User'S Manual: June 2006 T.O. #33D7-22-32-1

USER’S MANUAL
Sonic® 1200M Ultrasonic Flaw Detector

Operation/Maintenance Manual
June 2006
PN 7720136.01
T.O. #33D7-22-32-1
T.O. #33D7-22-32-1
In accordance with European Directive 2002/96/EC on Waste Electrical and Electronic Equipment, this symbol
indicates that the product must not be disposed of as unsorted municipal waste, but should be collected separately.
Refer to your local Olympus distributor for return and/or collection systems available in your country.
Copyright ¤ 2006 by Olympus NDT, Inc. 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, recording, or by any information storage and retrieval
system, without the written permission of Olympus NDT, except where permitted by law. For
information, contact: info@OlympusNDT.com.
Other product names mentioned in this document may be trademarks of their respective companies, and
are mentioned for identification purposes only.
Printed in the United States of America.

Warranty
Warranty
The Sonic® 1200M has been designed and manufactured as a high quality instrument.
Inspect the unit thoroughly upon receipt for evidence of external or internal damage that
may have occurred during shipment. Notify the carrier making the delivery immediately
of any damage, since the carrier is normally liable for damage in shipment. Preserve
packing materials, waybills, and other shipping documentation in order to establish
damage claims. After notifying the carrier, contact Olympus NDTTM so that we may assist
in the damage claims, and provide replacement equipment, if necessary.
Olympus NDT guarantees the Sonic 1200M to be free from defects in materials and
workmanship for a period of one year (twelve months) from date of shipment. This
warranty only covers equipment that has been used in a proper manner as described in this
instruction manual and has not been subjected to excessive abuse, attempted unauthorized
repair, or modification. DURING THIS WARRANTY PERIOD, Olympus NDT
LIABILITY IS STRICTLY LIMITED TO REPAIR OR REPLACEMENT OF A
DEFECTIVE UNIT AT ITS OPTION. Olympus NDT does not warrant the Sonic 1200M
to be suitable of intended use, or fitness for any particular application or purpose.
Olympus NDT accepts no liability for consequential or incidental damages including
damage to property and/or personal injury. In addition to our standard one year warranty,
Olympus NDT also offers an optional two year warranty (call for further details).
This warranty does not include transducers, transducer cables, or battery. The customer
will pay shipping expense to the Olympus NDT plant for warranty repair; Olympus NDT
will pay for the return of the repaired equipment. (For instruments not under warranty, the
customer will pay shipping expenses both ways.)
In this manual, we have attempted to teach the proper operation of the Sonic 1200M
consistent with accepted flaw detection techniques. We believe the procedures and
examples given are accurate. However, the information contained herein is intended
solely as a teaching aid and should not be used in any particular application without
independent testing and/or verification by the operator or the supervisor. Such
independent verification of procedures become more important as the criticality of the
application increases.
For these reasons, we make no warranty, expressed or implied, that the techniques,
examples, or procedures described herein are consistent with industry standards nor that
they will meet the requirements of any particular application. Olympus NDT expressly
disclaims all implied warranties of merchantability and of fitness for any particular
application.
Olympus NDT reserves the right to modify all products without incurring the
responsibility for modifying previously manufactured products. Olympus NDT does not
assume any liability for the results of particular installations, as these circumstances are
not within our control.
THE WARRANTIES SET FORTH HEREIN ARE EXCLUSIVE AND ARE IN LIEU
OF ALL OTHER WARRANTIES WHETHER STATUTORY, EXPRESS, OR
IMPLIED (INCLUDING WARRANTIES OF MERCHANTABILITY AND FITNESS
FOR A PARTICULAR PURPOSE, AND WARRANTIES ARISING FROM COURSE
OF DEALING OR USAGE OR TRADE).
T.O. #33D7-22-32-1
T.O. #33D7-22-32-1
(CE) Mark
The Sonic 1200M and it's accessories have been tested in accordance with EN61326:2002
as required by the EMC directive 2004/108/EC.
The Sonic 1200M, and it's accessories meet the emissions requirements of EN61326:2002
for Class "A" equipment and the immunity requirements of EN61326 Annex A:2002.
To ensure compliance to the EMC directive, any cable attached to the RS-232, VGA,
analog I/O, or BNC connectors must be shielded and must be less than three (3) meters in
length. Longer cables may be used if they are installed in conductive cable trays or
conduit and may require ferrites.
The Sonic 1200M has a performance characteristic “B” when operated from the charger
during the EN61000-4-4:2004 (EFT / Burst) immunity test when tested at 100 KHz burst
frequency.
Warning: Any changes or modifications to this instrument or use of unauthorized

accessories not expressly approved by the party responsible for compliance
could void the user’s authority to operate this equipment in countries that
require compliance with the EMC directive.
Hazardous Area Operations

The Sonic 1200M may be used in potentially explosive atmosphere areas as defined by
Class 1, Division 2, Group D of the National Fire Prevention Association Code 70 (NFPA
70), Section 500.
The Sonic 1200M and it's accessories have been tested to meet the requirements in
accordance with MIL-STD-810F, Method 511.4, Procedure 1.
Operators of this instrument must understand and be familiar with NFPA 70 and MIL-
STD-810F. The instrument must be checked for proper operation prior to entering any
hazardous area.
Limitations of Use in Hazardous Areas
This instrument must be operated from internal batteries and all external power sources
must be disconnected.
Warning: Any changes or modification to this instrument or use of unauthorized

accessories not expressly approved by Olympus NDT would void the user
authority to operate the Sonic 1200M in hazardous areas.
Table of Contents - T.O. #33D7-22-32-1
Table of Contents
Warranty
1 Preparation for Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Introduction to PowerLink™
1.1 Unpacking the Sonic 1200M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2 Sonic 1200M Optional Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3 Initial Inspection Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.4 Power Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.5 Li-Ion Battery Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.6 Charging the Li-Ion Battery Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.7 Operating Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.8 D-Cell Battery Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3 FastBreak Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.1 Getting Started with FastBreak Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.2 Ready . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.3 Operating Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.4 Set. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.5 Go - Weld Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4 Control Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.1 Instrument Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.2 Power Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.3 Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.4 Soft Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.5 INC/DEC Arrow Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.6 Main Menu Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.7 Enter Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.8 Print Key. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.9 SmartKnob™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.10 RCV and XMIT BNCs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.11 Pulser Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.12 Receiver Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.13 Range Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.14 Gate 1 Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.15 Gate 2 Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

4.16 Thickness Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.17 Angle Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.18 DAC Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.19 Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.20 SPCL Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.21 Program Sub-Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4.22 Report Form Sub-Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4.23 Clock Sub-Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.24 A-scan Sub-Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4.25 A-scan Attribute Sub-Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4.26 Data Sub-Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
4.27 New Block Editor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.28 Block Review Sub-Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4.29 Text Editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.30 Instrument Reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5 Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5.1 Pulse-Echo Contact Thickness Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5.2 Dual Transducer Thickness Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
5.3 Delay Line Thickness Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
5.4 Shear Wave (Angle Beam) Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
5.5 Distance Amplitude Correction (DAC) Testing. . . . . . . . . . . . . . . . . . . . . . . . . 104
6 Internal Datalogger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
6.2 Creating a New Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
6.3 Selecting a Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
6.4 Storing Readings into Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
6.5 Selecting Locations and Reviewing Readings . . . . . . . . . . . . . . . . . . . . . . . . . . 113
6.6 Clearing Readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
6.7 Clearing a Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
6.8 Deleting a Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
6.9 Deleting All Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
7 Computer Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

7.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
7.2 RS-232 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
7.3 Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

7.4 Command Strings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
7.5 Status Reporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
7.6 RS-232 Command Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
7.7 Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
8 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
9 Sonic® 1200M Maintenance and Service . . . . . . . . . . . . . . . . . . . . . . . . . 135

9.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
9.2 Periodic Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
9.3 Corrective Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
9.4 Illustrated Parts Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Appendixes
Opertion Verification (QIP-144) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
ASTM E317/AWS D1.1 (CTP-137) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Preparation for Operation
1 Preparation for Operation

What’s in this section?
1.1 Unpacking the Sonic® 1200M
1.2 Sonic® 1200M Optional Accessories
1.3 Initial Inspection Checklist
1.4 Power Requirements
1.5 Ni-MH Battery Characteristics
1.6 Li-Ion Battery Characteristics
1.7 Charging the Ni-MH / Li-Ion Battery
1.8 Operating Environment
The PowerLink™ feature enables the Sonic® 1200M instrument to recognize a Olympus NDT
PowerLink transducer type and provides the capability to modify selected instrument parameters
for program storage and recall. PowerLink has a separate screen with a sign-on message and
menu structure (as shown).
Each PowerLink transducer is programmed at the factory to identify itself by model, frequency,
serial number and type. The operator may select the factory default setup for each transducer type
in the event that an instrument setup has not been associated with that transducer.
The stored program feature is tied into the program store and recall features of the instrument.
This makes stored programs associated with transducers look the same to the operator as other
stored programs.
9 - T.O. #33D7-22-32-1
Before any stored transducer programs can be recalled, a Olympus NDT transducer must be
connected to the instrument and identified. Multiple programs are associated with each
transducer and the operator is allowed to select from the programs stored.
Note: When a transducer linked through PowerLink is removed and replaced with
another transducer, the Sonic® 1200M instrument MUST be recalibrated, or
the new transducer relinked before testing.
PowerLink™ Connection
After connecting a Olympus NDT transducer to your Sonic® 1200M instrument, touch and hold
the transducer to the PowerLink contact disc on your EL/LCD display for approximately 4
seconds, or 2 beeps. If contact is not maintained for the proper amount of time, the screen will
show the PowerLink display with N/A parameters. In this case, try again, until the PowerLink
connection is complete and parameters are displayed.
Menu Description
• Model - Transducer Model
• Frequency - Transducer Nominal Frequency
• S/N - Serial Number (stamped on the front of the transducer)
• Mode - Single or Dual
• Program Name and Date Stamp - Program number, optional operator-entered
description, and date stamp. The stored program number is shown in the
PROGRAM softkey menu box.
Program
This line displays the program storage location/transducer setup, which is to be
stored, recalled, or erased. Rotating the SmartKnob™ will cycle through the
storage locations associated with the identified transducer. If no stored loca-
tions are associated with the identified transducer, the number of the next
empty storage location will be displayed.
Store/Recall
Instrument settings associated with the identified transducer are stored to or
recalled from the selected program location. If the location is empty, the oper-
ator is allowed to store the instrument setup. Whenever a transducer setup is
recalled, the current instrument settings are overwritten and cannot be recov-
ered unless the setup was previously saved.
Erase
Allows the operator to erase the selected transducer setup. This needs to be
done only if the storage location is to be reused. An ENTER confirmation will
be required from the operator before the program location is cleared. An erased
location cannot be recovered.
10 - T.O. #33D7-22-32-1
Name
Allows the operator to enter a name of up to 26 characters to identify the setup.
Only program locations which are not empty may be named.
Default
Restores the factory default instrument setup and changes the PULSEWIDTH,
FREQUENCY, and MODE parameters of the receiver in accordance with the
identified transducer parameters.
The PowerLink menu may be exited at any time without changing instrument setups by pressing
any menu key on the main keypad. When recalling default setups for an angle beam transducer,
the operator will be sent to the ANGLE menu on return from the PowerLink menu. When
recalling the default setting from a nonangle beam transducer, the operator will be returned to the
RCVR menu on exit from PowerLink.
1.1 Unpacking the Sonic 1200M

All cartons should be opened and inspected upon receipt. The cartons and contents should be
inspected for any signs of damage that may have occurred during shipment. If damage is noted,
contact the carrier and retain the damaged shipping materials until an inspection can be
performed by a representative of the carrier. With the exception of the UBC (universal battery
charger) and external accessories, all Sonic® 1200M options are installed before the unit is
shipped. Check the contents of the carton or cartons against the Packing List to ensure that all
accessories ordered have been received.
1.2 Sonic® 1200M Optional Accessories

A variety of optional accessories are available for the Sonic 1200M. A short list of some of these
options follows. For specific needs not listed below, contact your Olympus NDT sales
representative for an additional list of optional accessories.
11 - T.O. #33D7-22-32-1
Description Function
Transducers and Probes Primary sensor for flaw detection, thick-

ness gauging, and conductivity mea-
surement
Hands-Free Chest Harness Supports the instrument while climbing
Protective Soft Cover Protection of instrument while in use
Hard Shell Travel Case Protection of instrument while not in use
Portable Printer (includes RS-232 cable) Printouts and Reports
Parallel to Serial converter For use with parallel printers
Printer Battery Power for portable printer
Computer Software Provides method of up/down load of

reports and test setups
Dual Li-Ion Charger Charges the batteries outside of the

instrument
Replacement Li-Ion batteries Primary power source
Color LCD Display Required for external VGA output,

includes VGA adapter cable
Heads-Up Display For use when you cannot see the instru-
ment display directly / hands free instru-
ment use
12 - T.O. #33D7-22-32-1
Optional outputs include:

• Alarm Output (Gate1 and Gate 2)
• Pulser Sync Output
• Thickness Alarm Output
• Distance Analog Output
• Flaw Amplitude Output.
Note: Hands-free Chest Harness/Battery Belt - This accessory is designed to hold

the weight of the Sonic®/Nortec®/BondMaster 1200 series of
nondestructive test (NDT) equipment and it’s accessories. Specifically, the
pouch on the chest harness is designed to hold the DR-35 battery sled, which
adds two batteries to the system to extend field operation time. THE CHEST
HARNESS IS NOT DESIGNED TO SAFELY SUPPORT THE WEIGHT
OF THE USER IN ANY SITUATION!
1.3 Initial Inspection Checklist
After the Sonic® 1200M has been unpacked and the contents of the carton have been checked
against the packing list, a visual inspection and a basic operation test should be performed.
• Cosmetic or structural damage?
• Instrument Power “On”
• Power On Self Test
• EL/LCD Sign On Message displays?
1.4 Power Requirements
Power Requirements
As a fully portable inspection instrument, the Sonic 1200M relies on one Lithium Ion (Li-Ion)
battery as the primary source of power. The battery compartment is located at the rear of the unit
and is conveniently accessed by loosening the quick release screw and rotating the battery cover
out of the way.
The Li-Ion batteries provided with the Sonic 1200M instrument are small, lightweight, portable,
and capable of delivering long service life between recharges or battery replacement.
A Universal Battery Charger (UBC) unit is provided with the Sonic 1200M for recharging the
Li-Ion batteries while in the instrument or external battery pack and allowing the Sonic 1200M
to be operated from AC line power. The UBC unit auto senses 90-264 VAC line power at 47 to
63 Hz.
13 - T.O. #33D7-22-32-1
The condition of the batteries used in the Sonic 1200M is monitored by the charger. Fully
discharged Li-Ion batteries will require approximately 6 hours to charge. The charger will not
charge batteries which are too hot, too cold, or too deeply discharged.
Li-Ion
RCV XMT
Top of Instrument
Figure 1-1: Battery Cover Location
For Optimum Performance:

• Refer to the manual that came with your instrument or charger for charging instructions.
• When you charge your battery for the first time, your charger may indicate that charging is complete after just
10 to 15 minutes. This is normal and can happen with all rechargeable batteries when first charged. Simply
remove the battery and then repeat the charging procedure.
• Upon first use, or after prolonged periods of storage, you may need to charge and discharge your battery two
or three times before obtaining optimum performance.
• It is best to charge the battery at room temperature ranging between 59°F (15°C) and 86°F (30°C).
• It is normal for the battery to become warm during charging or after use.
• It is not necessary to fully discharge your battery before charging. You can top-off the charge at any time.
• A charged battery will gradually lose its charge if left in storage. We therefore suggest that you top-off the
charge before use.
• Remove your battery from the equipment, charger or AC adapter when not in use. Store at room temperature
in a dry place.
TO AVOID DAMAGE TO THE BATTERY:

• Do not drop the battery or subject it to mechanical shock.
• Use the battery only with equipment that specifies its use.
SAFETY PRECAUTIONS:
• Do not disassemble or attempt to open the battery under any circumstances.
• The battery can explode, leak, or catch on fire if heated or exposed to fire or high temperatures.
• Do not short circuit the battery by directly connecting the metal terminals (+, -). Be certain that no metal
objects such as coins, paper clips, etc., touch the terminals.
• Only use the charger recommended by the device manufacturer.
14 - T.O. #33D7-22-32-1
MEMORY BATTERIES:
• Internal memory batteries should be changed as a preventative maintenance feature every 2 years.
Note: It is recommended that you refrain from operating the instrument while
recharging fully discharged batteries. The charge may be incomplete and
thus activate the temperature fault indicator — as a result, battery life and
instrument run time may be shortened significantly. If the indicator is
activated, shut off the instrument and disconnect the instrument from the
charger. Allow the batteries to cool, then reconnect the charger to the
instrument to start a new charge cycle.
1.5 Li-Ion Battery Characteristics

• Higher capacity - up to 60% longer run time than ordinary Ni-MH batteries of equiva-
lent size
• Fast Charge - approximately 6 hours
• Long cycle life - up to 300 charge/discharge cycles
• Temperature Range (charging) - 32°F to 104°F (0°C to 40°C)
• Temperature Range (operating) - -4°F to 140°F (-20°C to 60°C)
• Temperature Range (storage) - -4°F to 122°F (-20°C to 50°C)
• Environmental friendliness - 0% cadmium, no disposal problems
• Size L x W x H - 8.5 x 2.3 x 0.9 in. (215 x 59 x 23 mm)
• Weight - 17.6 oz. (493 g)
• Nominal Voltage - 10.8V
• Rated capacity - 6.6 Ah nominal
• Hours of Operation - 8+ hours with EL display, Monochrome LCD, or Color LCD
display
Wide Keyway
+
2¼" Wide
Li-Ion Battery
-
15 - T.O. #33D7-22-32-1
Note: Fully charge battery before first use. Instrument run time is affected by
variables such as: quality of charge, age of battery, and display type. The
battery charge indicator on the display is an estimation of expected run time.
Instruments are equipped with a circuit that shuts off power prior to full
discharge. Battery life is affected by: number of charge/discharge cycles,
storage conditions, temperature, and use. Batteries stored for extended
periods of time (months/years) without use may no longer recharge. Under
normal use, a Lithium-Ion battery will last approximately 300 cycles.
Expect to change the batteries after 1 year of heavy use or 3 years of light use
under normal conditions. Batteries must be disposed of in accordance to
local law or returned to Olympus NDT. Olympus NDT does not warranty
batteries, due to operating conditions beyond Olympus NDT control
affecting battery life.
1.6 Charging the Li-Ion Battery Pack

Proper charging of the Li-Ion battery packs is critical for overall life and performance. The
Universal Battery Charger (UBC) will charge the Li-Ion battery used in the instrument. Note
that the UBC to instrument cables are detachable and replaceable as catalog items.
The charger also functions as a battery eliminator to operate the instrument from the AC power
source. Batteries do not have to be installed to operate the instrument from AC. When operated
from the UBC without a battery installed in the instrument, disregard any battery charge status
indications from the UBC charge indicator. The instrument can be operated while a Li-Ion
battery is being charged.
1.6.1 UBC Specifications
Power Requirements: 90-264 VAC line power at 47 to 63 Hz.
The UBC contains an internal fuse.
Lithium Ion battery charging system: Charges one Li-Ion battery. Charges at approximately 1.5
ampere rate. A 6.6 AH battery charges in approximately 6 hours.
Temperature range: Batteries should be charged between 40° to 100° F (4° to 38° C) for best
results.
If the batteries become too hot, the battery charger will terminate the charging process.
If the batteries are being charged while using the instrument, the heat from normal operation of
the instrument may cause the battery charger to terminate the charging process before the
batteries are fully charged.
To start a charge cycle, the charger can be reset by disconnecting and reconnecting either the
instrument or AC power to the UBC.
16 - T.O. #33D7-22-32-1
1.6.2 Charger Status Indicators
The charger status is indicated by a red/green LED lamp
The light may blink red or green for a few seconds when first connected to either AC power or
an instrument. It will then light steady red as the charging process starts. This is normal as the
circuits initialize. If a problem is detected during charging, the light will blink red. Reset the
charger by disconnecting the AC power for a few seconds and re-connect. If the problem
persists, service is required.
UBC Charger (P/N #9522153)

