MD121

WIRE ROPE DEFECTOGRAPH

Instrument Set for Non-destructive
Magnetic Testing of Wire Ropes

Wire Rope Inspection Equipment

 The operation of our NDT instruments is based on
permanent magnet method, which was developed
in Poland and is used throughout the world.
Standard range of sensing test heads can be used
for ropes ranging from 8 to 105 mm diameter.
Custom designed heads are also available. For
smaller ropes our MD-20/25 hand-held head-tester
can be used.
The GP-series test/measuring heads are sources
of signals at magnetic inspection of the steel wire
ropes of various sizes. Recorded head signals
indicate LD/LF rope defects of stepwise changes of
the cross-section nature (wire breaks, pitting
corrosion, etc.) and also LMA distributed rope steel
cross-section reduction (corrosion, wear).
Analysis of the head generated signals makes possible determining the rope cross-section reduction rate as
well as the length and depth of the defected section of the rope.
The MD121 recording system includes a specially designed MD121 Wire Rope Defectograph, a portable
data recorder with chart recorder. This is new instrument based on embedded industrial computer system
which allows real time watching signal traces on 7” display, printing traces on strip chart simultaneously
and viewing recorded data after rope test, with many features as zooming traces, searching for pulses
crossing set limit, etc. Recorded data can be transferred to PC with USB pen drive memory and can be
viewed and analysed with PC version of MD121’ software . This unique instrument has been designed as a
helpful and comfortable tool, to meet the special needs of rope experts in heavy industrial environments.
transparent window IP65 version

MD121 Wire Rope Defectograph | Signal Recorder and IP67 version

Specifications
MD121 /GP System meets requirements of European standard EN 12927-8 and other standards
Number of direct sensor channels: 3 total, two LF/LD and one LMA
Number of additional channels: 1, INTEGRAL created on base of main LF/LD signal
Defect positioning on rope length: strip chart feed and/or screen view is synchronised with rope/test head feed
at 1, 2, 5, 10 div/m of rope or constant feed 1, 2, 5, 10 div/s, when recorded;
length measurement indications shown on screen and printed on strip chart
margin
"Zoom replay" ratio: 20 div/m of rope or div/s in immediate zoom mode, after interruption of
recording and next any zooming ratios are available in both axis, in file view
mode (zooming-in is signal resolution limited only);
Zoom-Out is not limited by user settings set during recording (whole signal
is stored, no signal over-range)
Strip chart paper: thermal sensitive 110 mm wide, length 20 to 30 m (roll)
Longitudinal data (sampling) resolution 1 or 2.5 mm at synchro mode or up to 5000 samples/s at time base mode
Data Memory Capacity up to 10 km long non-interrupted rope test (one file) and up to 400 km long
rope tests total at synchro mode
Rope speed range at compensation of speed influence to inductive sensor signals: 0.02 to 10 m/s
Operating conditions except printing: Temperature -20° to + 50° C, Relative humidity up to 95%
Operating conditions with chart printing: Temperature 0° to + 40° C, Relative humidity up 25 to 85%
Power: 100-240V ac; internal rechargeable Li Ion battery for 14.5 hours operation
without printing or 10 hours operation with printing strip chart (at 20° C)
Dimensions and Gross Weight with standard equipment: 41*33*17 cm 8 kg
Wet and dust protection, except printing: IP65 for transparent window version or IP67 if housing without window
Strip chart recording method
Thermal array line printing head, printing on thermal paper
resolution 8 dots/mm
channel format - overall width 103 mm

o two LF/LD Coil channels ± 18 mm each

o LMA Hall channel ± 9 mm
o Main LF/LD Integral channel 9 mm
• grid every 1 mm and 10 mm in separate channels
File browsing mode screen view
 Wire Rope Inspection
Equipment

GP-1h.105 Test Head

GP-1h. 90 Test Head
GP-2Sh.64 Test Head

GP-1h.90
The GP-1/2-series test/measuring heads are sources of measurement signals at magnetic
inspection of the steel wire ropes of various sizes. Head guides can be adjusted to requested
diameter within head range without additional equipment. Included reducing insert is provided to
increase sensitivity within lower sub-range, below specified diameter. Recorded head signals
indicate rope defects of stepwise changes of the cross-section nature (wire breaks, pitting
corrosion, etc.) and also distributed rope steel cross-section reduction (corrosion, wear). The
analysis of the head generated signals makes possible determining the rope cross-section
reduction rate as well as the length and depth of the defected section of the rope.

