Related Manuals for DAKOTA ULTRASONICS Z-303-0001
Summary of Contents for DAKOTA ULTRASONICS Z-303-0001
- Page 1 OPERATION MANUAL DAKOTA ULTRASONICS Ultrasonic Thickness Gauge P/N P-303-0002 Rev 1.10, September 2019...
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Page 3: Table Of Contents
CONTENTS CHAPTER ONE INTRODUCTION ..............1 1.1 D ......................... 1 ISCLAIMER CHAPTER TWO KEYPAD, MENU, DISPLAY & CONNECTORS ..... 2 2.1 ON/OFF/ENTER K … ..................... 2 2.2 PRB 0 K … ........................2 2.3 CAL K ….......................... 2 2.4 GAIN K …. - Page 4 7.1 G ..........................28 7.2 H ......................29 PEED 7.3 A ..........................29 LARM 7.4 D ........................31 IFFERENTIAL 7.5 B ..........................32 7.6 U ..........................33 NITS 7.7 L ........................... 33 7.8 Z ..........................35 7.9 V (VX) ........................35 ELOCITY 7.10 P ......................
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Page 5: Chapter One Introduction
CHAPTER ONE INTRODUCTION The Dakota Ultrasonics model ZX-5 is a basic dual element thickness gauge with the ability to locate blind surface pitting and internal defects/flaws in materials. Based on the same operating principles as SONAR, the ZX-5 is capable of measuring the thickness of various materials with accuracy as high as ... -
Page 6: Chapter Two Keypad, Menu, Display & Connectors
CHAPTER TWO KEYPAD, MENU, DISPLAY & CONNECTORS The Keypad 2.1 ON/OFF/ENTER Key The ON/OFF/ENTER key powers the unit ON or OFF. Since the same key is also used as an ENTER key, the gauge is powered off by pressing and holding down the key until the unit powers off. -
Page 7: Gain Key
ZX-5 Ultrasonic Thickness Gauge The CAL key is used to enter and exit the ZX-5's calibration mode. This mode is used to adjust the sound velocity value that the ZX-5 will use when calculating thickness. The tool will either calculate the sound-velocity from a sample of the material being measured, or allow a known velocity value to be entered directly. - Page 8 Dakota Ultrasonics Menu Feature Items: Alarm Diff Unit Lite Beep Zero Probe English Manual .187 Metric Auto .250 Options Options Options .500 Set Lo Nominal Set Hi High Here’s a quick overview of navigating through the various features in MENU:...
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Page 9: The Display
ZX-5 Ultrasonic Thickness Gauge 2.9 The Display The ZX-5 uses a custom glass LCD backlit low temperature display for use in a variety of climate conditions. It contains graphic icons, as well as both 7 and 14 segment display areas. Let’s take a closer look and what all these things are telling Note: This display is used for multiple gauge models in the ZX &... -
Page 10: The Transducer
Dakota Ultrasonics G. Small 7 Segment: The material velocity, speed the sound wave travels through a given medium/material, is displayed in this area, informing the user what material the ZX-5 is currently calibrated too. This area is also used for alpha messages in the menu and edit modes. - Page 11 ZX-5 Ultrasonic Thickness Gauge This is a bottom view of a typical transducer. The two semicircles of the wear face are visible, as is the barrier separating them. One of the semicircles is responsible for conducting ultrasonic sound into the material being measured, and the other semicircle is responsible for conducting the echoed sound back into the transducer.
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Page 12: Top End Cap
Dakota Ultrasonics (size or frequency) for the material being measured. See page 13 for information on transducer selection. While the transducer is in contact with the material that is being measured, the ZX-5 will perform four measurements every second, updating its display as it does so. - Page 13 ZX-5 Ultrasonic Thickness Gauge USB-C Connector Refer to Diagram: The USB-C connector, located on the bottom end cap, is a mini type C female connector. It is designed to connect directly from the ZX-5 to a standard USB type A port on a PC. The cable supplied with the ZX-5 is a USB type C to a USB type A (pt# N-003-0330).