Charge Status Light Code
No Battery OFF
Charge Error Blinking red
Charging Red
Charging Complete Green
1.6.3 Charger Operation Instructions
Connect the UBC to a source of AC power
Connect the cable to the instrument and charger.
Lithium-Ion batteries: The red charging indicator will light, indicating that the batteries are
charging. The indicator will turn green when the battery is charged.
The charger circuits can be reset if a problem occurs by disconnecting either the AC power for
at least 15 seconds or the UBC to instrument cable (either end) and then re-connecting. Li-Ion
batteries are sensitive to over charge. For this reason, the full charge detection system is very
sensitive and may shut off the charging process before the charge is complete. If this happens,
reset the charger.
During use, the UBC case will become warm.
The charger is designed to shut off after a Li-Ion battery is fully charged (the instrument power
is always available). It does not provide a maintenance charge, because Li-Ion batteries can be
damaged by trickle charging. To recharge a Li-Ion battery, reset the charger by either
disconnecting the AC supply or instrument for a few seconds to reset the charger circuit. Li-Ion
batteries have a long shelf life and should only require recharging after many months of storage
if not used.
17 - T.O. #33D7-22-32-1
1.6.4 Battery Safety
Old batteries that will no longer deliver satisfactory service should be disposed of in a legal and
environmentally friendly manner. In the USA, call 1-800-8BATTERY for the nearest battery
recycle center. If there is no convenient battery recycle center, the batteries may be returned to
Olympus NDT for proper disposal.
No battery should be disposed of by fire or abused by puncturing its case or disassembled. All
batteries contain potentially hazardous chemicals, however neither Ni-MH or Li-Ion batteries
contain lead, cadmium or mercury.
Lithium-Ion batteries contain an internal safety circuit. Both Nickel-Metal Hydride and Lithium-
Ion batteries contain internal fuses. If this fuse blows or the safety circuit shuts off the battery,
the battery is no longer fit for service. The internal safety circuits are not serviceable.
Olympus NDT purchases batteries from reputable vendors. Although Olympus NDT tests and
qualifies the batteries for use in Olympus NDT products, Olympus NDT cannot guarantee that
batteries obtained from other sources will be satisfactory or that Olympus NDT supplied
batteries will work in non Olympus NDT products. The Universal Battery Charger is designed
to work with Olympus NDT equipment only.
1.6.5 Battery Characteristics
Most batteries will not deliver their full charge on first use or after extended storage. Use them
until the instrument shuts off after full discharge (automatic low battery shut off) and recharge.
This will recondition the battery.
The battery is considered by the manufacturer to be beyond its service life when it delivers less
than 80% of its rated capacity. A Li-ion battery lasts approximately 300 charge/discharge
cycles. This specification is obtained under laboratory conditions and real world usage will be
different.
Battery life will be prolonged if they are not subjected to harsh temperatures, either hot or cold,
and stored in a charged condition.
Batteries have reduced capacity at low temperatures. Exact percentages are not specified but
operation below freezing is not recommended.
Newer versions of Li-Ion batteries, also known as "SMBus Smart Batteries," have a
microprocessor built into them that monitors the batteries usage and displays the condition on a
gas gage in the battery. It is possible to accumulate errors over time due to temperature extremes,
aging, self discharge, and other factors.
The gas gage in the battery is not the same as the one in the instrument. There is no way for the
instrument to read the gas gage in the battery.
18 - T.O. #33D7-22-32-1
The Li-Ion external charger has a "recalibration" feature that charges, discharges, re-charges, and
stores updated information in the microprocessor within the "SMB" capable batteries. This
process is only needed when the gas gage in the battery does not show the proper information.
Examples like after running the instrument for a short time and the battery gas gage has one or
no bars showing or when fully charged, the gas gage has four or less bars showing.
Refer to the instructions provided with the external charger for proper operation and usage.
1.6.6 UBC Spare Parts
Part Num-
Part Description
ber
Universal Battery Charger (UBC) 9522153
DIN connector cable for single battery instruments 9122229.31
AC power cable (US three prong to IEC320) 0205959
AC power cable (UK 13 amp to IEC320) 0222159
Lithium Ion Battery 0119451
1.7 Operating Environment
The Sonic® 1200M is designed as a portable instrument and, as such, requires no special site
preparation before operation. When operating, the instrument should be firmly supported to
prevent damage due to a fall. The unit should be protected as much as possible from water or
chemical splashes, rapid temperature changes, and should be operated away from large electrical
equipment that may interfere with the operation of internal circuitry.
1.8 D-Cell Battery Pack

Connect the D-Cell battery pack to the instrument using the charger/D-cell auxiliary cable (P/N
9122229.31 or greater). The D-cell battery pack uses 9 D-Cell batteries. This provides an
auxiliary battery pack that can be used in lieu of the Li-Ion or UBC power sources.
19 - T.O. #33D7-22-32-1
Note: The instrument will not automatically detect the presence of the D-cell
battery pack, and can not report that it is being powered by D-cell batteries.
Also, due to the variability and unpredictability of commercial D-cells and
their discharge rate, the instrumentís gas gauge may not accurately reflect
the current capacity of the D-cell battery pack. However, the battery low
indicator will still operate and give warning that the battery pack is
approaching the cutoff voltage.
Warning: Use the D-cell battery pack only with Olympus NDT recommended
instruments and cables. The battery pack is NOT compatible with previous
versions of the instruments.
1.8.1 D-cell Battery Pack Specifications
Overall Dimensions: (L x W x H) -10.30" x 5.03" x 1.60"

Battery Pack average weight (With 9 d-cells): 4.8 lbs. (2.17 Kg)
All D-Cells used in the battery pack must meet the specifications listed below:
• Nominal Voltage: 1.5 V

• Operating Temperature Range: -4 to 130°F (-20 to 54°C)
• Diameter (Maximum): 1.35” (34.2 mm)
• Overall Length (Maximum): 2.42” (61.5 mm)
• Average Weight: 5.1 oz. (145 grams)
1.8.2 Battery Safety

• Use only 1.5V D-cell type batteries.
• Do not attempt to recharge a battery unless the battery is specifically marked
“Rechargeable”.
• Remove worn out batteries from equipment immediately to prevent possible
damage.
• Do not mix new batteries with used cells since batteries in a different state of
discharge may drive the weakest battery into voltage reversal, which increases the
risk of leakage, and possibly rupture.
• Do not mix batteries of different chemistries such as Alkaline and Carbon-Zinc, as
this may also increase the risk of leakage and rupture.
Note: Dispose of spent batteries properly.
20 - T.O. #33D7-22-32-1
Technical Data
2 Technical Data
Pulser:
Type Selectable: Square wave or Spike.
Pulse Width 15 to 1000 ns
Accuracy ±10% or 10 ns, whichever is greater.
Pulse Voltage Selectable 300 or 150 volts.
Accuracy +10/-15%.
Rise Time < 15 ns.
Fall Time < 60 ns damping 200 ohms.

< 20 ns damping 50 ohms.
Damping Selectable 25, 50 or 200 ohms.
Modes Selectable single, dual, or through transmission.
Receiver:
Frequency
Band 0.3 to 20 MHz, +/-3 dB nominal.
Gain 0 to 100 dB in wideband, highpass, 10MHz, and 15MHz (HR). 0 to 110 dB in

0.5, 1, 2.25, 3.5, and 5 MHz frequency settings. Total instrument gain not to
exceed 110 dB with DAC active.
Accuracy ±0.5dB for any 10 dB increment, cumulative errror < ± 2.0 dB.
Control Continuous adjustment in selectable 0.1, 0.2, 0.5, 1.0, 2.0, 6.0 or 12 dB steps.
+dB switch Selectable 6, 12, 18, or 24 increment.
Accuracy ±0.5 dB.
Tuning
Range Selectable 0.5, 1, 2.25, 3.5, 5, 10, 15 MHz, wideband (0.3-20 MHz), and high-
pass (3-20MHz).
Q 0.9 less than or equal to Q less than or equal to 1.2
Linear Reject 0 to 80% full screen.
21 - T.O. #33D7-22-32-1
Accuracy ±0.5%.
Vertical
Linearity ± 2% full screen for 10% to 90% of full screen display.
Dynamic
Range > 34 dB (largest signal = 100% full screen height, smallest signal <= 2% full
screen height).
Sensitivity Better than 200 µV.
Noise <15 µV RMS
Display
Modes RF, RF+, RF-, fullwave, halfwave+, halfwave-, filter 1, 2, 3.
Thickness/RF Thickness measure on live and frozen RF display modes.
DAC Segmented with 25 operator selected points, segments generated automati-

cally.
Range 40 dB, total of gain and DAC limited to 110 dB maximum.
Accuracy DAC range ±2dB, echo adjustment ±0.5dB.
Slew Rate 6 dB per µs.
Depth Sum of timebase delay and range up to 400 µs.
DAC Display Selection of multiple curves showing compensation; single curve at signal
level (0 dB); three curves at +6 dB, 0, and -6 dB; four curves at +6 dB, 0, -6
dB, and -14 dB, JIS curves at +6 dB, 0, -6 dB, and -12 dB, DAC compensated
echoes only; single curves with DAC compensated echoes.
Gates:
Gate
Functions Gate 1 may be selected IP of IF Sync. Gate 1 time of flight, amplitude detection
and flaw alarm. Gate 2 amplitude detection and flaw alarm, time of flight for
echo-to-echo mode.
Gate Position
Start -1.16 to 185" (-29 mm to 4694 mm) of steel (-10 to 1600 µs).
Width 0.001 to 296" (0.001 mm to 7510 mm) of steel (0.001 to 2560 µs).
Control Continuous over full range adjustment.
22 - T.O. #33D7-22-32-1
Technical Data
Display Alarm bar indicating position and threshold.
Accuracy ±1% of indicated position.
Threshold
Control Variable, 5 to 100% of full screen.
Accuracy ±1%.
Flaw Alarm
Logic Selectable, positive or negative occurrence.
Indicator Switchable horn and flashing display indicators.
Peak Detector
Amplitude Peak amplitude of gated signal in percent of screen height.
Accuracy ±1%.
Analog Output
Amplitude Scalable. 1000 mV to 4000 mV with offset -4000 mV to +4000 mV.

Accuracy Greater of 30 mV or 2% of display indication with a 1000 ohm load.
Alarm Output 3.3 V logic signals (0V = no alarms, 2V = alarm condition).
Timebase:
Range
Range 0.060 to 296" (1.52 mm to 7511 mm) of steel (0.523 to 2560 µs).
Accuracy ±1%.
Delay
Range -1.16 to 185" (-29 mm to 4690mm) of steel (-10 to 1600µs).
Accuracy ±1%.
Velocity 0.0250 to 0.6000 in/µs (635 to

15240 m/s).
23 - T.O. #33D7-22-32-1
Repetition
Rate 4000 Hz maximum limited by range and pulse width settings.
Control Selectable in 50Hz steps.
Accuracy ± 0.05%.
Horiz.
Linearity ± 1% of full screen.
Thickness:
Range 0.0050" -296" (or maximum display range, whichever is smaller).
Resolution 0.0005” when display range is <1.00 inch; 0.5% of display range when display
range is equal to or greater than 1.00 inch
Distance Output
Amplitude Scalable. 1000 mV to 4000 mV.
Accuracy Greater of 30 mV or 2% of display indication with a 1000 ohm load.
Modes Selectable. Start-to-echo, echo-to-echo, autocal start-to-echo, autocal echo-to-

echo.
Freeze Thickness measurements on freeze display mode.
Trig
Functions Angle beam calculations are performed and displayed, correction for curved
surfaces.
Display Soundpath, surface distance, and depth from the surface.
Angle 0° - 90° in 0.1° increments.
Diameter 0.250" - 100", flat (OFF).
RF Thickness Thickness measurements in RF display mode.
Alarm Output 3.3 v logic signals. (0 = no alarms; 2 v = alarm condition)
24 - T.O. #33D7-22-32-1
Technical Data
Connector:
Inputs
POWER Runs the instrument and recharges the battery from an external charger.
I/O
RS232C DB9P connector, provides bi-directional serial RS232C communication port;

port provides control and reporting of all instrument functions using a terminal
or host computer.
Display Features:
Screen
Freeze On command, currently displayed signal is frozen
Waveform
Recall Select and display a stored waveform.
Reference
Memory Waveform recall and active signal displayed position control separate.
Peak Hold Simultaneous display of peak amplitude waveform and active signal.
Storage Up to 100 A-scan waveforms may be stored for future playback or printout.
Control
Resolution Selection of 3 or 4 digit control.
Zoom Expands gated region under Gate 1 to full display.
Persistence User selectable, up to 10 seconds in 0.1 second steps.
Average Display average of the last 2 to 16 frames.
Additional Features:
Program
Storage Provides the ability to store up to 100 test setups in nonvolatile memory.
Report Fields User-defined, 40 character report header; up to 7 user-defined, 40 character

report fields and 26-character labels: and up to 3 user- defined, 26-character
report entries may be downloaded through the RS-232 port, or entered through
the report edit function.
Clock,
Calendar Time and date information stored and printed with each waveform.
Instrument ID Manufacturer name and model printed with each waveform.
Int’l menu Selectable languages include English, Spanish, French, and German.
25 - T.O. #33D7-22-32-1
Lemo
XMT/RCV Optional European spec Lemo connectors for transmit and receive connectors.
PowerLink™ Automatic transducer recognition, instrument setup, and report field entry.
A-scan Security Read-only selection prevents accidental erase of A-scan settings.
General:
Dimensions 9.5" L x 5.5" W x 3.5" D (241 mm x 140 mm x 89 mm).
Weight 1200M: 4 lbs (1.8 Kg) with battery installed; 3.6 lbs. (1.6 Kg) without batteries.
Display
(EL) EL (electroluminescent), 4.7" x 3.5" (5.7" diagonal) (120 mm x 90 mm x 145
mm diagonal) active display area. 240 H x 320 pixel display resolution. 72 Hz
refresh rate.
Display
(LCD) Monochrome LCD (liquid crystal display), 3.0" x 3.8" (5" diagonal), 320 H x
240 V pixel. 72 Hz refresh rate. Backlight is adjustable for different viewing
conditions.
Display
(Color LCD) Available as option for 1200M+ models. Color LCD (liquid crystal display),
3.0" x 3.8" (5" diagonal), 320 H x 240 V pixel. 72 Hz refresh rate. Backlight is
adjustable for different viewing conditions.
Operating
Temp -4° to 140°F (-20° to 60°C)
Storage
Temp -40° to 176°F (-40° to 80°C)
Operating
Humidity 0% to 95% RH.
Power
DC (1) 10.8 V Li-Ion battery.
AC External. Will recharge the battery pack in approximately 4-6 hours, and run
the instrument simultaneously.
Battery Level Front panel display. A warning message indicates when there is less than ½
hour of operating time left.
Operating
Time 8 to 10 hours typical at 75°F. The estimated operating time remaining is indi-
26 - T.O. #33D7-22-32-1
Technical Data
cated by an icon on the status display.
Note: This data sheet has been carefully checked and is believed to be reliable;
however, no responsibility is assumed for possible inaccuracies or
omissions. All specifications are subject to change without notice.
27 - T.O. #33D7-22-32-1
28 - T.O. #33D7-22-32-1
FastBreak Operation
3 FastBreak Operation
3.1 Getting Started with FastBreak Operation

3.2 Ready
3.3 Operating Menu Structure
3.4 Set - Horizontal Screen Calibration-Angle Beam Inspection (10.0 Range)
3.5 Go - Weld Inspection
3.1 Getting Started with FastBreak Operation

The FastBreak Operation section was created for the more experienced nondestructive testing
(NDT) operator. The intent is to provide a shortcut to instrument operation for the two most
frequently used methods of flaw detection and thickness testing, Angle Beam Weld Inspection
and Dual Element Thickness Measurement. Specific examples are given for 10.0" angle beam
and 0.500" thickness measurements. If your particular application requires another method of
flaw detection or thickness testing, a complete guide of step-by-step applications is provided in
Section 5, Applications.
3.2 Ready
The following controls and menus are required for instrument set-up and calibration. Menus are
activated by pressing the associated menu key. Parameters are selected by pressing the soft key
below the parameter to be adjusted. Parameters may be changed by either rotating the
SmartKnobTM or pressing the up and down arrow keys on the display module.
29 - T.O. #33D7-22-32-1
3.3 Sonic® 1200M Operating Menu Structure
Sonic® 1200M Operating Menu Keys
GATE 1 GATE 2 THICK PULSER RCVR RANGE ANGLE MAIN SPCL DAC
GAIN GAIN GAIN GAIN GAIN GAIN GAIN GAIN GAIN

GATE 1 GATE 2 T-GAUGE PULSE DB DIFF RANGE TRIG FREEZE DAC
POSN POSN TRIGGER DAMPING DISPLAY DELAY ANGLE ZOOM CURSOR
WIDTH WIDTH OFFSET MODE FREQ VEL THICK T-STORE SEL/ADJ
LEVEL LEVEL (THKCAL) VOLTAGE REJECT MAX REP O-DIAM A-LOC CLEAR
T-VEL
* GAIN
* GAIN
SCALE
OFFSET
SCALE
OFFSET
* T-RANGE
SCALE
GAIN
MODE
COLOR
CHOICE
ALARM LEVEL
ALARMLO HOLDOFF
ALARMHI
* Second menus for Instruments with CONTRAST [CLOCK] [PROGRAM] [A-SCAN] [DATA]
optional accessory outputs LOCK HORN [REPORT] COLOR** DEFAULT
+dB VALUE GRAT BAUD KNOB RES
** Menu for Instruments with Color DB STEP
UNITS
PEAKHOLD
SIGNAL
PRINTER
LANGUAGE
REF MEM
ALM DWL
PERSIST
AVERAGE
LCD Display installed
3.4 Set — Horizontal Screen Calibration — Angle Beam Inspection (10.0" range)
• Adjust the timebase RANGE and VELocity to 10.0" and 0.1260 in/µs respectively.
• Set the timebase DELAY to 0.600".
• Set the PULSER mode to SINGLE.
• Select RCVR GAIN and FREQuency appropriate for the transducer in use (60 dB is a
good starting point).
• Choose the RCVR DISPLAY mode which gives the best signal response.
• Verify the transducer wedge angle and index point.
• Using a standard block such as IIW Types I or II or the AWS B1 block, calibrate the
screen range as follows:
1. Move the transducer to intercept the calibration reflector on the calibration block.
2. Adjust the timebase DELAY until the first echo falls on the graticule line outlined for
the block in use.
3. Adjust the timebase VELocity until the second display echo falls on the graticule
listed.
30 - T.O. #33D7-22-32-1
FastBreak Operation
4. Repeat until all echoes align with appropriate graticule lines.
BLOCK INDICATIONS
- First Reflection Second Reflection Other Reflections
IIW Type 1 Line 4 (4") Line 9 (9")
IIW Type 2 Line 2 (2") Line 4 (4")
B1 Block Line 1 (1") Line 4 (4") Lines 7,10 (7",10")
3.4.1 Horizontal Screen Calibration

• Adjust the timebase RANGE and VELocity to 0.500" and 0.2310 in/µs,
respectively.
• Set the timebase DELAY to 0.400".
• Set the PULSER mode to DUAL.
• Select RCVR GAIN and FREQ appropriate for the transducer in use (60 dB is a
good starting point).
• Choose the RCVR DISPLAY mode which gives the best signal response.
Using a standard step block with graduated steps of at least 0.100" and 0.500", make the
following instrument adjustments:
1.Move the transducer to the 0.100" step

2.Adjust the timebase DELAY until the first echo falls on the 2nd graticule line
(0.100").
3.Move the transducer to the 0.500" step
4.Adjust the timebase VELocity until the first echo falls on the 10th graticule line
(0.500").
5.Repeat the above adjustments and checks until the echoes fall on the correct graticule
lines.
The calibration may be checked by testing other steps and verifying that the echoes fall on the
correct lines.
3.5 Go - Weld Inspection

• Calibrate the search unit reference level sensitivity using a calibrated reference
block.
• Adjust the RCVR GAIN in accordance with the inspection code.
The weld may now be inspected using the scanning pattern indicated by code. Flaw
31 - T.O. #33D7-22-32-1
location and sizing may be done using traditional methods.
Using the Thickness Gauge for Flaw Location
• Change the THICK T-GAUGE to IP-1 (IP to 1st echo).