Specifications
The test heads meet requirements of European standard EN 12927-8
Sensor channels: 3 total, two LF/LD and one LMA
Rope length/speed transducer: included, RIZ type roller (2*100 pulses/m)
GP-1h.105 GP-1h.90 GP-2Sh.64
Size range of wire ropes
diameter 38 - 108 mm 30 - 90 mm 20 – 64 mm
with reducing insert 38 - 70 mm 30 - 50 mm 20 – 40 mm
without reducing insert 70 - 108 mm 50 - 90 mm 40 – 64 mm
cross sectional area of steel, up to: 6800 mm2 4700 mm2 2700 mm2

Diameter of the head hole without reducing

insert (absolute max. diameter of rope): 118 mm 98 mm 75 mm
Overall dimensions (including roller): 27*28* 82 cm 25*24* 82 cm 21* 24* 79 cm
Weight of the head: 64 kg 60 kg 45 kg
Overall dimensions of container box: two 19*36*81cm 31.5*32.5*81cm 31.5*25.5*79 cm
Gross Weight, together with the container: 76 kg 70 kg 54 kg
 Wire Rope Inspection
Equipment

GP-3Arh.35 Test Head

The GP-3Arh.35 test/measuring head is a source of measurement signals at magnetic inspection
of the steel wire ropes of diameters from 10 up to 35 mm Head guides can be adjusted to
requested diameter within the range without any additional equipment . Recorded head signals
indicate rope defects of stepwise changes of the cross- section nature (wire breaks, pitting
corrosion, etc.) and also distributed rope steel cross-section-reduction (corrosion, wear). The
analysis of the head generated signals makes possible determining of the rope cross-section
reduction rate as well as of the length and depth of the damaged section of the rope.

Specifications
The test head meets requirements of EN 12927-8
Size range of wire ropes :
10 - 35 mm diameter
2
up to 750 mm cross sectional area of steel
Sensor channels: 2 total, one LF/LD and one LMA
Overall dimensions in cm: 9 * 19 * 40 without roller / 59 including roller
Weight of the head: 15 kg (23 kg together with standard cable and container)
Diameter of the head hole: 40 mm (absolute max. diameter of rope)
Container dimensions in cm: 25 * 24 * 64.5
 MD-20 WIRE ROPE TESTER
MD-25 WIRE ROPE TESTER

An Instrument to Detect Damage in Wire Ropes

The MD 20 / MD 25 Wire Rope Tester is a simple to use instrument to test the condition of small
diameter ropes. It indicates the occurrence of rope defects that exceed the set level of
detectability.

It can also be used as a sensor head connected to the more advanced Meraster MD 120, which
determines defects more accurately, or can be connected to a general purpose recorder.

Applications
The instrument is designed to detect stepwise defects such as wire breaks and localised corrosion.

It is intended for quick tests and can be used even by non-skilled personnel. Provided with a
handle and light in weight, it can be used as a hand-held instrument during visual inspection to
ensure that no important defect is missed and that any damage inside a rope is detected. The
instrument can also be fixed in position (i.e. not hand held). Any signaling of serious defects
identified by the tester means that the rope's condition should be checked by an expert.

Operation
The instrument's operation is based on the permanent magnet magnetic, a world renowned
method developed by the Academy of Mining and Metalurgy in Cracow. During the rope's
passage through the tester defects are signalled by a beep sound, a yellow light-emitting
diode flashing and a red LED operates, remaining on until the instrument is switched off,
using the on-off switch. If there are no defects in rope that exceed the detection value set,
then the green LED is illuminated

Technical Data

z Range of rope sizes

MD-20 : 8 to 22 mm diameter
MD-25 : 10 to 25 mm diameter
suitable for detecting any typically broken wire
z Sensitivity:
Detection level, adjustable by ten-turn potentiometer
z Speed of checked rope:
Recommended 0.1 to 2.5 m/s (6 to 150 m/min); results are
independent of rope speed
z Indicators:
4 light-emitting diodes
{ LB (red) - low battery/charging
{ OK (green) - lack of rope defects
{ D (yellow) - defect (flashing at defect location)
{ DM (red) - faulty rope (continuous light)
z Sound beeper
z Supply:
Ni-Cd or NiMH 8.4-9V/100-160 mAh rechargeable battery
(included)
or 9V type 6F22 primary battery
Rechargeable battery can be charged inside the instrument by
internal circuits and external transformer/charger
(230 V a.c. to 12-19 V d.c. version included)
z Operating temperature:
standard MD 20/25 : -10 to +40°C
MD 20L : –25 to +40°C
z Output socket:
stereo jack coupling
1. Damage detection signal
2. Inductive transducer signal
z Length: 205 mm
z Width: 46 mm
z Height with rollers (hand operated, full diameter range): 280 mm
z Height with sliding guides for up to 18 mm diameter (mounted tester): 243 mm
z Height without rollers and sliding guides (frictionless rope passage through the mounted tester): 163 mm
z Weight: MD-20 4,5 kg / MD-25 4,9 kg