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Page 14: Chapter Three Principals Of Ultrasonic Measurement
CHAPTER THREE PRINCIPALS OF ULTRASONIC MEASUREMENT 3.1 Time versus thickness relationship Ultrasonic thickness measurements depend on measuring the length of time it takes for sound to travel through the material being tested. The ratio of the thickness versus the time is known as the sound velocity. In order to make accurate measurements, a sound velocity must be determined and entered into the instrument. -
Page 15: Temperature
ZX-5 Ultrasonic Thickness Gauge 3.5 Temperature Temperature has an effect on sound velocity. The higher the temperature, the slower sound travels in a material. High temperatures can also damage transducers and present a problem for various liquid couplants. Since the sound velocity varies with temperature it is important to calibrate at the same temperature as the material being measured. - Page 16 Dakota Ultrasonics two elements and their delay lines are packaged in a single housing but acoustically isolated from each other with an insulated sound barrier. This allows the transducer the ability to achieve very high sensitivity for detecting small defects. Also, the surface of the test material does not have to be as flat in order to obtain good measurements.
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Page 17: Chapter Four Selecting The Measurement Mode
CHAPTER FOUR SELECTING THE MEASUREMENT MODE 4.1 Which mode & transducer do I use for my application? High penetration plastics and castings The most common mode for these types of applications is pulse-echo. Cast iron applications require 1 - 5MHz frequencies, and cast aluminum requires a 7 - 10MHz frequency depending on the thickness. - Page 18 Dakota Ultrasonics Noisy Material Materials such as titanium, stainless steel, and aluminum may have inherent surface noise issues or mirroring effect. Higher frequency transducers 7 – 10MHz offer improved resolution to avoid erroneous measurements. Restricted access Measuring materials with extreme curvatures or restricted access are best suited for...
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Page 19: Chapter Five Making Measurements
CHAPTER FIVE MAKING MEASUREMENTS The steps involved in making measurements are detailed in this section. The following sections outline how to setup and prepare your ZX-5 for field use. An automatic or manual zero must always be performed. The auto zero is an ‘off block’... - Page 20 Dakota Ultrasonics 2) On Block Zero (Manual Probe Zero) – When this feature is enabled the transducer must be placed on the probe zero disk (battery cover) located on the top of the unit. Both zero procedures are outlined as follows:...
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Page 21: Material Calibration
ZX-5 Ultrasonic Thickness Gauge 2) Be sure all six repeatability/stability bars in the top left corner of the display are fully illuminated and stable, and last digit of the measurement is toggling only +/- .001” (.01mm). 3) Press the key to perform the manual zero. “PRB0” will briefly be displayed on the screen, indicating the zero calculation is being performed. - Page 22 Dakota Ultrasonics 2) Use the keys to scroll the velocity to the known target value. Note: The longer the keys are pressed and held, the faster the value will increment/decrement. Note: Pressing the key prior to pressing the key will abort the cal routine without saving any changes.
- Page 23 ZX-5 Ultrasonic Thickness Gauge Note: A sample or location on the test piece should be used as close to the maximum thickness of the test range to minimize error. 2) Apply a drop of couplant on the transducer and place the transducer in steady contact with the sample or actual test material.
- Page 24 Dakota Ultrasonics Two Known Thicknesses The two point calibration should be considered when an application requires improved accuracy over a small measurement range based on tolerance requirements. This calibration option calculates both the ‘probe zero’ and ‘velocity value. If the two point option is used, a probe zero is not required. For example, if the measurement range was .080”...
- Page 25 ZX-5 Ultrasonic Thickness Gauge 3) Press the key to enter the calibration edit screen displaying the current measurement value. 4) Use the keys to scroll to the known thickness value. Note: The longer the keys are pressed and held, the faster the value will increment/decrement.