• Adjust the T-VEL to the welded material velocity.
• Set the OFFSET to the wedge thickness (to find the wedge offset in µs, divide the
wedge thickness by the wedge velocity) or use a calibration plate to find wedge
offset.
• From the ANGLE menu, set TRIG=ON.
• Set the angle beam ANGLE to the wedge angle.
• Change the angle beam THICKness to the plate or wall thickness.
• Adjust the GATE1 POSN to cover the weld area.
• Adjust the GATE1 LEVEL to approximately 70% of the reference level.
• If a flaw is detected, adjusting the gain to determine flaw size will cause the defect
echo to cross the flaw gate.
The display will indicate flaw sound path, distance, and depth.
3.5.1 Dual Element Thickness Measurement - Manual Mode

• Turn the THICK T-GAUGE to IP-1 (IP to 1st echo).
• Adjust the T-VEL to the test material velocity.
• Set the ANGLE beam ANGLE to OFF.
• Adjust the GATE1 POSN and WIDTH to cover the test range.
• Using a step block with graduated steps of at least the test range, make the
1.Move the transducer to the smallest desired step. Be sure the echo breaks the
gate. Readjust the gate and GAIN as necessary.
2.Adjust the THICK OFFSET until the thickness readout reads the correct
value.
3.Move the transducer to the largest desired step.
4.Adjust the THICK T-VEL until the thickness readout reads the correct value.
Repeat the above adjustments and checks until both test values read correctly.
The test piece may now be inspected.
32 - T.O. #33D7-22-32-1
FastBreak Operation
Multi-echo Thickness Measurement
The multi-echo mode may be used by selecting the THICK T-GAUGE E-E mode and repeating
the above procedure with GATE1 placed over the first back echo and GATE2 over the second.
3.5.2 Dual Element Thickness Measurement - Auto Mode

• Turn the THICK T-GAUGE to A IP-1 (Auto IP to 1st echo).
• Set the ANGLE beam ANGLE to OFF.
• Adjust the GATE1 POSN and WIDTH to cover the test range.
• Using a step block with graduated steps of at least the test range, make the
1.Move the transducer to the largest desired step.

2.Select THK CAL (Cal Pt 1), and rotate the SmartKnob™ to select the largest
step value.
3.Move the transducer to the smallest desired step. Be sure the echo breaks the
gate. Readjust the gate and GAIN as necessary.
4.Press THK CAL soft key (Cal Pt 2), and rotate the SmartKnob™ to select the
smallest step value. Press THK CAL.
The operator may begin the THK CAL either from the larger or the smaller
thickness step block. Please keep in mind that Cal Pt 1 < Cal Pt 2 OR Cal Pt
1 > Cal Pt 2.
Calibration is complete.
The test piece may now be inspected.
Multi-echo Thickness Measurement
The multi-echo mode may be used by selecting the THICK T-GAUGE E-E mode and repeating
the above procedure with GATE1 placed over the first back echo and GATE2 over the second.
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34 - T.O. #33D7-22-32-1
Control Descriptions
4 Control Descriptions
4.1 Instrument Controls

4.2 Power Button
4.3 Displays
4.4 Soft Keys
4.5 INC/DEC Arrow Keys
4.6 Main Menu Keys
4.7 Enter Key
4.8 Print Key
4.9 SmartKnob™
4.10 RCV and XMIT BNCs
4.11 Pulser Menu
4.12 Receiver Menu
4.13 Range Menu
4.14 Gate 1 Menu
4.15 Gate 2 Menu
4.16 Thickness Menu
4.17 Angle Menu
4.18 DAC Menu
4.19 Main Menu
4.20 SPCL Menu
4.21 Program Sub-Menu
4.22 Report Form Sub-Menu
4.23 Clock Sub-Menu
4.24 A-Scan Sub-Menu
4.25 A-Scan Attribute Sub-Menu
4.26 Data Sub-Menu
4.27 New Block Editor
4.28 Block Review Sub-Menu
4.29 Text Editor
4.30 Instrument Reset
4.1 Instrument Controls
This section covers the operational controls of the Sonic® 1200M.
35 - T.O. #33D7-22-32-1
Figure 4-1: Sonic® 1200M Controls
4.2 Power Button

The POWER Button toggles instrument power on and off. Immediately after power is turned ON,
an initialization routine is started. The instrument’s microprocessor determines the instrument
configuration, performs power-up diagnostics and calibration, and readies the instrument for
operation. The instrument will normally attempt to restore its last configuration, but can be made
to load factory default settings by pressing and holding the RANGE key while the instrument
powers up.
4.3 Displays
The display contains a symbol indicating remaining battery life. When the unit has
approximately one half hour operating time remaining, a status message in the battery level
window indicates a low-battery condition. A low-battery cutoff circuit will automatically switch
the unit off to protect the batteries from excessive discharge.
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The instrument may be configured with either an electroluminescent (EL), monochrome, or color
liquid crystal display (LCD). All displays offer 240 H x 320 V resolution. The display area is
divided into four sections.
Note: The Sonic® 1200M has user-interchangeable displays. Failure to turn off
power before exchanging displays will result in loss of stored programs and
A-scans, and may cause other memory corruption errors.
Note: DO NOT attempt to plug a VGA monitor into the 15 pin D connector.
This will result in a damaged instrument and/or VGA monitor.
Signal Display Signal Display is used to display the ultrasonic signal return from the
transducer. It contains a 10 division by 10 division electronic grati-
cule for signal amplitude and position measurements. The graticule
display is operator selectable.
Numeric Display Numeric reading of display shows thickness or peak amplitude read-
ings. In angle beam inspections, display will show sound path, dis-
tance, and depth readings simultaneously.
Status Display The Status Display shows the operating status of the instrument and
indicates when features are activated or conditions occur. It is also
used to display prompts and error messages.
Menu Display The Menu Display consists of menu soft key blocks for displaying
instrument operating parameters. Each menu soft key block contains
a descriptive label of the parameter and its current setting.
Note: Placing the LCD display in direct sunlight will result in temporary fade due
to the elevation of internal liquid temperature beyond design specification.
Shade or angle the display away from the sun to assure optimal function.
Status
C ondition Menu
Indicators
Instrument parameters (excludi ng GA IN and LOC K )
LOC K are locked and cannot be changed from the front panel SPCL
unti l unlocked.
ZOOM The di splay i s i n zoom to di splay the gated regi on MAIN
150V Whi ch pulser voltage i s selected (150V or 300V). PULSER
D UAL The pulser/recei ver i s operati ng i n dual element mode. PULSER
REJ Li near reject i s bei ng appli ed to the recei ved si gnal. RC VR
+dB +dB feature status. SPC L/ALL
DAC Indi cates D AC i s bei ng appli ed to the reci eved si gnal. DAC
PL Indi cates PowerLi nk™ transducer i s bei ng used.
REP D i splays actual i nstrument repeti ti on rate. RANGE
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The EL Hi-Brite Display is capable of switching from a 100% to 30% brightness level. This
feature is accessed by highlighting the Contrast block in the Special Menu, then pressing
ENTER. As with all of our displays, the instrument must be powered off prior to disconnecting/
connecting a new display. Failure to follow this warning may result in instrument and/or display
damage.
Note: The EL Hi-Brite Display may go blank for approximately 1 second after
connecting or disconnecting the Universal Battery Charger. This is normal
operation.
4.4 Soft Keys

The soft keys located directly below the display are used to select instrument parameters for
adjustment (using the arrow keys and the SmartKnobTM). For some parameters, the soft keys,
when repeatedly pressed, will toggle through specific parameter settings (discrete steps). The
first time a soft key is pressed, the parameter located in the display box directly above the key will
be highlighted using inverse video.
4.5 INC/DEC Arrow Keys

The Increase/Decrease arrow keys may also be used to change parameter settings. The parameter
being adjusted will be displayed in inverse video directly above one of the menu soft keys.
Holding these keys down will cause the rate of adjustment to be increased over time.
4.6 Main Menu Keys

Referring to the front panel view, the PULSER, RCVR, RANGE, GATE 1, GATE 2, THICK,
ANGLE, SPCL, DAC, and MAIN keys are all used to select menus. The parameter to be
adjusted or selected is shown in inverse video above one of the five soft keys. The
microprocessor keeps track of which parameter was last adjusted for each menu. It then returns
the operator to that parameter when the menu key is struck again after moving to a different
menu. The following sections show the different menus and briefly describe the parameters in
each.
Ten types of menu keys are associated with normal inspection procedures that may be displayed
in the soft key Display. Each menu key contains up to five parameters associated with instrument
operation which may be adjusted. The ten primary menus are organized so that the most
important instrument parameters are accessible within two key presses. The SPCL menu contains
a grid of less frequently adjusted parameters.
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Sonic® 1200M Operating Menu Keys
GATE 1 GATE 2 THICK PULSER RCVR RANGE ANGLE MAIN SPCL DAC
GAIN GAIN GAIN GAIN GAIN GAIN GAIN GAIN GAIN

GATE 1 GATE 2 T-GAUGE PULSE DB DIFF RANGE TRIG FREEZE DAC
POSN POSN TRIGGER DAMPING DISPLAY DELAY ANGLE ZOOM CURSOR
WIDTH WIDTH OFFSET MODE FREQ VEL THICK T-STORE SEL/ADJ
LEVEL LEVEL (THKCAL) VOLTAGE REJECT MAX REP O-DIAM A-LOC CLEAR
T-VEL
* GAIN
* GAIN
SCALE
OFFSET
SCALE
OFFSET
* T-RANGE
SCALE
GAIN
MODE
COLOR
CHOICE
ALARM LEVEL
ALARMLO HOLDOFF
ALARMHI
* Second menus for Instruments with CONTRAST [CLOCK] [PROGRAM] [A-SCAN] [DATA]
optional accessory outputs LOCK HORN [REPORT] COLOR** DEFAULT
+dB VALUE GRAT BAUD KNOB RES
** Menu for Instruments with Color DB STEP
UNITS
PEAKHOLD
SIGNAL
PRINTER
LANGUAGE
REF MEM
ALM DWL
PERSIST
AVERAGE
LCD Display installed
Figure 4-2: Sonic® 1200M Operation Menu Structure
4.7 ENTER Key

The ENTER key may be used to select a sub-menu, toggle a parameter value, execute or confirm
an instrument operation, or respond to an instrument prompt.
4.8 PRINT Key

The PRINT key may be used to produce a hard copy output of the screen information to an
external printer via the RS-232 I/O port. If the printer is not connected or improperly configured,
a SERIAL ERROR! warning will be displayed. Otherwise, a PRINTING message will be
displayed.
4.9 SmartKnobTM
The primary function of the SmartKnob™ is to change the selected instrument parameters. The
parameter being adjusted will be displayed in inverse text directly above one of the menu soft
keys. The SmartKnob™ is also used to select characters in the edit function for the programmable
report form. In some instances, the SmartKnob™ may be used to respond to various prompts.
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4.10 RCV and XMIT BNCs
The two transducer BNCs (RCV and XMIT) are connected together when the Pulse Echo mode
of operation is selected. A single element transducer may be connected to either BNC with the
same results.
For Dual and Through transmission modes of operation, the transducer excitation pulse is present
at the XMIT BNC only. A fixed 100 ohm load is connected to the RCV BNC in these modes.
The RCV connector monitors the return echoes from the dual element transducer. The damping
control is connected to the XMIT BNC only.
RCV XMT
Top of Instrument
Note: Poor quality or excessively long cable, while not detrimental to the
instrument, can adversely affect signal-to-noise ratio. For best results, use
quality cables no longer than necessary for the operation.
4.11 Pulser Menu
PULSER
The PULSER menu key invokes the pulser menu shown and is used to adjust the operating
characteristics of the square wave pulser.
GAIN See GAIN parameter description in the Receiver menu section.
PULSE Adjusts the square wave pulse width. The adjustment range is Spike, 15 ns to
1000 ns in 1ns increments. To select Spike, press the PULSE softkey until
SPIKE appears.
DAMPING Selects the damping applied to the transducer crystal. The selections are 25, 50,
and 200 ohms. In PULSE ECHO mode, the damping load is electrically con-
nected to both transmit XMIT and receive RCV BNCs. In DUAL and THRU
XMIT modes, the receive crystal is connected to a fixed 100 ohm load and the
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damping load is electrically connected to the transmit BNC only.
MODE Selectable among SINGLE, DUAL, and THRU XMIT modes. In SINGLE and
DUAL modes, the sound path distance displayed and the Menu Display range
values are corrected for sound path down and back time.
VOLTAGE Adjusts the square wave pulse voltage. The selections are 150 V and 300 V.
The selected voltage is shown on the status portion of the display.
4.12 Receiver Menu
RCVR
The RCVR key invokes the receiver menu. This menu is used to adjust the receiver and display
video characteristics.
GAIN Adjusts the receiver gain in 0.1, 0.2, 0.5, 1.0, 2.0, 6.0, or 12.0 dB steps (estab-
lished in the SPCL menu). The adjustment range is 0 to 110 dB. The maximum
gain is limited to 100 dB in wideband, 10 MHz tuned settings, and all RF dis-
plays to limit screen noise. The gain setting is a relative value and does not
reflect actual overall signal gain.
The instrument’s +dB feature is toggled OFF and ON alternately by pressing

the gain soft key when the gain parameter is highlighted. A +dB icon is shown
in the status portion of the display if this feature is active.
DB DIFF Allows the operator to establish a gain reference for signal amplitude compar-
ison. Pressing this soft key will force the instrument DB DIFF value to +0.0
dB. The DB DIFF value will track all future changes in the gain value (+/-).
DISPLAY Selects the type of video. Available modes are positive halfwave “HALF+”,
negative halfwave“HALF-”, fullwave “FULLWAV”, “RF”, “RF+”, “RF-”,
and display filter functions (FILTR1, FILTR2, and FILTR3). Filters are only
accessible with software revision R00A or greater.
FREQ Selects the frequency of operation of the receiver filtering circuitry. Selections
are 0.5 MHZ, 1MHz, 2.25 MHz, 3.5 MHz, 5 MHz, 10 MHz, 15 MHz, WIDE-
BAND (0.3 - 20 MHz), and HIPASS (3 - 20 MHz). When the frequency con-
trol is changed, the square wave pulse width is automatically set to one-half the
wavelength of the selected setting.
REJECT Adjusts the linear reject level (adjustable from 0 to 80% of full screen height
in 1% increments). When reject is on, a status indicator is displayed.
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4.13 Range Menu
RANGE
The RANGE key calls up the range menu shown and is used to adjust the time base parameters.
RANGE Adjusts the time base range from 0.060 to 296 inches in steel. Adjustment step
size varies from 0.001 to 1 unit. The range is corrected for the down and back
time of the signal when operating in PULSE ECHO mode. Refer to the VEL
description for further Range limits.
DELAY Adjusts the time base delay from -1.16 to 185 inches in steel. Adjustment step
size varies from 0.001 to 1 unit. Refer to the VEL description for further Delay
limits.
VEL Selects the material sound propagation velocity. The adjustment range is
0.0250 in/µs to 0.6000 in/µs. The allowable minimum and maximum values
for range and delay are based on the velocity setting. If the instrument limits
the adjustment for range, delay, gate position, or gate width, it may be due to
the current velocity setting.
MAX REP Adjusts the frequency of the square wave pulse applied to the transducer crys-
tal. The maximum rate is limited by the Range, Pulse Voltage, and Pulse Width
settings. Decreasing MAX REP may reduce the noise on the display.
MENU: MODE
GAIN MODE LEVEL HOLDOFF
IP 40% 0.0
GAIN See Above.
MODE Selects sweep and gate sync mode. Selections are IP (initial pulse) and IF
(interface).
LEVEL Interface level adjustment.
HOLDOFFInterface holdoff adjustment.
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4.14 Gate 1 Menu
GATE 1
The GATE 1 key calls up the gate 1 menu shown and is used to adjust the gate 1 parameters. This
menu sets up parameters such as polarity, position, width, and level for flaw gate 1. Gate 1 may
also be used for thickness measurement by enabling the T-GAUGE control.
GAIN See GAIN parameter description in the Receiver menu section
GATE 1 Selections are “+”, “-”, and “OFF”; “+” signals a gate alarm when the signal
amplitude is above the threshold level, and “-” signals an alarm when the flaw
amplitude is below the threshold level. “OFF” turns off the flaw gate. If a gate
is in the alarm state when the thickness gauge is OFF, the amplitude is dis-
played under the associated gate bar in inverse video.
POSN Adjusts the gate 1 start position from -1.160 to 185.0 inches in steel. The posi-
tion is displayed as the distance from IP in the selected units. Adjustment step
size varies from 0.001 to 1 unit. Refer to the VEL description for further Gate
Position limits.
WIDTH Adjusts the width of gate 1 from 0.001 to 296.0 inches in steel. Adjustment
step size is 0.001 to 1 unit. Refer to the VEL description for further Gate Width
limits.
LEVEL Sets the gate 1 threshold value in terms of % of full screen height (FSH) for the
alarm. Adjustable from 5% to 100% of FSH in 1% increments.
To access the Gate 1 second menu, press the GATE 1 key twice. This second menu sets up gate
1 parameters, such as scale and offset, for analog output of echo peak amplitude. When Gate 1 is
turned off, the output 1 is set to 0mV. Thickness gauge operation disables Gate 1 outputs.
SCALE Any value from 1000 mV to 4000 mV in 250 mV increments. Default is 4000
mV.
OFFSET Adjustable between -4000 mV and 4000 mV in 10 mV increments. Default is

0 mV.
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4.15 Gate 2 Menu
GATE 2
The GATE 2 key calls up the gate 2 menu shown and is used to adjust the gate 2 parameters. This
menu sets up parameters such as polarity +/-, position, width, and level for flaw gate 2. Gate 2
may also be used by the thickness gauge for echo-echo thickness measurement.
GATE 2Selections are “+”, “-”, and OFF; “+” selects the gate alarm when the signal
amplitude is above the threshold, and “-” selects that gate alarm when the flaw
amplitude is below the threshold level. “OFF” turns off the flaw gate. If a gate
is in the alarm state when the thickness gauge is OFF, the amplitude is dis-
played under the associated gate bar in inverse video.
POSN Adjusts the gate 2 start position from -1.16 to 185.0 inches in steel. The posi-
tion is displayed as the distance from IP in the selected units. Adjustment step
size varies from 0.001 to 1 unit. Refer to the VEL description for further Gate
Position limits.
WIDTH Adjusts the width of gate 2 from 0.001 to 296.0 inches in steel. Adjustment
step size is 0.001 to 1 unit. Refer to the VEL description for further Gate Width
limits.
LEVEL Sets the gate 2 threshold value in terms of % of full screen height (FSH) for the
alarm. Adjustable from 5% to 100% of FSH in 1% increments.
To access the Gate 2 second menu, press GATE 2 key twice. This second menu sets up gate 2
parameters, such as scale and offset, for analog output of echo peak amplitude. When Gate 2 is
turned off, the output 2 is set to 0mV.
SCALE Any value from 1200 mV to 4000 mV in 250 mV increments. Default is 4000
mV.
OFFSET Adjustable between -4000 mV and 4000 mV in 10 mV increments. Default is

