starting the date of sale.10.ACCESSORIESFor different pipelines with different diameters, there’s varies accessories you can choose for the system, please find it on the separate accessories list.。