0m V.
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4.16 Thickness Menu
THICK
The THICK key calls up the thickness menu shown and is used to adjust the thickness gauge
parameters. The thickness gauge controls are used to enable, configure, and calibrate the
thickness gauge. The thickness gauge uses gate 1 for IP - 1ST and both gates (1 and 2) for ECHO
- ECHO.
T-GAUGE Enables or disables the thickness gauge feature and selects the measurement
mode. The thickness gauge may be set to operate in IP - 1st, Echo-to-Echo,
Auto IP-1st, or Auto Echo-to-Echo mode. In Auto IP-1st or Auto Echo-to-Echo
mode, Auto-Cal is based on acquiring readings of two known thickness refer-
ences. Notice that in the Auto IP - 1st, or Auto Echo-to-Echo mode, the OFF-
SET soft key is replaced by the THK CAL soft key function.
Thickness gating is performed using the instrument’s flaw gate(s). IP - 1st

thickness measurements require gate 1, while Echo-Echo thickness measure-
ments require both gates 1 and 2.
Turning the thickness gauge ON forces the appropriate gate or gates ON. Con-
versely, turning the thickness gauge OFF forces the appropriate gate or gates
OFF. When the thickness gauge alarm is enabled and an alarm condition
occurs, readings will be displayed in inverse video. Gate alarm conditions
cause amplitude readings to be displayed in inverse video.
TRIGGER Selects the part of the signal used to trigger for the thickness measurement.
Selections include edge (leading) or peak.
OFFSET Selects and displays the thickness gauge zero offset. The offset adjustment
range is used to establish the starting point for IP - 1ST measurements. Offset
is adjustable from -5µs to 100µs.
THK CAL Selects the thickness reference value for CAL PT 1 and CAL PT 2. Press
ENTER key at each CAL PT to advance and calibrate.
T-VEL Selects and displays the thickness gauge material sound propagation velocity.
The adjustment range is 0.0250 in/µs to 0.6000 in/µs. The allowable minimum
and maximum values for part thickness and outer diameter are based on the T-
velocity setting. If the instrument limits the adjustment for part thickness and
outer diameter, it may be due to the current T-velocity setting.
45 - T.O. #33D7-22-32-1
To access the Thickness second menu, press the THICK key twice. This second menu provides
additional thickness gauge parameters.
T-RANGE Selectable 1in./25mm, 5in./125mm, 25in./600mm, 100in./2500mm, and

300in./7500mm. Default is 1in/25mm.
SCALE Output voltage scaleable between 1000mV and 4000mV in 250mV incre-
ments. Default is 4000mV. Over range voltage is 4000mV.
ALARM When the thickness gauge is turned off, the thickness alarm is set to OFF.
Default is OFF.
ALARM LO Default is 0.0 inch. The low alarm cannot be set for a larger value than the high
alarm.
ALARM HI Default is 1 inch. The high alarm cannot be set for a smaller value than the low
alarm.
When the thickness gauge is OFF, the thickness alarm output is set to 0mV or
to Gate 1 output (if the gate 1 is ON).
When the thickness gauge is ON and no signal intersects the gate(s), the alarm
output is 4000mV.
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4.17 Angle Menu
ANGLE
The ANGLE key activates the angle beam measurement menu. This function allows weld and
other shear wave inspection trigonometric calculations to be displayed.
TRIG This control enables and disables the angle beam calculation feature.
ANGLE This control enables/disables angle beam calculations and specifies the refrac-
tion of the sound beam into the test part (wedge angle). This control may be
adjusted from 0° (OFF) to 90° in 0.1° increments. When an angle is specified,
the sound path, depth, and distance measurements are displayed simulta-
neously.
THICK The actual thickness of the part under inspection can be specified from 0.001
to 185.0 inches. This entry allows the microprocessor to determine which “leg”
the sound beam is in when an echo is detected, and hence correct the sound
path, distance, and depth values for the leg. This provides the operator with
electronic weld soundpath calculation ability. Refer to the T-VEL descrip-
tion for further THICK limits.
O-DIAM Outer diameter of the curved surface for correction of depth and distance mea-
surements. The outer diameter may be set to a value in the range of 0.001
inches to 185.0 inches, or it may be turned OFF for flat objects. Refer to the
T-VEL description for further O-DIAM limits.
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4.18 DAC Menu
DAC
The DAC key activates the DAC menu. This menu offers controls that allow the operator to
construct and modify a DAC/Curve.
DAC The DAC control selects the operating mode of the DAC circuitry. The
options are OFF, CURVONLY, 3 CURVES, 4 CURVES, JIS, DACONLY,
and DAC+CURV. 3 CURVES displays the programmed curve and the curves
±6dB above and below the programmed curve. 4 CURVES displays the pro-
grammed curve, the curves 6dB above and below the programmed curve, and
-14dB below the programmed curve. JIS displays the programmed curve, the
curves 6dB above and below the programmed curve, and -12dB below the
programmed curve.
CURSOR Allows a DAC cursor, a small display circle that tracks signal peaks, to be
moved back and forth across the screen to select points where DAC compen-
sation will be calculated, and the amplitude of the selected points will be
adjusted. Repeated presses of this soft key control will jump the cursor from
one previously defined point to the next.
SELECT/
ADJUST This control allows selection of a new DAC point and/or amplitude adjustment
of the selected DAC point. Amplitude adjustment is only available when the
DAC control is set to DACONLY or DAC+CURV.
CLEAR Allows clearing the DAC/DAC Curve.
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4.19 MAIN Menu
MAIN
The MAIN key invokes the main menu and its parameters. The main menu contains parameters
that offer one touch storage and feature control.
FREEZE The FREEZE control activates and deactivates the freeze feature. The
FREEZE function will “freeze” the current A-Scan display and allow thick-
ness measurement. Pressing the PULSER, RCVR, RANGE, or SPCL key
turns off the Freeze function.
ZOOM The ZOOM feature allows the operator to expand the contents of the gate 1
region to full screen width. Toggle ZOOM off and on for the desired display.
T-STORE With this parameter highlighted, repeated presses of the T-STORE soft key
store the displayed thickness reading in the specified location and increment
the location numbers. The arrow key may be used to increase or decrease the
storage location. The instrument will not advance the location number beyond
the limit of the block. To use T-STORE, T-gauge must be on and a data logger
block defined.
A-LOC The A-LOC function stores the displayed A-Scan in the specified storage loca-
tion and automatically increments the location number. If the selected location
is FULL, the location number will have an “(F)” next to it, the store operation
will NOT take place, and an “INVALID” indicator will be displayed on the
status line. The instrument will not advance the location number beyond the A-
Scan storage limit of 100.
The color palette is user-definable. There are 8 preset color palettes (1-8), and one user-definable
color palette (9). To edit the user-definable color palette, press the SPCL key and then select the
COLOR menu key. Set the color palette to 9 by using the SmartKnob or up/down arrow keys.
Press the MAIN key twice, and the color menu screen displays.
49 - T.O. #33D7-22-32-1
DAC Cursor
Live Signal Background
Graticule
Text
To change the color palette, highlight the softkey that corresponds to that feature on the screen
and adjust with the SmartKnob or up/down arrow keys. The colors available are as follows:
Black, Cyan, White, Magenta, Blue, Red, Yellow, Green.
Please note that selections that would cause features to disappear (white text on a white
background, for instance), are disallowed (the instrument will not allow this to happen). Also,
regardless of whichever color palette is selected, if adjustments are made in the color menu
screen, it only affects the user-definable color palette (9), which means if, for example color
palette 2 is selected, and adjustments are made in the color menu screen, it will appear as if
nothing is happening (no color change). However, if palette 9 is then selected, it will reflect the
changes that were made previously in the color menu screen when palette 2 was selected.
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4.20 SPCL Menu
SPCL
COLOR
DEFAULT
PERSIST
AVERAGE
SPCL key provides parameters and features not associated with normal inspection operations.
These include menus for front-panel lockout, date, program, A-Scan storage, and
communications. Select SPCL menu parameters by pressing the appropriate column arrow soft
key until the desired parameter box is highlighted. Use the SmartKnob, arrow keys, or ENTER
key to activate or adjust a parameter. The sub-menus are described in the following sections.
CONTRAST Adjusts the contrast for the Monochrome LCD display. If the ambient temper-
ature causes the LCD to become invisible, this adjustment can be reached on
power up by simply pressing the SPCL key.
LOCK Enables or disables instrument front panel lock feature. When lock feature is
enabled, all controls, except gain/lock, are disabled. Pressing ENTER invokes
COLOR function if COLOR display exists.
COLOR COLOR palette option. If a color LCD module is detected, COLOR options
are 1 to 9. 9 is the user-selectable palette. See 2nd Main Menu: Color for
details.
+dB VALUE Establishes the amount of gain applied by the +dB feature. The selections
include +6 dB, +12 dB, +18 dB, and +24 dB.
dB STEP Establishes step size used by SmartKnobTM and arrow keys to adjust gain
value. Selections are 0.1, 0.2, 0.5, 1.0, 2.0, 6.0, and 12.0 dB.
51 - T.O. #33D7-22-32-1
UNITS Selects various operating units. Selections: inches (in), millimeters (mm) or
microseconds (µs).
CLOCK System clock menu for setting the instrument time and date.
HORN Enables or disables the audible alarm horn.
GRATICULE Sets graticule to OFF, 5x5 graticule, 10x10 graticule, or JIS 10x10 graticule.
PEAKHOLD Performs a peak detect and hold function of the digitized wave forms. The peak
amplitude of the digitized signal is displayed, held, and updated whenever a
new higher peak amplitude is detected. The peak hold may be reset by pressing
the ENTER key when this function is active.
SIGNAL Allows selection between a hollow or filled A-Scan display.
PROGRAM Program storage and retrieval sub-menu.
REPORT Report form editor sub-menu.
BAUD Used to set the baud rate for the RS-232 serial port selections. If the printer
does not appear to work properly, or the instrument is connected to a host PC
and is responding incorrectly, check to make sure this selection matches your
application. For the optional printer available for use with this instrument, the
default setting is 9600 baud.
PRINTER Used to select one of the printers supported by the Sonic® 1200M. The printer
selection includes Epson, HP-PCL, Canon, and Pentax II. Each of these selec-
tions may be used with a wide range of printers. To use a specific printer, your
selection must support or emulate one of the printer selection modes and be
configured accordingly. Some printers support several printer modes, so
experimentation may be required to determine which mode provides the best
printout.
LANGUAGE Sets language used for text. Selections include English, Spanish, French, Ger-
man, Italian, Romanian.
A-SCAN A-Scan storage and retrieval sub-menu.
KNOB RES Knob Resolution allows selecting between 3-digit display or 4-digit display.
REF MEM The Reference Memory function allows the operator to save a waveform
through normal A-Scan save in the Main menu, recall it as “REF MEM”, then
compare the “REF MEM” with a live echo pattern. When recalled, the saved
“REF MEM” waveform is displayed as a dotted line.
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ALM DWL Alarm dwell is accessed through the Special Menu. Selections for alarm dwell
are OFF, 0.2, 0.4, ..., 10.0 seconds and LATCH. If LATCH is chosen, the
alarm is activated whenever an alarm condition is met and keeps alarming. To
deactivate the latched alarm, press the SPCL key when the alarm condition no
longer exists.
DATA Thickness data logger sub-menu.
PERSIST User Selectable, up to 10 seconds in 0.1 second steps.
AVERAGE Display average of the last 2 to 16 frames.
DEFAULT Will set instrument to default parameters. Stored data (Programs, A-Scans,
Blocks) will not be erased.
4.21 Program Sub-Menu
The Sonic® 1200M is capable of storing and retrieving 100 complete instrument programs.
These setups are recorded with date and time, and may be named using up to 29 alphanumeric
characters. Functions pertaining to program storage are store, recall, erase, name, and print.
PROGRAM This line displays the program storage location which is to be stored, recalled,
erased, named, or printed. Turning the SmartKnob™ will cycle through the
100 program storage locations and highlight the current selection. The loca-
tions are displayed in pages of 16. Along with its storage location, the pro-
gram’s empty status or name and time stamp will be displayed.
STORE/
RECALL Instrument settings are stored to or recalled from the selected program loca-
tion. If the selected location is full, this control allows the operator to recall the
stored program. If the location is empty, the operator is permitted to store the
53 - T.O. #33D7-22-32-1
program. Whenever a program setting is recalled, the currently active instru-
ment settings are overwritten and cannot be recovered unless these settings
were previously stored in another program location.
ERASE The erase function allows the operator to erase the selected program location.
This is normally done before saving a new program to that location. If it is
desired to erase all program settings, the program location must be set to the
ALL state. Operator confirmation ENTER is required to complete the erase
operation. Note that this operation is irreversible.
NAME The name function allows the operator to enter a name of up to 29 characters
for a stored program. Names may be used to describe the test settings that are
stored, reference a written test procedure, and so on. Only programs that are
not empty may be named.
PRINT The program print function uses the optional external serial printer option to
make a hard copy of the currently selected program settings.
4.22 Report Form Sub-Menu
The Sonic® 1200M offers an internal text editor to customize the report form. The report consists
of a header, seven fields and associated labels, and three report entries. Each of these items is
programmable by the user.
ITEM This line displays the report item currently selected. The selected item will also
be highlighted. Turning the SmartKnob™ will cycle through the items
(HEADER, ENTRY1-3, LABEL1-7, and FIELD1-7).
EDIT Invokes the text editor to customize the selected report item.
CLEAR Clears the currently selected report form item.
DEFAULT Replaces all report items with their factory default strings.
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4.23 Clock Sub-Menu
The Clock sub-menu is used to observe and modify the system clock parameters. The system date
is expressed in DD MM YYYY format, while the system time is expressed in HH:MM format.
MONTH Sets the system clock month (i.e., 1 = January, 2 = February, etc.).
DAY Sets the system clock to the day of the month (days 1 through 31).
YEAR Sets the last 4 digits of the system clock year (1996 through 2095).
HOUR Sets the system clock to the hour (0 through 23).
MINUTES Sets the system clock to minutes (0 through 59).
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4.24 A-Scan Sub-Menu
The Sonic® 1200M is capable of storing and retrieving 100 complete A-Scans. These A-Scans
are recorded with date and time, and may be named using up to 29 alphanumeric characters. A-
Scans are stored in the MAIN menu using the A-LOC feature. Functions pertaining to stored A-
Scans are recall, erase, name, and print.
A-SCAN This parameter displays the A-Scan memory location which is to be stored,
recalled, erased, named, or printed. Turning the SmartKnob™ will cycle
through the 100 A-scan storage locations and highlight the current selection.
Along with the displayed A-Scan storage location will be its empty status or
name and time stamp. Rotating the SmartKnob™ CCW past A-Scan will will
allow access to the ATTRIB submenu. ATTRIB allows a selected A-scan to
have a read-only attribute enabled or disabled.
RECALL A-Scan images may be recalled from the selected A-Scan location to the
instrument screen for review. Only full A-Scan locations may be recalled. To
resume normal instrument operation, press any key.
ERASE The erase A-Scan function allows the operator to erase the selected A-Scan
location. This is normally done before saving a new A-Scan to that location.
To erase all A-Scans, the A-Scan location must be set to the ALL state. Oper-
ator confirmation ENTER is required to complete the erase operation. Note
that this operation is irreversible.
NAME The name function allows the operator to enter a name of up to 29 characters
for a stored A-Scan. Names may be used to describe the test settings that are
stored, reference a written test procedure, and so on. Only A-Scans that are
full may be named.
PRINT The A-Scan print function uses the optional external serial printer option to
make a hard copy of the stored A-Scan, program settings, and a custom report
56 - T.O. #33D7-22-32-1
form.
ATTRIB Attribute appears only when A scan location is ALL. Press ENTER to access
the A scan Attribute sub menu when this soft key is highlighted.
4.25 A-Scan Attribute Sub Menu
The first character in the table above indicates the attribute of the A-Scan location.
[r] read-only
[e] extension of previous location
Setting the attribute of A-Scan locations protects these locations from accidentally being erased.
SET sets the attribute of the stored A-Scan, and CLEAR clears the attribute.
ATTRIB This parameter displays the A-Scan memory location on which the attribute is
to be changed. Rotating the SmartKnob™ will cycle through the 100 A-Scan
locations.
SET The SET function is used to set the attribute of the highlighted A-Scan loca-
tion. The A-Scan can NOT be erased if the attribute is set.
CLEAR The CLEAR function is for clearing the attribute of the highlighted A-Scan
location. The attribute must be cleared before attempting to erase the location
in the A-Scan Sub-Menu.
A-SCAN Pressing this softkey or ENTER while it is highlighted returns unit to A-SCAN
sub-menu.
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4.26 Data Sub Menu
The data logger menu offers block creation, editing, and review features. Having selected a block
number, the operator performs an operation by pressing ENTER or the appropriate soft key.
BLOCK Selects the block number to be REVIEWed, NAMEd, DESCRIBEd,

DELETEd, or PRINTed. All blocks will be listed by name in the top part of the
display. Setting the BLOCK number to less than 1 will allow the ALL selection
to be used by the DELETE and PRINT features. Setting the block number to
one greater than the last block number will allow the NEW selection to create
a new data block. To create a new data block or review an existing block, press
the ENTER key.
NAME The name function allows the operator to enter a name of up to 8 characters for
data block.
DESCRIBE The describe function allows the operator to enter an alphanumeric block
description of up to 26 characters.
DELETE Allows the operator to delete the selected block number. If it is desired to
delete all data blocks, the block location must be set to the ALL state. Operator
confirmation ENTER is required to complete the delete operation. Note that
this operation is irreversible.
PRINT The block print function uses the optional external serial printer option to make
a hard copy report of data contained in the selected block.
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4.27 New Block Editor
The new block editor is used to establish the storage requirements for a newly created data block.
The operator must specify the number of rows and columns, as well as the storage direction. If
a sequential configuration is desired, simply set either the rows or columns value to 1. This menu
also offers the operator an opportunity to define the blockís name and description.
ROWS Sets the number of grid rows for this data block. The number of rows is adjust-
able in the range of 1 to 5000, but may be limited by the number of columns or
available reading locations.
COLUMNS Sets the number of grid columns in this data block. The number of columns is
adjustable in the range of 1 to 5000, but may be limited by the number of rows
or available reading locations.
DIR Sets the load direction for data storage. The selection (ROW or COLUMN)
determines which index will advance after each store operation.
NAME The name function allows the operator to enter a name of up to 8 characters for
the new data block.
DESCRIBE The describe function allows the operator to enter an alphanumeric block
description of up to 26 characters.
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4.28 Block Review Sub Menu
The block review sub-menu is used to review the contents of stored data blocks. The screen
contains the block definition items (name, rows, cols, ...) and a page of stored thickness readings.
The readings are listed sequentially (in the order they were stored), but may be accessed
sequentially by row or by column.
LOCATION Selects the block reading location. The location number will change either the
row or column values, or both. Conversely, changes to the row and column
values will affect the location number. Setting the LOCATION number to less
than 1 will allow the ALL selection for use by the CLEAR feature.
ROW Changes the row selection, which in turn changes the location value.
COLUMN Changes the column selection, which in turn changes the location value.
T-MIN Establishes the minimum allowable thickness reading permitted by this block.
All readings that are less than this value are marked with an asterisk.
CLEAR Clears the reading(s) from the selected location(s). Operator confirmation
ENTER is required to complete the clear operation. This operation will leave
the selected location empty. Note that this operation is irreversible.
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4.29 Text Editor
The text editor presents a screen similar to the figure shown above, displaying a list of available
characters and a highlighted entry line with a pointer used to indicate the current character
location.
The right and left arrow keys are used to move the current character space. Rotating the
SmartKnob moves the highlight from character to character. Pressing ENTER selects the
character and moves the pointer from one location to the right.
Right and Left

Arrow Keys This line moves edit cursor left and right 1 character position (respectively).
When the cursor exceeds either end of the string, its position wraps around to
the other end.
CLEAR Clears the entire text line and places the edit cursor at the first character.
QUIT Terminates the text editor and aborts any changes made to the text string.
SAVE Saves the text string and exits the text editor.
4.30 Instrument Reset

The instrument operating parameters are reset to the default settings if the RANGE key is
depressed when the instrument is turned on. The instrument will prompt “Press RANGE key for
default reset” during the initialization routine. Stored programs, thicknesses, and A-Scans are not
affected by the reset operation. The default parameters are listed in the following charts.
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Pulser Receiver R an g e
PULSE 100ns GAIN 0.2 30dB RANGE 1.00in
DAMPING 200 DISPLAY FULLWAV DELAY 0.000in
MODE Single Freq FREQ 5MHz VEL 0.2310in/µs
PULSER 150v REJECT 0% UNITS in
Gate 1 Gate 2 Thickness
GATE 1 Off GATE 2 Off T-GAUGE Off
LE V E L 40% LE V E L 50% TRIGGER E dge
POSN 0.500in POSN 0.500in OFFSET 0.000µs
WIDTH 0.250in WIDTH 0.250in T-VEL 0.2310in/µs
Angle Special
TRIG Off CONTRAST 14 GRATICULE 5x5
ANGLE 0.0° LOCK Off PEAK-HOLD Off
THICK 1.00in +dB VALUE +6dB SIGNAL Hollow
O-DIAM Off dB STEP 0.2dB BAUD RATE 9600
--- --- UNITS IN PRINTER HP-PCL
--- --- HORN Off LANGUAGE English
All DAC curves and DAC points are cleared, and the DA function is turned off.
62 - T.O. #33D7-22-32-1
Applications
5 Applications
What's in this section?
5.1 Pulse-Echo Contact Thickness Testing

5.2 Dual Transducer Thickness Testing
5.3 Delay Line Thickness Testing
5.4 Shear Wave (Angle Beam) Testing
5.5 Distance Amplitude Correction (DAC) Testing
5.1 Pulse-Echo Contact Thickness Testing

One of the major methods of ultrasonic thickness testing is the pulse-echo contact method. It
provides excellent accuracy and is best suited for smooth surfaces. The test range is usually 0.10
inch to 20.0 inches. A wideband transducer is normally used. The thickness gauge offsets and
sound velocity must be recalibrated each time the instrument is powered up.
The following accessories are required for this setup procedure:
STEP BLOCK — Sonic® #1920105.00 Steel Step Block or equivalent 0.100,

0.200, 0.300, 0.400, and 0.500 inch steps.
TRANSDUCER — The transducer used will depend on the material and

thickness being tested. For steel or aluminum up to 5 inches thick, a Spectrum
E8L (5 MHz) transducer is a good selection. For rough, corroded, or highly
attenuative materials, a 2.25 MHz transducer (Spectrum™ E4L) may be
required. Larger and lower frequency transducers may give better results on
rough materials (that is, cast iron).
TRANSDUCER CABLE — Use a Sonic® BNC/Microdot (#9102894) or

BNC/BNC (#9102892) to connect the specific transducer.
COUPLANT — Use a couplant that “fills in” the surface. On smooth surfaces,
thinner couplants can be used such as water, light oil, or mineral oil. On rough
surfaces, Sonic® X30S couplant (#3317450) is more appropriate.
5.1.1 Instrument Calibration - 0.5” Thickness Range, Steel
1. Connect the transducer cable to the Spectrum™ E8L transducer, and then to
either BNC connector.
2. Turn on instrument power and adjust the operating controls as follows:
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Note: To select and change the following parameters, press the menu soft key
below the selected menu box, then rotate the SmartKnob™ or press the INC/
DEC arrow keys to change the value.
3. Place X30S couplant on the step block and position the transducer on the thin-
nest (0.100) step.
4. Press the RCVR menu key, then the DISPLAY menu soft key, and rotate the
SmartKnob™ to select HALF-. Observe the signals and select “+” or “-”
depending upon best signal display.
5. Adjust Delay by pressing the RANGE menu key, then the DELAY menu soft
key, and rotate the SmartKnob™ to line up the leading edge of the first echo
on the #2 graticule line.
6. Adjust Gain by pressing the RANGE menu key, then GAIN menu soft key, and
rotate the SmartKnob™ to increase the first echo amplitude to approximately
80% of full screen height (refer to Figure 5-1).
7. Move the transducer to the thickest (0.500) step. Adjust the Velocity by press-
ing the RANGE menu key, the VEL menu soft key, and rotate the Smart-
Knob™ to line up the leading edge of the first echo on the last graticule line
(refer to Figure 5-2).
8. Repeat steps 3 - 8 to verify that both the 0.100 and 0.500 inch signals line up.
64 - T.O. #33D7-22-32-1
Applications
9. Check the 0.200, 0.300 and 0.400 inch steps. If they line up, the Sonic® 1200M
is calibrated. If they do not line up closely, repeat calibration steps 4 - 8.
10. The instrument should now be calibrated for 0.500 inches of steel across the
full screen width. Each major graticule division corresponds to 0.050 inches of
steel. For other ranges and materials, the Sonic® 1200M is calibrated similarly.
Use step blocks made of the same test material and thickness range as the mate-
rial being measured.
Figure 5-1: Multiple Echoes From 0.100 Step and Figure 5-2: Echo From 0.500 Step Block
5.1.2 Instrument Calibration - 1 to 10” of Aluminum
Use the same procedure as the previous 0.5 inch steel test, but adjust the controls using 1-to-10
inch aluminum step blocks as the thin and thick steps. After calibrating at 1.0 inch and 10.0
inches, check at 5.0 inches for accuracy.
To select and change the following parameters, press the menu soft key below the selected menu box, then
rotate the SmartKnob™ or press the INC/DEC arrow keys to change the value.
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The Sonic® 1200M is now calibrated for 10 inches of aluminum at full screen range with each
major graticule division equal to 1 inch.
Different materials have different velocity attenuation and noise characteristics. The best
accuracy is obtained by using step blocks made from the same material as that being tested.
With practice, you may optimize the displayed ultrasonic signals by using the Gain, Damping,
Display, Frequency, and Reject control settings. The Reject setting can be used to improve the
display by eliminating small baseline signals (or noise).
An operator must recalibrate the thickness gauge when changing from IP mode to 1st back wall
reflection mode and to Multiple Echo mode to compensate for transducer offsets, surface
variations, and couplant thickness. In the Multiple Echo mode, the ultrasonic echoes being
measured only include material thickness. Compensation for these offsets in the Multiple Echo
mode is not required.
5.1.3 Alternate Calibration Test Method - Multiple Echo, 1.0 to 10.0” of Steel
Notice that several multiple echo signals can be observed during the thickness calibration and
testing. These echoes can be used to calibrate over a wider range than when using the first echo
technique. This method is especially useful if there is only one known thickness available.
For example, using only a 1 inch steel block (B1 Block), calibration of 1 to 10 inches or more
can be performed. In highly attenuative materials, (that is, cast materials), it may not be possible
to obtain multiple echoes over the desired thickness range, limiting this technique.
The same accessories (transducer, cable, couplant) are used except a block of only one known
66 - T.O. #33D7-22-32-1
Applications
thickness is required, such as a B1 Block with a 1 inch thickness.
1. Connect the transducer by cable to either instrument BNC.

3. Place the transducer (with couplant) on the 1.0 inch thickness portion of the
test block and press the RANGE menu key.
4. Press DELAY menu soft key and rotate SmartKnob™ to line up the 1st echo
on #1 graticule line.
5. Press VEL menu soft key and rotate SmartKnob™ to line up the 5th echo with
#5 graticule line.
6. Repeat steps 3 - 5 until both echoes line up. All 10 echoes should then line up
with a graticule line, as shown in Figure 5-3. If they do, the instrument is
calibrated for 1.0 to 10.0 inches. If not, repeat calibration.
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Figure 5-3: Multiple Echoes From 1.0 Block
5.1.4 Digital Thickness Calibration for Contact Transducers
Adjust the operating controls as follows:
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Applications
These settings are approximate and may vary due to the different types of transducers used.
1. Place couplant on the step block and position the transducer on the thinnest
(0.100) step.
2. Press RCVR menu key, then DISPLAY menu soft key, and rotate the Smart-
Knob™ to select HALF-. Observe the signals and select “+” or “-” depending
upon best signal display.
3. Adjust Delay by pressing the RANGE menu key, then DELAY menu soft key,
and rotate the SmartKnob™ to line up the leading edge of the first echo on the
No. 1 graticule line.
4. Adjust Gain by pressing the GAIN menu soft key, and rotate the SmartKnob™
to increase the first echo amplitude to approximately 80% of full screen height
(see Figure 5-4).
5. Move the transducer to the thickest (0.500) step and press the THICK menu
key, then select the T-VEL menu soft key, and rotate the SmartKnob™ to line
up the leading edge of the first echo on the #5 graticule line (see Figure 5-5).
69 - T.O. #33D7-22-32-1
7. The instrument should now be calibrated for 1.0 inch of steel across the full
screen width. Each major graticule division corresponds to 0.100 inch of steel.
is calibrated. If not, repeat calibration steps 1 - 5.
Figure 5-4: Echo From 0.100 Step and Figure 5-5: Echo From 0.500 Step
5.1.5 Digital Thickness Measurement From the Initial Pulse to the 1st Back Wall
Reflection
Press th eGATE1 menu key and the following menu will appear. This menu provides changeable
parameters, such as Polarity, Position, Width, and Level, for either flaw or thickness
measurements of Gate1.
GATE 1
For thickness measurements, adjust the controls as follows:
1. To enable Gate1, press GATE1 menu key again and rotate the SmartKnob™
to select the “+” Gate1 alarm.
2. Press the Gate LEVEL menu soft key and rotate the SmartKnob™ to the
desired screen height, such as 40%.
3. Press the Gate POSN menu soft key and rotate the SmartKnob™, or press the
POSN menu soft key repeatedly, to adjust the Gate position so that the start of
the gate is to the left of the thinnest (0.100 inch) step (see Figure 5-6).
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Applications
4. Press the Gate WIDTH menu soft key and rotate the SmartKnob™, or press the
WIDTH menu soft key repeatedly, to adjust the Gate width to full screen or to
the right of the thickest step (0.500 inch).
Figure 5-6: Echo From 0.100 Step and Figure 5-7: Echo From 0.500 Step
5. Press the THICK menu key, then the T-GAUGE softkey, and the following
menu will display.
6. Use the SmartKnob™ to toggle through the selections. Select AIP - 1st. Press
the TRIGGER softkey and rotate the SmartKnob™ to toggle between peak or
leading edge triggering for thickness measurements. Select EDGE.
7. Place the transducer on the thickest step (0.500 inch of steel), press the THK
CAL softkey, and rotate the SmartKnob™ until the THK CAL value for CAL
PT1 reads 0.500 inch. Press the ENTER key to log this value.
8. Place the transducer on the thinnest step (0.100), press the THK CAL softkey
and rotate the SmartKnob™ until the THK CAL value for CAL PT2 reads
0.100 inch. Press the ENTER key to log this value.
9. Calibration is now done. Check the 0.200, 0.300, and 0.400 inch steps. If the
thickness readings are correct, the thickness gauge is calibrated. If the thick-
ness gauge is not calibrated, repeat calibration steps 5 through 8.
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5.2 Dual Transducer Thickness Testing
Dual (pitch/catch) transducers produce better results for measuring thin (0.030 inch) materials or
rough and corroded metals in the 0.050 inch to 5.00 inch range. They can also be used on smooth
materials to more than 10 inches.
STEP BLOCK — Sonic® #1920105.00 steel step block or equal (0.100 to

0.500 inch).
TRANSDUCER — Harisonic® J4MD (¼ in. 5 MHz).
use thinner couplants (water, light oil, or mineral oil). On rough surfaces, the
Sonic® X30S couplant (P/N #3317450) is more appropriate.
5.2.1 Instrument Calibration - 0.100 to 0.500 inch steel.
1. Connect the two transducer leads into both BNC connectors.

2. Turn instrument power on.
3. Set the Sonic® 1200M for Dual mode by pressing the PULSER menu key and
then selecting the MODE menu soft key.
4. Adjust the operating controls as follows:
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Applications
5. Place X30S couplant on the step block and position the transducer on the thin-
nest (0.100) step.
depending upon which signal displays the largest amplitude of the first cycle
(see Figure 5-8).
8. Adjust Gain by pressing the GAIN menu soft key, and rotate the SmartKnob™
to increase the first echo amplitude to approximately 70% of full screen height
9. Move the transducer to the thickest (0.500 inch) step. Adjust the Velocity by
pressing the RANGE menu key, the VEL menu soft key, and rotate the Smart-
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11. Check the 0.200, 0.300. and 0.400 inch steps. If they line up, the Sonic®
1200M is calibrated. If they do not line up closely, repeat calibration steps 5
through 9.
12. The Sonic® 1200M is now calibrated for steel from 0.100 inch to 0.500 inch
This method provides an accurate test over this range.
Figure 5-8. Pitch-Catch echo from a 0.100 step block

Figure 5-9. Pitch-Catch echo from a 0.500 step block
5.2.2 Instrument Calibration - 1.0 to 10.0 Inches of Steel
Use the same procedure as the previous 0.100 to 0.500 inch steel test, but adjust the controls using
1 to 10 inch steel step blocks as the thin and thick steps. After calibrating at 1.0 inch and 10.0
inches, check at 5.0 inches for accuracy.
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Applications
The Sonic® 1200M is now calibrated for 10 inches of steel at full screen range with each
major graticule division equal to 1 inch.
Different materials will have different velocity, attenuation, and noise characteristics. The best
accuracy will be obtained by using step blocks made from the same material as that being tested.
With practice, you may optimize the displayed ultrasonic signals by using the Gain, Damping,
Display, Frequency, and Reject control settings. The Reject setting can be used to improve the
display by eliminating small baseline signals (or noise).
5.2.3 Alternate Calibration Method - Multiple Echo, 1” - 10” Steel
The multiple echo calibration method can be used with the dual transducer. This method is
especially useful if there is only one known thickness available.
For example, using only a 1 inch steel block (B1 Block), calibration of 1 to 10 inches or more
can be performed. In highly attenuative materials (for example, cast materials), it may not be
possible to obtain multiple echoes over the desired thickness range, thus limiting this technique.
The same accessories (transducer, cable, couplant) are used, except a block of only one known
thickness is required, such as a B1 block with 1 inch thickness.
1. Connect the two transducer leads into both BNC connectors.
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3. Place the transducer (with couplant) on the 1.0 inch thickness portion of the
test block and press the RANGE menu key.
4. Press DELAY menu soft key and rotate the SmartKnob™ to line up the 1st
echo on the #1 graticule line.
5. Press VEL menu soft key and rotate the SmartKnob™ to line up the 5th echo
with the #5 graticule line.
6. Repeat steps 4 and 5 until both echoes line up. All 10 echoes should then line
up with a graticule line. If they do, the instrument is calibrated for 1.0 to 10.0
inches. If not, repeat calibration.
7. After calibration, you are ready to start testing for flaws. If the calibration
block surfaces are similar to the test material, you can proceed. If the surface
(inner or outer) is rougher or curved, you will need to adjust the Gain to acquire
signals back up to about 70%. Rough outer surfaces will also cause echoes
after the initial pulse which restricts the resolution of thin surfaces. Always
make sure that the display signals are clear and “make sense” before proceed-
ing with the test.
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Applications
5.2.4 Dual Element High/Low Digital Thickness Calibration
5.2.5 Thickness Measurement from Initial Pulse to 1st Back Wall Reflection
Press the GATE1 menu key and the following menu will appear. This menu provides changeable
For thickness measurements, adjust the controls as follows:

POSN menu soft key repeatedly, so that the start of the gate is to the left of the
thinnest step (0.100 inch). (Please refer to Figure 5-10).
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4. Press the Gate WIDTH menu soft key, and rotate the SmartKnob™, or press
the WIDTH menu soft key repeatedly, to adjust the Gate width to full screen or
to the right of the thickest step (0.500 inch). (Please refer to Figure 5-11).
Figures 5-10 and 5-11

5. Press the THICK menu key and the following menu will display. Press the T-
GAUGE menu soft key, and use the UP/DOWN arrow keys to toggle through
the selections. Select A IP - 1st.
6. Press the TRIGGER softkey and rotate the SmartKnob™ to toggle between
peak or leading edge triggering for thickness measurements. Select EDGE.
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Applications
5.2.6 Thickness Using Multiple Echoes From the 1st Back Wall to 2nd Back Wall
Reflection, Echo-to-Echo
To measure between echoes, both Gate 1 and Gate 2 are used for thickness measurements. Gate
1 position (start) must be to the left of the thinnest step (echo) for thickness measurements. The
width must be wide enough to cover the area where the 1st back wall echo will appear (see
Figure 5-12).
Gate 2 position (start) must be to the right of the 1st back wall echo and to the left of the thinnest
2nd back wall echo for accurate thickness measurements. The width of Gate 2 must be wide
enough to cover the area where the 2nd back wall echo will appear (see Figure 5-13).
79 - T.O. #33D7-22-32-1
Press GATE1 menu key and the following menu will appear. This menu provides changeable
For thickness measurements, adjust the controls as follows.
thinnest step (0.200 inch). (Please refer to Figure 5-14).
WIDTH menu soft key repeatedly, to adjust the Gate width until it goes past or
through the 1st echo from the thinnest step (see Figure 5-15).
The Gate width must extend past the thickest step in the calibration procedure.
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Applications
For this application, Gate2 is used for thickness.
1. To enable Gate2, press the GATE2 menu key again and rotate the Smart-
Knob™ to select the “+” Gate2 alarm.
2nd back wall echo, or just to the right side of the 1st back reflection (see
Figure 5-16).
WIDTH menu soft key repeatedly, to adjust the Gate width to go past or
through the 2nd back wall echo (see Figure 5-17).
Figure 5-16 and 5-17
5. For echo-to-echo measurements on thinner material than 0.500 inch, the Gate
2 position (start) and width must be adjusted for the thinnest echo-to-echo mea-
surement, such as 0.200 inch (see Figure 5-18).
6. Gate 2 must start prior to the 2nd back wall echo (left side of echo) and the
width must be wide enough so the 2nd back wall echo passes through it (see
Figure 5-18).
81 - T.O. #33D7-22-32-1
Note: Gate 1 must start prior to the first echo (left side of echo), and the width must
be wide enough so that the first backwall echo passes through it.
the selections. Select Auto Echo - Echo.
8. Place the transducer on the thinnest step (0.200 inch). Verify proper Gate1 and
Gate2 positioning, as above (the thickness gauge starts the measurement with
the 1st echo to break Gate1, and stops the measurement with the 1st echo to
break Gate2). Press the THK CAL softkey, and rotate the SmartKnob until the
THK CAL value for CAL PT1 reads 0.200 inch. Press ENTER to log this value
(Please refer to Figure 5-19).
9. Place the transducer on the thickest step (0.500 inch of steel). Verify proper
Gate1 and Gate2 positioning, as above (a slight adjustment of the Gate2 posi-
tion may be required to prevent triggering on unwanted signals), press the
THK CAL softkey, and rotate the SmartKnob until theTHK CAL value for
CAL PT2 reads 0.500 inch. Press ENTER to log this value.(Please refer to
Figure 5-20).
10. Calibration is now done. Check other thickness values to verify; if the thick-
ness readings are correct, the thickness gauge is calibrated. If the thickness
gauge is not calibrated, repeat calibration steps 5 through 14 (velocity of the
material under test).
82 - T.O. #33D7-22-32-1
Applications
Figures 5-18, 5-19, and 5-20
5.3 Delay Line Thickness Testing

In testing thin materials with smooth surfaces, the use of a wideband delay line transducer is a
good method. The delay through the plastic enables better resolution. Thicknesses down to 0.010
inch can be resolved, since the delay moves the echoes away from the initial pulse ringing, as
shown in Figure 5-21.
The range is limited by the delay in the plastic as the 2nd echo will interfere with the multiple
echoes. Usually the range is from 0.010 inch to 0.500 inch, but it can go up to 0.750 inch.
The measurement is made between the echoes (for best accuracy, the 1st and 2nd back echoes).
The thickness gauge offsets, and sound velocity must be recalibrated, each time the instrument
83 - T.O. #33D7-22-32-1
is powered up.
IP
DELAY
Figure 5-21: Delay Line Test Echoes
The following accessories are required for this procedure:
STEP BLOCK: Sonic® #1920105.00 Steel Step Block or equal (0.100, 0.200,
0.300, 0.400, 0.500 inch steps).
TRANSDUCER: A 10 MHz highly damped delay line transducer is usually

the best choice, but a 5 MHz transducer may be used if the material is above
0.050 inch. Spectrum™ C17L is a good selection.
TRANSDUCER CABLE: Sonic® BNC/Microdot (#9102894).
COUPLANT: A thin couplant is preferred, such as Sonic® X30S couplant

(#3317450), mineral oil, light oil, or possibly water.
5.3.1 Instrument Calibration - 0.500” Thickness Range, Steel
1. Connect the transducer cable to the Spectrum™ C17L transducer and to either
BNC connector.
2. Turn on the instrument power, and adjust the operating controls as follows:
84 - T.O. #33D7-22-32-1
Applications
3. Place couplant on the test block and position the transducer on the thinnest
(0.100) step.
depending upon best signal display.
6. Adjust Gain by pressing the RANGE menu key, then GAIN menu soft key, and
rotate the SmartKnob™ to increase the first echo amplitude to approximately
70% of full screen height, #7 line vertical (refer to Figure 5-22).
85 - T.O. #33D7-22-32-1
Figure 5-22: First Back Echo at 0.100”
7. Move the transducer to the thickest (0.500) step. Adjust the Velocity by press-
ing the RANGE menu key, the VEL menu soft key, and rotating the Smart-
Figure 5-23: First Back Echo at 0.500”
8. Repeat steps 4 - 8 to verify that both the0.100 and 0.500 inch signals line up.
is calibrated. If they do not line up closely, repeat calibration steps 4 - 8.
86 - T.O. #33D7-22-32-1
Applications
5.3.2 Instrument Calibration - Other Ranges
The instrument is calibrated similarly for other ranges and materials. Use step blocks made of the
same test material and thickness range as the material being measured.
With practice, you may optimize the displayed ultrasonic signals by the use of Gain, Damping,
Display, and Reject controls. Reject controls can be used to improve the display by eliminating
small baseline signals or noise.
5.3.3 Instrument Calibration - Testing
When using the delay line method, the best results are obtained only when several multiples or
echoes are displayed. In some attenuative materials or plastics, only one back echo may be
obtained. In this case, the surface echo to 1st back echo signals can be used as a measurement,
but accuracy will not be quite as good.
5.3.4 Thickness Measurements From Delay Line Interface to the 1st Back Wall
Reflection
parameters, such as Polarity, Level, Position, and Width, for either flaw or thickness measure-
ments of Gate1.
1. To enable Gate1, press the GATE1 menu key again, and rotate the Smart-
thinnest (0.100 inch) step (see Figure 5-24).
WIDTH menu soft key repeatedly, to adjust the Gate width to full screen or to
the right of the thickest step (0.500 inch). (Please refer to Figure 5-25).
87 - T.O. #33D7-22-32-1
Press the THICK menu key and the following menu will display. Press the T-GAUGE menu soft
key, and use the UP/DOWN arrow keys to toggle through the selections. Select A IP - 1st.
6. Press the TRIGGER softkey and rotate the SmartKnob™ to toggle between
peak or leading edge triggering for thickness measurements. Select EDGE.
5.3.5 Thickness Using Multiple Echoes From the 1st Back Wall to 2nd Back Wall
Reflection, Echo-to-Echo
88 - T.O. #33D7-22-32-1
Applications
To measure between echoes, both Gate 1 and Gate 2 are used for thickness measurements. Gate
1 position (start) must be to the left of the thinnest step (echo) for thickness measurements. The
width must be wide enough to cover the area where the 1st back wall echo will appear (see
Figure 5-26).
Gate 2 position (start) must be to the right of the 1st back wall echo and to the left of the thinnest
2nd back wall echo for accurate thickness measurements. The width of Gate 2 must be wide
enough to cover the area where the 2nd back wall echo will appear (see Figure 5-27)
89 - T.O. #33D7-22-32-1
Press GATE1 menu key and the following menu will appear. This menu provides changeable

1. To enable Gate1, press GATE1 menu key again, and rotate the SmartKnob™
thinnest step (0.100 inch). (Please see Figure 5-28).
WIDTH menu soft key repeatedly, to adjust the Gate width until it goes past or
through the 1st echo from the thinnest step (see Figure 5-29).
The Gate width must extend past the thickest step in the calibration process.
90 - T.O. #33D7-22-32-1
Applications
For this application, Gate2 is used for thickness.
5. To enable Gate2, press the GATE2 menu key again and rotate the Smart-
6. Press the Gate LEVEL menu soft key and rotate the SmartKnob™ to the desired
screen height, such as 30%.
2nd back wall echo, or just to the right side of the 1st back reflection (see
Figure 5-30).
WIDTH menu soft key repeatedly, to adjust the Gate width to go past or
through the 2nd back wall echo (see Figure 5-31).

the selections; select Auto Echo - Echo (AUTO E-E).
91 - T.O. #33D7-22-32-1
10. Place the transducer on the thinnest step (0.100 inch). Verify proper Gate1 and
Gate2 positioning, as above (the thickness gauge starts the measurement with
the 1st echo to break Gate1, and stops the measurement with the 1st echo to
break Gate2). Press the THK CAL softkey, and rotate the SmartKnob until the
THK CAL value for CAL PT1 reads 0.100 inch. Press ENTER to log this value
(Please refer to Figure 5-32).
11. Place the transducer on the 0.400 inch step. Verify proper Gate1 and Gate2
positioning, as above (a slight adjustment of the Gate2 position may be
required to prevent triggering on unwanted signals), press the THK CAL soft-
key, and rotate the SmartKnob until the THK CAL value for CAL PT2 reads
0.400 inch. Press ENTER to log this value.(Please refer to Figure 5-33).
12. Calibration is now done. Check other thickness values to verify; if the thick-
ness readings are correct, the thickness gauge is calibrated. If the thickness
gauge is not calibrated, repeat calibration steps 10 through 11.
Figure 5-32
92 - T.O. #33D7-22-32-1
Applications
Figure 5-33
5.4 Shear Wave (Angle Beam) Testing

The primary method of testing welds is Angle Beam Shear Wave Ultrasonic Inspection. The
angle beam allows testing at the proper angle to detect flaws in the weld zone. This is
accomplished by using a Lucite wedge to convert the ultrasound into a shear wave at the proper
angle. This angle is usually specified in AWS and ASME Standards to obtain the best results on
a particular weld.
TRANSDUCER — A 2.25 MHz transducer with Lucite wedge is usually

used, such as the Spectrum™ F2L, with a wedge at the desired angle. The trans-
ducer used will depend on the material, surface condition, and thickness.
TRANSDUCER CABLE — Use a Sonic® BNC/Microdot (P/N #9102894) to

match the transducer.
use thinner couplants (water, light oil, or mineral oil). For rough surfaces,
Sonic® X30S couplant (P/N #3317450) is more appropriate.
5.4.1 Instrument Calibration - 10” Thickness Range, Steel
1. Connect the transducer cable to the Spectrum™ F2L transducer and to either
BNC connector.
93 - T.O. #33D7-22-32-1
3. Place couplant on the top surface of the test block at the index point matching
the wedge angle.
4. Place transducer on a calibration block at the index point. Refer to Figure 5-

34 and Figure 5-35 for IIW Blocks and Figure 5-36 for the B1 block positions.
O O O
Figure 5-34: IIW Block Type 1
94 - T.O. #33D7-22-32-1
Applications
60° 70° 75° 80°
Figure 5-35: IIW Block Type 2
5. Swivel the transducer to peak the echoes.
6. Calibrate the EL/LCD display to the sound path by adjusting Delay.

Adjust Delay by pressing the RANGE menu key, then the DELAY menu soft
key, and rotate the SmartKnob™, or press the UP/DOWN arrow keys, so that
the first echo lines up as follows for the three test blocks:
IIW Type 1 Block: Line 4 (4 inches). See first echo in Figure 5-37.
IIW Type 2 Block: Line 2 (2 inches). See first echo in Figure 5-38.
B1 Block: Line 1 (1 inch). See first echo in Figure 5-39.
0° 30° 45° 60°

0°
°
60
°
70
Figure 5-36: B1 Block
7. Adjust Velocity by pressing the RANGE menu key, then the VEL menu soft
key, and rotate the SmartKnob™ to line up the second echo as follows:
IIW Type 1: Line 9 (9 inch). See second echo in Figure 5-37.

IIW Type 2: Line 4 (4 inch). See second echo in Figure 5-38.
B1: Line 4 (4 inch). See echo pattern in Figure 5-39.
95 - T.O. #33D7-22-32-1
8. Repeat steps 6 and 7 until both signals fall on the correct graticule lines.
Example:
Test Block IIW Type 1 will have echoes positioned exactly at 4

inches and 9 inches.
Test Block IIW Type 2 echoes will be at 2 and 4 inches.
The B1 block will have echo signals at 1, 4, 7, and 10 inches.
See Figure 5-37, Figure 5-38, and Figure 5-39.
Figure 5-37: IIW Type 1 Block Echoes
Figure 5-38: IIW Type 2 Block Echoes
96 - T.O. #33D7-22-32-1
Applications
Figure 5-39: B1 Block Echoes
All figures represent a 10 inch screen range.
9. When the echoes are lined up at both points, the horizontal sweep is calibrated.
Measurement of the wedge angle by use of a IIW Test Block:
10. If the index point of the wedge is not known exactly, it is first necessary to
determine it.
To find the true index point on the wedge:
11. Place the transducer with couplant on the block to reflect from the large 4 inch
radius end (as shown in Figure 5-40).
12. Move the transducer to maximize the echo. The true index point will be
directly at the center index mark. If this is different from the marking on the
wedge, re-mark the index.
13. Check the wedge refraction angle by the following procedure: a) for IIW Block
Types 1 and 2, and b) for the B1 Block.
97 - T.O. #33D7-22-32-1
60° 70° 75° 4"
RA
D.
5 10 80° 15 20
Figure 5-40: Leading Edge Index Point
a) Determination of the Angle of Refraction - The echo from the surface of the 2 inch (50
millimeter) diameter hole is used. The calibration markings engraved on both sides of the block
make a direct determination of angles between 35° and 75° possible.
The exact angle of refraction can be read at the wedge index when the echo is
at its maximum height. When measuring angles of refraction between 75° and
80°, the small hole (0.062 inch/1.6 millimeters) is used. Both transducer posi-
tions are shown in Figure 5-41. The wedge angle is always measured from the
vertical.
(1) Move the transducer back and forth to maximize the reflection.
(2) Read the angle from the true index mark to where it reads on the degree marks
on the block. (Use the other side for above 60°).
60° 70° 75°
5 10 80° 15 20
Figure 5-41: IIW Block Refraction Angle Calibration
98 - T.O. #33D7-22-32-1
Applications
b) B1 Block Refraction Angle Transducer Locations - For the B1 Block, use the reflection
from the side drill hole, as shown in Figure 5-42, and maximize the echoes as before.
12. The measured angle should be within the specifications of the code or proce-
dures used, normally ±2 degrees.
O O O O
0 30 45 60
60°
70°
FIgure 5-42: B1 Block Refraction Angle Transducer Locations
13. Setting the reference level: Set the echo signal level according to the specific
code requirement. For example, use the 0.062 side drill as shown in Figure 5-
43. The echo should be set to vertical line 5 to 7 (50 to 70%) as a reference.
14. Increase the Gain as specified in the code or procedure, and you are ready to
scan.
40° 50° 60°
Figure 5-43: Reference Level Adjustment
5.4.2 Defect Location in Weld Inspection
It is important to determine the distance and depth of a located flaw or defect in a shear wave test.
A Sonic® Ultrasonic Calculator for Weld Inspection can be used to graphically locate defects, or
99 - T.O. #33D7-22-32-1
simple sine-cosine trigonometry can be used.
Direct Reflection Location of Flaws
1.Distance = sound path (as measured on EL/LCD) times the sine of the wedge angle.
Dist = S • sin(angle)
2.Depth = sound path (as measured on the EL/LCD) times the cosine of the wedge angle.
Depth = S • cos(angle)
3.Example:
A 60° wedge and EL/LCD measured sound path of 2 inches (refer to Figure
5-44).
Dist = 2 • sin 60° = 1.74 inches

and
Depth = 2 • cos 60° = 1.00 inches
1.74"
1"
60 O 2"
Figure 5-44: Defect Location in Shear Wave Inspection
5.4.3 Multiple Bounce Weld Inspection
If the sound path bounces or reflects one or more times from the sides of the test piece, the sound
path and surface distance readings will be the same as for direct reflection. However, the depth
calculation will give a result greater than the actual thickness (as shown in Figure 5-45).
100 - T.O. #33D7-22-32-1

Applications
WELD
FLAW
1
W Ø
2
Figure 5-45: Multiple Bounce Shear Calibration
1 = actual depth w = wall thickness

2 = calculated depth s = sound path (measured on EL/LCD)
Depth calculation for one bounce: calculate the depth as in Direct Reflection.
depth (2) = S • cos (angle)
Subtract the depth (2) from twice the wall thickness to obtain the actual depth.
actual depth (1) = 2w - depth (2)
Example:
W = 1 inch and S = 3 inches and angle 0 = 60° then:
depth(2) = 3 • cos 60°

= 1.5”
actual depth(1) = (2 x 1”) - 1.5”
= 0.5”
5.4.4 Shear Wave (Angle Beam) Digital Thickness Calibration
Once the screen range is calibrated, continue with the setup of the Angle Beam (Trig functions)
mode. Adjust the operating controls as follows:
101 - T.O. #33D7-22-32-1

1. For the correct thickness measurements, Gate1 must be adjusted as follows:
A IIW Type 1 Block is used for this application.
2. Press the GATE1 menu key, GATE1 menu soft key, and press the UP/DOWN
arrow keys or rotate the SmartKnob™ until the “+ “ is selected.
3. Press the LEVEL menu soft key and adjust the level to the desired screen
height, such as 40%, with the UP/DOWN arrow keys or the SmartKnob™.
4. Press the POSN menu soft key and adjust the position: the start of the gate is to
the right of the transducer wedge noise or IP, and to the left of the first echo
(see Figure 5-46).
5. Press the WIDTH menu soft key and adjust the width to full screen, or to the
right of the farthest echo, by rotating the SmartKnob™ or pressing the UP/
DOWN arrow keys (see Figure 5-47).
6. Ensure that both echoes (thinnest and thickest) go through the gate bar.The
Thickness Gauge is now ready for calibration.
1. Press the THICK menu key and the following soft key menu will appear:
2. Press the T-GAUGE menu soft key and rotate the SmartKnob™, or press the
UP/DOWN arrow keys, to turn on T-gauge to A IP-1st.
102 - T.O. #33D7-22-32-1

Applications
3. Select peak or leading edge triggering; normally, the leading edge is chosen.
4. Place the transducer on the calibration block and peak out the thickest (far-
thest) echo by swiveling the transducer. Press the THK CAL softkey, and
rotate the SmartKnob™ until the THK CAL value for CAL PT1 reads 9.00
inches. Press the ENTER key to log this value. (see Figure 5-48.)
5. Adjust the thinnest (closest) echo by swiveling the transducer to peak out the
echo at 4.00 inches, press the THK CAL softkey and rotate the SmartKnob™
until the THK CAL value for CAL PT2 reads 4.00 inches. Press the ENTER
key to log this value.(see Figure 5-49.)
6. Calibration is now done. (see Figure 5-50.)
Figure 5-48
Figure 5-49
103 - T.O. #33D7-22-32-1

Figure 5-50
7. Press the TRIG menu soft key and turn ON the trig function by using the UP/
DOWN arrow keys or SmartKnob™.
8. Press the ANGLE menu soft key and adjust the incidence angle to the desired
value using the UP/DOWN arrow keys, SmartKnob™, or by pressing the
ANGLE menu key repeatedly.
9. Press the THICK menu soft key and use either the UP/DOWN arrow keys, the
SmartKnob™, or press the THICK menu soft key repeatedly to enter the thick-
ness of the part to be inspected. By entering the part thickness, the DEPTH of
the reflector will always be measured from the surface of the part, no matter
what leg or V path you are in.
10. If the inspection is on a curved surface, press the O-DIAM menu soft key. Enter
the outer diameter of the curved surface by pressing the UP/DOWN arrow keys
or rotating the SmartKnob™. This corrects the trigometric functions for the
curved surface.
5.5 Distance Amplitude Correction (DAC) Testing

Press the DAC menu key, and then DAC menu soft key, and with the UP/DOWN arrow keys or
the SmartKnob, select one of the following modes of operation: 1) DAC CURVONLY; 2) 3
CURVES; 3) 4 CURVES; 4) DACONLY; and 5) DAC+CURV. For setup purposes, start with
the DAC CURVONLY.
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Applications
Be sure the Sonic® 1200M instrument is set up with the correct transducer setting. Adjust the
screen range parameter to include the total range of the test part. For setup purposes, the screen
display is for multiple echoes (see Figure 5-51).
Figure 5-51
5.5.1 DAC CURVONLY
1. Press the CURSOR menu soft key; a small circle will appear on the display that
selects the points/echoes where DAC compensation is calculated and the
amplitude of the selected points is adjusted. With the UP/DOWN arrow keys
or the SmartKnob™, move the cursor to the point/echo where the DAC Curve
Only is to start (see Figure 5-52).
105 - T.O. #33D7-22-32-1

2. Press the SELECT menu soft key; this will start the DAC Curve and log the
point.
3. Press the CURSOR menu soft key, and with the UP/DOWN arrow keys or
SmartKnob™, adjust the cursor to the second point/echo (see Figure 5-53).
4. Press the SELECT menu soft key; this will log the second point/echo of the
DAC Curve.
5. Press the CURSOR menu soft key and with the UP/DOWN arrow keys or
SmartKnob™, adjust the cursor to the next point/echo.
6. Press the SELECT menu soft key; this will log the next point/echo of the DAC
Curve.
SmartKnob™, adjust the cursor to the last point/echo.
8. Press the SELECT menu soft key; this will log the last point/echo of the DAC
Curve (see Figures 5-54 and 5-55).The DAC Curve Only is now complete. If
the curve is not correct, repeat the above steps.
Note: Follow the same steps above (DAC CURVONLY) for the 3 CURVE or 4
CURVE mode of operation.
106 - T.O. #33D7-22-32-1

Applications
5.5.2 DACONLY
1. Press the CURSOR menu soft key and a small circle will appear on the display
that selects the points/echo where DAC compensation is calculated and the
amplitude of the selected points is adjusted. With the UP/DOWN arrow keys
or the SmartKnob™, move the cursor to the point/echo where the DAC Only
is to start (see Figure 5-56).
2. Press the SELECT menu soft key; this will log the next point/echo. SELECT
will automatically change to ADJUST. With the UP/DOWN arrow keys or
SmartKnob™, adjust the gain to increase the echo amplitude to the desired
height: for example, from 70% FSH (full screen height) to 80% FSH (see Fig-
ure 5-57).
SmartKnob™, adjust the cursor to the next point/echo (see Figure 5-58).
4. Press the SELECT menu soft key; this will log the next point/echo. SELECT
height: for example, from 60% FSH to 80% FSH (see Figure 5-59).
107 - T.O. #33D7-22-32-1

Figure 5-56, 5-57, 5-58, and 5-59
SmartKnob™, adjust the cursor to the next point/echo (see Figure 5-60).
6. Press the SELECT menu soft key, this will log the next point/echo. SELECT
height: for example, from 60% FSH to 80% FSH.
7. Continue following the above steps for all the points/echo that require DAC
(see Figures 5-61 and 5-62 for the points/echo at the same amplitude).
108 - T.O. #33D7-22-32-1

Applications
Figures 5-60, 5-61, and 5-62
5.5.3 DAC+CURV
1. Press the DAC menu soft key, and with the UP/DOWN arrow keys or the
SmartKnob™, select the DAC+CURVE mode.
2. Press the SELECT menu soft key; this will log all the Dac Curve points and
automatically draw for the selected points/echoes (see Figure 5-63).
3. If the points/echoes are adjusted to the correct amplitude, the DAC+CURVE

is complete. If the points/echoes are not at the correct amplitude, you may go
back to the point/echo that needs adjustment by pressing the CURSOR menu
109 - T.O. #33D7-22-32-1

soft key until the cursor is at the desired point/echo. The amplitude is adjusted
by pressing the ADJUST menu soft key, and then the UP/DOWN arrow keys,
or rotating the SmartKnob™.
Figure 5-63
110 - T.O. #33D7-22-32-1

Internal Data Logger
6 Internal Data Logger

6.1 Introduction
6.2 Creating a New Block
6.3 Selecting a New Block
6.4 Storing Readings into Memory
6.5 Selecting Locations and Reviewing Readings
6.6 Clearing Readings
6.7 Clearing a Block
6.8 Deleting a Block
6.9 Deleting All Blocks
6.1 Introduction
The internal Data Logger of the Sonic1200M instrument provides a simple and reliable way to
record thickness readings. Displayed readings are stored in one or more data blocks by pressing
the T-STORE menu soft key in the MAIN menu. A built-in report format outputs a selected block
or blocks, or the entire Data Logger memory, to a PC or compatible printer. As with instrument
control settings, stored readings are retained in memory, even when batteries are removed.
A data block is a group of Data Logger locations for storing thickness readings (one reading per
location) and reporting measurement data. Block size is determined when the operator sets the
row and column definitions during the creation of a new block. The Sonic 1200M permits up to
a maximum of 100 separate data blocks, although the actual number of data blocks allowed will
vary with the number of available thickness storage locations. The Sonic 1200M has a total
memory capacity of 5,000 thickness storage locations.
The first reading is stored in each block, starting with location number 1, unless the operator
selects a different starting location. The Data Logger automatically advances to the next location,
and subsequent readings are stored sequentially until all locations have been filled or another
location or data block is selected to receive readings.
Location numbers and stored readings can be viewed from the data block editor. Readings in
individual block locations, entire blocks, or all of the Data Logger memory can be cleared.
The Sonic 1200M stores readings in memory indefinitely, even when the batteries have been
removed. However, data could be lost or corrupted if the instrument were damaged or exposed
to extreme environmental conditions. For extended storage, data blocks should be transferred to
a computer for storage on disk or tape.
111 - T.O. #33D7-22-32-1

6.2 Creating a New Block
Readings cannot be stored in the Data Logger until at least one data block has been created and
selected, and the thickness gauge must be on and calibrated. The number of data blocks and their
size is dependent upon the number of available Data Logger storage locations. The data logger
offers up to 5,000 thickness readings.
Use the following procedure to create a new data block:
1. Select SPCL, DATA Sub-menu, and ENTER.
2. Highlight the block number parameter using the corresponding soft key.
3. Select a NEW block by adjusting the block number as high as the instrument
will permit. When the last block number is exceeded, the word NEW will
appear. If all 100 blocks are in use, the Sonic® 1200M will not permit a new
block to be created.
4. Press the ENTER key to create the new block and activate the new block edi-
tor.
This new block will be assigned the next available sequential block number. The block is
automatically stored in the column direction with one row by one column grid dimensions. The
block name and description are initially blank.
To customize the block, use the following controls:

1. Set the desired number of rows and columns using the appropriate menu soft
key and the SmartKnob™. If the instrument prevents a particular row or col-
umn setting, the problem is likely to be a lack of available memory.
2. Toggle the storage direction between ROW and COLUMN by pressing the
direction menu soft key.
3. Enter an 8 character block name by pressing the NAME menu soft key (also
available in the Data sub-menu).
4. Enter a 26 character block description by pressing the DESCRIBE menu soft

key (also available in the Data sub-menu).
Ensure that the correct number of rows, number of columns, and storage direction are selected
before leaving this menu. Once defined, the rows, columns, and storage direction cannot be
modified. Changing a block definition requires deleting the block and creating a new block with
the correct definition.
The Sonic 1200M automatically sets the current Data Logging block to the new block number
and the location to 1. To begin data storage, switch to the main menu by pressing the MAIN key.
112 - T.O. #33D7-22-32-1

6.3 Selecting a Block

Before readings can be stored in the Data Logger, one of the data blocks created using the
procedure in the preceding section must be selected to receive the data.
When a new block is created, it automatically becomes the current block selection. To select a
different data block:
1. Select the SPCL menu.
2. Highlight the BLOCK parameter box using the column menu soft key.
3. Adjust the BLOCK number using the SmartKnobTM or the Increase/Decrease

keys.
Each time the block number is changed, the reading storage location (T-STORE) is automatically
reset to that location. The Sonic 1200M automatically returns to the last selected data block
when the instrument is switched on.
6.4 Storing Readings into Memory

To store thickness or other soundpath distance measurements in the Data Logger, the following
function settings must be enabled:
• The thickness gauge must be set ON.

• A data block must be created and selected.
• An EMPTY storage location must be selected.
• The main menu will be displayed when the MAIN key is pressed.
The enlarged thickness reading is automatically displayed in the numeric display portion of the
screen.
To record a displayed thickness value in the current location, press the T-STORE menu soft key.
Once the reading has been stored, the block location number will be incremented automatically.
The Sonic 1200M will not advance the location number beyond the end of the block, nor will the
Sonic 1200M record the displayed value(s) if they are zero (0).
6.5 Selecting Locations and Reviewing Readings

Any location in the currently selected block number and the value stored in that location can be
selected and viewed from either the SPCL menu or the Data Review sub-menu. From the
instrumentís MAIN menu, the T-STORE location number may be altered using the arrow keys.
The value presently stored in memory is displayed in one of three ways:
113 - T.O. #33D7-22-32-1

EMPTY No measurement has been stored.
X.XXX in
(XX.X mm) The value presently stored in the displayed location number. Stored readings
are always displayed in the “as stored unit of measure.” The set using the
UNITS function is in the SPCL menu. The units for the data block are set to
the instrument setting when the block is defined.
To review stored readings from the SPCL menu:
1. Display the SPCL menu.

2. Select the desired location number T-STORE.
3. Observe the stored thickness reading or message.
To review readings from the Data Review sub-menu:
1. Display the Data Review sub-menu SPCL, DATA sub-menu, ENTER,

BLOCK #, ENTER.
2. Select the desired storage location either by the location number or by row and
column.
3. The selected stored thickness reading or message will be highlighted.
6.6 Clearing Readings

The value stored in any location in the currently selected block number can be cleared from Data
Logger either from the SPCL menu or the Block Review sub-menu.
Note: Clearing a stored reading permanently erases it from memory. It cannot be

recovered.
The contents of the currently selected block location will be permanently lost. However, the
contents of the data block may be transferred to a printer or personal computer prior to clearing.
To clear the contents of a storage location from the SPCL menu:
1. Display the SPCL menu.

2. Select the desired BLOCK number.
3. Select the desired location number T-STORE.
4. Select the CLEAR function using menu soft keys and the ENTER key.
5. Press the ENTER key to confirm the clear location operation, any other key to
abort.
To clear the contents of a storage location from the Data Review sub-menu:
114 - T.O. #33D7-22-32-1

BLOCK #, ENTER
2. Select the desired storage location either by the location number or by row and
column.
3. Select the CLEAR function using the CLEAR menu soft key.
4. Press the ENTER key to confirm the clear location operation, any other key to
abort.
Once the location has been cleared, it is then available for the recording of new measurement
data.
6.7 Clearing a Block

The entire contents of the currently selected block can be cleared from Data Logger memory and
from the Block Review sub-menu. All data in the cleared data block will be permanently lost.
However, the contents of the data block may be transferred to a printer or personal computer prior
to clearing.
To clear the contents of a data block:

BLOCK #, ENTER.
2. Press LOCATION menu soft key.
3. Use the SmartKnob™ to decrease the location number until the word ALL
appears.
Note: Clearing a selected block permanently erases all data stored in that block
number. It cannot be recovered.
4.Press the CLEAR menu soft key

5.Press the ENTER key to confirm the clear operation, any other key to abort.
All locations in the data block have been cleared and are available for recording of measurement
data.
6.8 Deleting a Block

A data block and its contents can be deleted from the Data sub-menu, but the block definition and
its contents will be permanently lost. However, the contents of the selected block may be
transferred to a printer or personal computer prior to deleting.
To delete a Data Logger block:
1. Display the Data sub-menu SPCL, DATA sub-menu, ENTER.

2. Press BLOCK menu soft key.
3. Adjust the block number until the desired number is displayed.
115 - T.O. #33D7-22-32-1

Note: Deleting a selected block permanently erases it’s definition and all data
stored in that block number. It cannot be recovered.
4. Press the DELETE menu soft key

5. Press the ENTER key to confirm the delete operation, any other key to abort.
6.9 Deleting All Blocks

The All Data Logger blocks can be deleted from the Data sub-menu. All data in the Data Logger
will be permanently lost. However, the contents of one or all blocks may be transferred to a
printer or personal computer prior to deleting.
To delete the entire Data Logger memory:
1. Display the Data sub-menu SPCL, DATA sub-menu, ENTER.

2. Press BLOCK menu soft key.
3. Decrease the block number below 1 until the word ALL appears.
Note: Deleting a selected block permanently erases its definition and all data stored
in that block number.
4. Press the DELETE menu soft key.

5. Press the ENTER key to confirm the delete operation, any other key to abort.
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Computer Interface
7 Computer Interface
6.1 Description
6.2 RS-232C Communication
6.3 Modes of Operation
6.4 Command Strings
6.5 Status Reporting
6.6 RS-232 Command Set
6.7 Examples
7.1 Description
The Sonic® 1200M instrument has the capability of being controlled and monitored by an
external computer or terminal. The RS-232C communication port allows an external device to
send commands to or obtain information from the Sonic® 1200M. With the exception of a few
controls, all operations available from the front panel are also available from the RS-232
interface.
Note: Use of single quotes (‘) and double quotes (“) throughout this description are
for the purpose of discussion only. These two symbols are used to delineate
specific characters and character strings used in the RS-232 interface, and
are NOT to be used in actual RS-232 communications.
7.2 RS-232C Communication
The Sonic® 1200M serial interface is configured as Data Terminal Equipment (DTE). This
allows a direct connection between the instrument and Data Communication Equipment (DCE)
without the need for crossover connections. The default communication protocol is shown in the
following table:
RS-232 Parameter Sonic® 1000S Configuration
Baud Rate 9600 bps
Word Size 8
Parity NONE
Stop Bits 1
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The RS-232C serial interface will communicate with either a serial interface printer or an
externally connected computer. The 9-pin D-subminiature male connector is designed to connect
directly to an industry standard IBM-AT compatible serial port. Pinouts are listed below:
1 Not connected
2 Output; TXD (transmitted data)
3 Input; RXD (received data)
4 Input; CTS (clear to send)
5 Signal ground
6 Not connected
7 Not connected
8 Output; RTS (request to send)
9 Not connected
Using a readily available 9-pin to 25-pin serial adapter cable, it will also connect to standard
IBM-PC serial connectors by using a 25-pin to 25-pin cable with female connectors on both ends.
Interface cables are also available from Olympus NDT Instruments.
Proper connections of the serial port to various devices are tabulated below:
7.2.1 9-Pin Auxililary Output
The 9-pin, D-subminiature female connector, labeled OUTPUT, provides optional alarm and
analog level signals from the gates and the thickness gauge. Separate digital and analog ground
pins and a pulse for synchronizing to the pulser are also provided. Alarm signals should be
referenced to digital grounds, and peak signal and distance outputs referenced to the analog
ground. Pinouts are listed below:
1 Gate 1 Alarm 1
2 Thickness Gauge Alarm
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Computer Interface
3 Digital Ground
4 Synchronize to Pulser
5 Peak 1/Distance Analog Out
6 Gate 2 Alarm 2
7 Digital Ground
8 Analog Ground
9 Peak 2 Analog Out
7.3 Modes of Operation

Two communication modes are available: HOST mode, which permits computer communication
with the instrument, and TERMINAL mode, which is designed for use with a terminal. Each time
the Sonic® 1200M is powered on, the operating mode is set to HOST mode. The RS-232
command set is identical for both modes, but the way in which the Sonic® 1200M responds to
serial input differs.
Terminal Mode
In terminal mode, each character is echoed back as it is received. Carriage returns are echoed
back as carriage return and line feed. All responses are terminated by carriage return and line
feed. Prompts, terminated by carriage return and line feed, are returned in all cases.
PromptDescription
“>”....Command Accepted
“C?”....Invalid Command
“V?”....Invalid Value
HOST Mode
In HOST mode, characters are not echoed back. All responses are terminated by a carriage return
only. Prompts are only returned in the event of error conditions, such as the following:
Prompt Description
“C?” ....Invalid Command

“V?” ....Invalid Value
Space (20 Hex) and line feed (0A Hex) characters are ignored in most cases. To prevent the loss
of data, it is important that the HOST/TERMINAL not attempt another serial transaction until a
response from the previous transaction is received (carriage return for HOST mode; prompt,
carriage return, and line feed for TERMINAL mode). All commands to the Sonic® 1200M must
be terminated by a carriage return (0D Hex). All information sent by the Sonic® 1200M is
terminated according to the serial mode (carriage return for HOST mode; carriage return and line
feed for TERMINAL mode).
119 - T.O. #33D7-22-32-1

7.4 Command Strings
Serial communication is performed using ASCII characters (with the exception of binary data
transfers). A command string is comprised of three or more ASCII characters and a carriage
return (terminator). The command string has three parts, not all of which are used in every case.
1. Command Code: A three character code that identifies the instrument item or
function (refer to RS-232 Command Set).
2. Command Operation: A one character code that identifies the operations as

READ ‘?’, WRITE ‘=’, or EXECUTE (carriage return).
3. Command Value: The type and number of ASCII characters in this part of the
command string is variable and depends on the parameter specification.
The Sonic® 1200M recognizes three types of commands: READ, WRITE, and EXECUTE. The
type of command is indicated by the command operation. To perform a read operation, the ‘?’
symbol is used. To perform a write operation, the ‘=’ symbol is used. To perform an execute
operation, a carriage return is used.
Note: The Sonic® 1200M does NOT process a command string until a carriage
return is received.
7.5 Status Reporting
After receiving a command, the Sonic® 1200M checks the string for errors. If no errors are
detected, the desired operation is executed. Upon completion of error checking or command
execution, the Sonic® 1200M reports back to the host/terminal with a prompt. The prompts vary
with the RS-232 mode and the results of the error detection.
Prompts indicating successful completion of a command are to be used by the host/terminal as a

signal indicating that the Sonic® 1200M is ready for another command. In host mode, the prompt
is simply a carriage return (0D Hex). In terminal mode, an angle bracket ‘>’ is sent, followed by
a carriage return (0D Hex) and line feed (0A Hex).
If an error is encountered, error prompts are returned to the host/terminal. Two types of error
prompts are used to indicate BAD COMMANDS and BAD VALUES. If a bad command is
received (Command code), the Sonic® 1200M will return C? terminated with a carriage return
(and line feed for terminal mode). If a bad value is received (Command value), the Sonic®
1200M will return V? terminated with a carriage return (and line feed for terminal mode).
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Computer Interface
7.6 RS-232 Command Set
RS-232 control of the Sonic® 1200M is achieved using ASCII command strings terminated by a
carriage return (0D Hex). For commands that require ASCII letters A-Z (or a-z), upper or lower
case may be used. Space (20 Hex) and line feed (0A Hex) characters may be included in the
command strings (that is, spaces may be included in report strings), but are usually ignored.
When specifying a real number value, the decimal point is only required when resolution beyond
integers is desired.
Each instrument parameter permits a specific subset of the three available command types (Read,
Write, or eXecute). Command types permitted by each parameter are listed in the following
tables.
Function RMX Code Range Description
Pulse Width RW PUL 15-1000 ns Pulser pulse

width
Damping RW DMP 25 Pulser damping

50
200
Mode RW MOD SINGLE Transducer Mode

DUAL
THRU
Pulser Voltage RW PVO 150 Pulser Voltage

300 Selection
Gain RW GAN 0.0-110.0 dB Receiver gain

setting
Display RW DSP RF, RF+, RF-, Receiver display

HALF+, HALF-, mode
FULLWAV,
FLTR 1, FLTR 2,
FLTR 3
Color RW CSH 1-9 Changes color
palette on +
instruments
Reject RW REJ 1-80 Receiver linear
reject
Range Mode RW SYN IP, IFSYNC Range mode
Holdoff RW SYD 0.0-432.9 Holdoff in IF
Sync mode
IF Level RW IFL 5-80 IF Sync level
Pulse Width RW WDM OFF, ON (spike) Pulse Width
Mode mode (on=spike
pulser)
Persist RW SIS OFF, 0.1-10.0 Persistence time
Average RW AVG OFF, 2, 4, 8, 16 Average
Table 1 RS-232 Command Set
121 - T.O. #33D7-22-32-1

Frequency RW FRQ 500 KHz Receiver tuning
1 MHz frequencies
2.25 MHz
3.5 MHz
5 MHz
10 MHz
15 MHz
HIPASS
WB
Gate 1 RW GT1 OFF, +, - Gate 1 OFF/ON
and polarity
Gate 1 Level RW LV1 5-100 Gate 1 Alarm
Level
Gate 1 Position RW PS1 -1.16-185” Gate 1 start
-29.0-4694 mm position
Gate 1 Width RW WD1 0.001-296” Width (depends
0.1-7510 mm on Gate 1 position
and velocity
settings)
Gate 2 RW GT2 OFF, +, - Gate 2 OFF/ON

and polarity
Gate 2 Level RW LV2 5-100 Gate 2 Alarm
Level
Gate 2 Position RW PS2 -1.16-185” Gate 2 start
-29.0-4694 mm position
Gate 2 Width RW WD2 0.001-296” Width (depends

0.1-7510 mm on Gate 2 position
and velocity
settings)
Range RW RNG 0.048-296” Sweep range
1.23-7510 mm
Delay RW DLY -1.16-185” Sweep delay
-29.0-4694 mm
Velocity RW VEL 0.025-0.600”/µs Sweep velocity

635-15240 m/s
Maximum RW RRM 50-4000 Hz Max pulser pulse

Repetition Rate repetition rate
Actual Repetition R REP 50-4000 Hz Actual pulser
Rate pulse repetition
rate
Units RW UNT US Operating units
IN
MM
Thickness Enable RW TGE OFF T-gauge enable
IP-1ST
E-E
A IP-1ST
AUTO E-E
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Computer Interface
Thickness RW TGT EDGE T-gauge

Trigger PEAK measurement
trigger on EDGE
(rising edge only)
or on PEAK
Face Plate Offset RW FPO -5.0-100.0 µs T-gauge

transducer offset
Thickness RW TMV 0.025-0.600”/µs Velocity setting
Velocity 635-15240 m/s for T-Gauge
functions
Angle Beam RW ABE OFF Trigonometric
Enable ON function enable
Angle Degrees RW ADG 0.0-90.0° Angle beam angle
Part Thickness RW PTH 0.001”-185” Angle beam part
0.1 mm - 4694 thickness
mm (depends on
thickness
velocity)
Outer Diameter RW DIA OFF - 185” Curved surface

OFF - 4694 mm diameter:
OFF=Flat surface
Sound Path R TSP ____ OR floating Sound path

point number
Thickness R TDP ____ OR floating Thickness
point number reading
Distance R TDS ____ OR floating Distance reading
point number
Thickness RW TK1 0.001”=185” Thickness cal

Calibration Point 0.1 mm - 4694 point 1 value
1 mm
Thickness RW TK2 0.001”=185” Thickness cal
Calibration Point 0.1 mm - 4694 point 2 value
2 mm
Calculate W STK Start Thickness
Thickness Calibration on
Calibration Point current
calibration Point
Program Status W PEF 1-100 Stored program
status.
Response:
EMPTY or FULL
Program Store W PST 1-100 Program store
operation
123 - T.O. #33D7-22-32-1

Program recall W PRC 0-200 Program recall
operation
0: Load all
defaults
1-100: Recall
program stored in
location 1-100
101-200: Recall
program stored in
ascan location 1-
100
Program Erase W PER 1-100 Program Erase
operation
Read Program W PRN 1-100 Read stored

Name program name
Write Program W PWN 1-100 Write tsored
Name program name
Program Upload W PUP 1-100 Upload stored

program (binary)
Program W PDN 1-100 Download

Download program (binary)
Scan Status W SEF 1-100 A-scan storage

location status
Response:
EMPTY
FULL
PK-1, PK-2
RF-1, RF-2
Add R if attribute
is set.
Scan Store W SST 1-100 Store A-scan
Scan Erase W SER 1-100 Erase

Read A-Scan W ARN 1-100 Read stored A-
Name scan Name
Write A-Scan W AWN 1-100 Write stored A-
Name scan Name
Scan Upload W SUP 1-100 Upload stored A-

scan
Scan Download W SDN 1-100 Download stored

A-scan
Upload Wave W UPW 0-101 Upload

waveform data
(220 points
0=current display
sweep
1-100=stored A-
scan
101=current
display second
sweep)
124 - T.O. #33D7-22-32-1

Computer Interface
Upload Display R UPD N/A Upload bit image

reproduction of
the display
(10240 points)
Read Report W RHD N/A Read report
Header header
Set Report W SHD N/A Write the report
Header header
Read Report W RLB 1-7 Read a report
Label label
Set Report Label W SLB 1-7 Write a report

label
Read Report W RFL 1-7 Read a report
Field field
Set Report Field W SFL 1-7 Write a report

field
Read Report W REN 1-3 Read Report
Entry entry
Set Report Entry W SEN 1-3 Write a report
entry
LCD Backlight RW CNT 0-31 LCD backlight

Brightness brightness
adjustment
Knob Resolution RW RES 3, 4 Knob resolution

Gain Step Size RW GSS 0.1 Gain adjustment
0.2 step size
0.5
1.0
2.0
6.0
12.0
+dB Value RW +DB 6 +dB feature gain

12 setting
18
24
+dB Status RW DBS OFF +dB feature status
ON
dB Difference RW DIF -110.0-110.0 dB reference gain
difference
Look Out RW LOK OFF Front panel lock

ON out
Battery Status R BAT OK Battery status
LOW
Alarm Dwell RW ADW OFF, .2, .4 ...10, Alarm dwell in

LATCH seconds
Clock Hours RW HR. 0-23 Clock hours

setting
125 - T.O. #33D7-22-32-1

Clock Minutes RW MIN 0-59 Clock minute
setting
Clock Month RW MON 1-12 Clock month
setting
Clock Year RW YR. 1996-2095 Clock year setting

Peak Hold RW PKH OFF Peak Hold feature
ON enable
Signal Fill RW FIL OFF Signal fill enable
ON
Alarm 1 Status R G1A OFF Gate 1 Alarm

ON Status
Alarm 2 Status R G2A OFF Gate 2 Alarm
ON Status
Gate 1 Peak R PA1 0-246 Gate 1 Peak

Amplitude Amplitude
reading
Gate 2 Peak R PA2 0-246 Gate 2 Peak

Amplitude Amplitude
reading
Color RW CSH 0-9 0=monochrome

1-8=preset colors
9=user palette
Settings listed in
the next five
rows:
Background RW CBR See colors below. Sets Background
Text RW CTX Sets Text
Graticule RW CGR Sets Graticule

Signal RW CSG Sets Signal
Cursor RW C2S Sets Cursor

BLACK, RED, YELLOW, GREEN, CYAN, WHITE, MAGENTA, BLUE
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Computer Interface
127 - T.O. #33D7-22-32-1

128 - T.O. #33D7-22-32-1
Computer Interface
129 - T.O. #33D7-22-32-1

1 Text Read/Upload Commands
The instrument responds to text read commands with an ASCII string terminated with a carriage
return (0D Hex). To ensure proper transfer, the following steps are used to upload a text string:
1. Host sends a “Read Text” command.

2. Host waits for the Sonic® 1200M to respond with an ASCII text string (termi-
nated with a carriage. return, 0D Hex) or an error prompt.
2 Text Write/Download Commands

The Sonic® 1200M utilizes only a subset of the printable ASCII characters (A-Z, 0-9, ., -, /, #,
%, and SPACE). All other characters should be avoided. To ensure proper transfer, these steps
are used to write a text string:
1. Host sends the appropriate “Write Text” command.

2. Host waits for the Sonic® 1200M to respond with a carriage return (0D Hex)
or an error prompt.
3. If no error was encountered, the host sends the text string and waits for a
prompt.
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Computer Interface
3 Binary Read/Upload Commands

The binary upload transfer consists of a 2-byte size count (SS), followed by the binary data
information (B..B), and a 1-byte checksum (C). The size count is sent in low byte then high byte
order. To ensure data integrity, the host should calculate its own checksum and compare it to that
sent by the Sonic® 1200M. The checksum is generated by summing all byte values, excluding
the size count and checksum, modulus 256.
(Byte1 + Byte2 + ... + ByteN) % 256
To ensure proper transfer, the following steps are used to upload a scan:
1. Host sends a “Binary Upload” command.

or an error prompt.
3. If no error was encountered, the Sonic® 1200M proceeds immediately with the
upload.
4 Binary Write/Download Commands
The binary download transfer consists of a 2-byte size count (SS), followed by the binary data
information (B..B), and a 1-byte checksum (C).
This command is used to send stored binary data, acquired through the corresponding binary
upload command, back to the Sonic® 1200M. The Sonic® 1200M assumes that the data has not
been altered. Altered data will yield unpredictable results. To ensure proper transfer, the follow-
ing steps are used to download stored data.
1. Host sends a “Binary Download” command.

or an error prompt.
3. If no error was encountered, the host sends the binary data information and
waits for a prompt.
7.7 Examples
Example 1. Set instrument gain to 30.0 dB.
H o st G A N = 3 0 . 0 C/R
Sonic®
C/R
Instrument
131 - T.O. #33D7-22-32-1

Example 2.Read instrument gain.
H o st G A N ? C/R
Sonic®
3 0 . 0 C/R
Instrument
Example 3.Set report label 1 string to L1...L26.
H o st S L B = 1 C/R L1 . . . L 26 C/R
Sonic®
C/R C/R
Instrument
Example 4.Read report label 1 text string.
H o st R L B = 1 C/R
Sonic®
L1 . . . L 26 C/R
Instrument
Example 5.Upload stored program 1.
H o st P U P = 1 C/R
Sonic®
S1 S2 P1 . . PN C1 C/R
Instrument
Example 6.Download to program location 2.
H o st P D N = 2 C/R S1 S2 P1 0 0 PN C1
Sonic®
C/R C/R
Instrument
132 - T.O. #33D7-22-32-1

Glossary
8 Glossary
amplitude - Vertical pulse height of a signal, usually base to peak, when indicated by an A-scan
presentation.
angle beam - Wave train traveling at an angle, measured from the normal to the test surface to
the centerline of the beam.
A-scan - Method of data presentation utilizing a horizontal baseline that indicates distance or
time, and a vertical deflection from the baseline that indicates amplitude.
attenuation - Loss of energy per unit distance.
back reflection - Indication of the echo from the far boundary of the material under test.
baseline - The distance trace (horizontal) across the A-scan display.
contact inspection - The method in which the search unit makes direct contact with the material,
with a minimum couplant film.
couplant - Substance used between the search unit and test surface to permit or improve
transmission of ultrasonic energy.
damping - Limiting the duration of vibration in the search unit by either electrical or mechanical
means.
decibel (dB) - Logarithmic expression of a ratio of 2 amplitudes or intensities.
DAC (distance amplitude correction) (swept gain, time corrected gain, time variable gain, etc.)
- Electronic change of amplification to provide equal amplitude from equal reflectors at different
depths.
dynamic range - The ratio of maximum to minimum reflective areas that can be distinguished on
the display at a constant gain setting.
echo - Indication of reflected energy.
frequency (inspection) - Effective ultrasonic wave frequency of the system used to inspect the
material.
frequency (pulse repetition) - Number of pulses per second.
gate - Electronic means to monitor a selected segment of the distance trace.
initial pulse - Response of the display unit to the transmitted pulse.
133 - T.O. #33D7-22-32-1

interface - Boundary between two materials.
linearity:
amplitude - Characteristics of an ultrasonic testing system indicating its ability to respond in a

proportional manner to a range of echo amplitudes produced by specified reflectors.
distance - Characteristics of an ultrasonic testing system indicating its ability to respond in a

proportional manner to a range of echo signals, produced by specified reflectors, variable in time,
usually a series of multiple back reflections.
multiples - Successive echoes of ultrasonic energy between two surfaces.
pulse echo method - Inspection method in which the presence and position of a reflector are
indicated by the echo amplitude and time.
rf (radio frequency presentation) - Signal display that is not rectified.
range (see sweep) - Maximum ultrasonic path length that can be displayed.
reference block - Block used to establish a measurement scale, and a means of producing a
reflection of known characteristics.
reject (suppression) - Control for minimizing or eliminating low amplitude signals (electrical or
material noise), so that larger signals are emphasized.
resolution - Ability of ultrasonic equipment to give simultaneous, separate indications from

discontinuities having nearly the same range and lateral position with respect to the beam axis.
shear wave - Wave motion in which the particle motion is perpendicular to the direction of
propagation.
through transmission - Test procedure in which the ultrasonic vibrations are emitted by one
search unit and received by another at the opposite surface of the material examined.
transducer - Electro-acoustical device for converting electrical energy into acoustical energy and
vice versa.
ultrasonic - Pertaining to mechanical vibrations having a frequency greater than approximately
20,000 Hz.
vee path - Angle beam path in materials starting at the search-unit examination surface, through
the material to the reflecting surface, continuing to the examination surface in front of the search
unit, and reflecting back along the same path to the search unit. The path is usually shaped like
the letter V.
wedge - Device used to direct ultrasonic energy into the material at an angle.
134 - T.O. #33D7-22-32-1

Sonic® 1200M Maintenance and Service
9 Sonic® 1200M Maintenance and Service

What's in this section?
9.1 Introduction
9.2 Periodic Preventative Maintenance
9.3 Corrective Maintenance
9.4 Illustrated Parts Breakdown
9.1 Introduction
The Sonic®1200M maintenance is separated into two categories: periodic preventive
maintenance and corrective maintenance. With proper preventive maintenance, your instrument
will provide maximum operating performance with optimum reliability. Peak operating
condition is maintained through a schedule of preventive maintenance routines performed at
regularly spaced time intervals.
The corrective maintenance procedures are then used to correct malfunctions and return the
instrument to operational readiness with downtime held to a minimum period. A prerequisite to
performing either type of maintenance is for the maintenance technician to be thoroughly
familiar with the basic operating principles, as described in Sections 4, Control Descriptions and
Section 5, Applications.
9.2 Periodic Preventative Maintenance

Preventive maintenance is based upon regularly scheduled inspections performed to detect and
correct conditions that lead to malfunctioning of the equipment. The inspections are both visual
and electrical.
The electrical consists of an operational check that exercises all controls to obtain the required
display.
A schedule should be set up for periodic performance of the inspection listed below. If a unit has
been out of service for any extended period, perform the visual inspection and the electrical tests
given in this section.
9.2.1 Visual Inspection

• Examine cable connectors for cracked or broken insulation and bent or corroded
connector pins.
• Examine seating of all mating connectors.
• Inspect transducers for damage.
• Inspect instrument base unit and display for damage.
135 - T.O. #33D7-22-32-1

9.2.2 Cleaning the Sonic 1200M Instrument
• Outer Case:Use soft lint-free cloth to remove dust. Use a mild detergent to remove
any surface dirt.
• Front Panel:Use mild detergent to remove any surface dirt.
• Cables:Use dry cloth to remove dust, mild detergent to remove any surface dirt
from cables, and isopropyl alcohol to clean electrical connectors, and probes.
• Carrying Case:Use clean cloth for removal of dust, mild detergent for removal of
dirt.
Note: DO NOT use any solvents that will affect the paint or plastic knobs and
bezels on the outer case and panels. Acetone and Methyl Ethyl Ketone are
particularly bad for the plastic parts.
9.3 Corrective Maintenance

Corrective maintenance is performed to correct malfunctions in the operation of the instrument.
A trouble-shooting table is provided in this section as a guide for step-by-step actions to localize
a fault and then the recommended corrective action.
136 - T.O. #33D7-22-32-1

9.3.1 Troubleshooting Guide
Note: There are no operator replaceable components or adjustments inside the

modules. Fusing is provided by PTC (Positive Temperature Coefficient)
devices in the batteries which are self resetting and fuse protection inside the
AC powered battery charger / eliminator.
Note: Cable faults and transducer faults can produce the same problems.
Substitution is the best way to determine which is defective. Cable faults are
sometimes indicated by noise on the display when the cable is flexed. Cables
can be repaired if the problem is in the connector.
Note: The software is reset by turning the instrument off, then while pressing the
ERASE button, turn the instrument ON. This resets the instrument to its
factory default values. It does not erase the contents of stored programs or
traces. This can be used to clear the instrument of unwanted and in some
cases unknown settings and insures a clean start.
The operating set up can also be cleared by a choice in the Program menu. The Program menu
also contains a sequence to clear stored programs. The operating program can also be cleared
through commands via the RS-232 link and second order programming available in PowerLink
probes. Second order programming in PowerLink probes program the instrument with test set
ups that are recalled when that particular probe is used. Contact Olympus NDT about
137 - T.O. #33D7-22-32-1

programming probes.
9.4 Illustrated Parts Breakdown
Figure 1: Keyboard Housing External
138 - T.O. #33D7-22-32-1

Figure 2: Keyboard Housing Internal
139 - T.O. #33D7-22-32-1

Figure 3: Label Placement
140 - T.O. #33D7-22-32-1

Figure 4: Base Unit Exploded View
141 - T.O. #33D7-22-32-1

Figure 5: Battery Housing Exterior and Figure 6: Battery Door
142 - T.O. #33D7-22-32-1

Figure 7: Battery Housing Exploded View
143 - T.O. #33D7-22-32-1

Figure 8: Battery Housing Interior
144 - T.O. #33D7-22-32-1

Figure 9: Hand Strap Assembly
145 - T.O. #33D7-22-32-1

146 - T.O. #33D7-22-32-1
147 - T.O. #33D7-22-32-1

148 - T.O. #33D7-22-32-1
Figure 10: Display Window
149 - T.O. #33D7-22-32-1

Figure 11: LCD Display, Exploded
150 - T.O. #33D7-22-32-1

Figure 12: Display, Front
151 - T.O. #33D7-22-32-1

Figure 13: Display, Internal Assembly
152 - T.O. #33D7-22-32-1

Figure 14: Display, Back Shell
153 - T.O. #33D7-22-32-1

154 - T.O. #33D7-22-32-1
Notes:
155 - T.O. #33D7-22-32-1

156 - T.O. #33D7-22-32-1
T.O. #33D7-22-32-1
T.O. #33D7-22-32-1

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USER’S MANUAL

Sonic® 1200M Ultrasonic Flaw Detector

Copyright ¤ 2006 by Olympus NDT, Inc. All rights reserved.

Printed in the United States of America.

Warning: Any changes or modifications to this instrument or use of unauthorized

Hazardous Area Operations

Warning: Any changes or modification to this instrument or use of unauthorized

1 Preparation for Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

4.15 Gate 2 Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

6 Internal Datalogger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

7 Computer Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

7.3 Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

9 Sonic® 1200M Maintenance and Service . . . . . . . . . . . . . . . . . . . . . . . . . 135

1 Preparation for Operation

1.1 Unpacking the Sonic 1200M

1.2 Sonic® 1200M Optional Accessories

Transducers and Probes Primary sensor for flaw detection, thick-

Hands-Free Chest Harness Supports the instrument while climbing

Protective Soft Cover Protection of instrument while in use

Hard Shell Travel Case Protection of instrument while not in use

Portable Printer (includes RS-232 cable) Printouts and Reports

Parallel to Serial converter For use with parallel printers

Printer Battery Power for portable printer

Computer Software Provides method of up/down load of

Dual Li-Ion Charger Charges the batteries outside of the

Replacement Li-Ion batteries Primary power source

Color LCD Display Required for external VGA output,

Optional outputs include:

Note: Hands-free Chest Harness/Battery Belt - This accessory is designed to hold

1.3 Initial Inspection Checklist

1.4 Power Requirements

Figure 1-1: Battery Cover Location

For Optimum Performance:

TO AVOID DAMAGE TO THE BATTERY:

• Only use the charger recommended by the device manufacturer.

1.5 Li-Ion Battery Characteristics

1.6 Charging the Li-Ion Battery Pack

1.6.1 UBC Specifications

Power Requirements: 90-264 VAC line power at 47 to 63 Hz.

The UBC contains an internal fuse.

1.6.2 Charger Status Indicators

The charger status is indicated by a red/green LED lamp

UBC Charger (P/N #9522153)

Charge Error Blinking red

Charging Complete Green

1.6.3 Charger Operation Instructions

Connect the UBC to a source of AC power

Connect the cable to the instrument and charger.

During use, the UBC case will become warm.

1.6.5 Battery Characteristics

1.6.6 UBC Spare Parts

Universal Battery Charger (UBC) 9522153

DIN connector cable for single battery instruments 9122229.31

AC power cable (US three prong to IEC320) 0205959

AC power cable (UK 13 amp to IEC320) 0222159

Lithium Ion Battery 0119451

1.7 Operating Environment

1.8 D-Cell Battery Pack

1.8.1 D-cell Battery Pack Specifications