- Page 26 Dakota Ultrasonics thickness values with minimal error. If the thicknesses are not correct, repeat the steps above. Basic Material Type If the material velocity is unknown, a sample thickness cannot be taken directly from the material, but the general type of material is known, selecting a basic material type from the common material (MATL) list in the ZX-5 would offer a reasonable approximation of the thickness.
- Page 27 ZX-5 Ultrasonic Thickness Gauge in/µs ALUMINUM 0.250 6350 (2024) 0.233 5918 STEEL (4340) 0.223 5664 STAINLESS (303) 0.180 4572 CAST IRON 0.106 2692 PLEXIGLASS 0.094 2388 0.092 2337 POLYSTYRENE 0.070 1778 POLYURETHANE USER PROGRAMMABLE 3) When the desired MATL setting is displayed, press the key to set the material velocity and return to the measurement screen.
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Page 28: Chapter Six Velocity Gauge
CHAPTER SIX VELOCITY GAUGE 6.1 Velocity Gauge (VX) The ZX-5 includes a function to convert the unit into a dedicated velocity gauge. With this feature enabled, the ZX-5 will display all measurements in terms of velocity, inches per microsecond (IN /s) or meters per second (M /s), rather than dimensional inches or millimeters. -
Page 29: Calibration To A Known Thickness
ZX-5 Ultrasonic Thickness Gauge 5) When the desired VX setting is displayed, press the key to set the status and return to the measurement screen. 6.2 Calibration to a known thickness In order to calibrate the ZX-5 a ‘known thickness’ on the material or part will be used. The same location will be used for all the other parts in the group/batch to determine the velocity. -
Page 30: Calibration To A Known Velocity
Dakota Ultrasonics 5) Use the keys to scroll to the known thickness value. Note: The longer the keys are pressed and held, the faster the value will increment/decrement. Note: Pressing the key prior to pressing the key will abort the cal routine without saving any changes. - Page 31 ZX-5 Ultrasonic Thickness Gauge 1) Apply a drop of couplant on the transducer and place the transducer in steady contact with the sample or actual test material. Be sure that the velocity measurement is stable and the repeatability indicator, in the top left corner of the display, is fully lit and stable.
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Page 32: Chapter Seven Additional Features
CHAPTER SEVEN ADDITIONAL FEATURES 7.1 Gain The gain, or amplification of the return echoes, can be adjusted in the ZX-5 to accommodate a variety of materials and applications. The setting of the gain is crucial in order to obtain valid readings during the measurement process. Too much gain may result in erroneous measurements, detecting on noise rather than the actual material back wall surface. -
Page 33: High Speed Scan
ZX-5 Ultrasonic Thickness Gauge 1) Press the key to edit the gain setting. The edit icon will be illuminated and flashing. 2) Use the keys to scroll through the gain settings (VLOW, LOW, MED, HIGH, VHI) until the desire setting is being displayed. 3) Press the key to set the gain and return to the measurement screen. - Page 34 Dakota Ultrasonics applications to verify the material thickness is within the manufacturer specifications. The settings available are ON/OFF/BEEP, where beep enables the audible beeper. Both the on and beep settings will illuminate the led alarm lights above the keys on the keypad.
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Page 35: Differential
ZX-5 Ultrasonic Thickness Gauge Note: Pressing the key prior to pressing the key will abort to the measurement screen without saving changes to the HI limit value. 9) When the target HI limit is displayed, press the key to set the value and return to the measurement screen. -
Page 36: Beep
Dakota Ultrasonics 6) Use the keys to scroll the NOMINAL value to the target value. Note: Pressing the key prior to pressing the key will abort to the measurement screen without saving changes to the NOMINAL value. 7) When the target value is displayed, press the key to set the value and return to the measurement screen. -
Page 37: Units
ZX-5 Ultrasonic Thickness Gauge 5) When the desired BEEP setting is displayed, press the key to set the status and return to the measurement screen. 7.6 Units The ZX-5 will operate in both English (inches) or Metric (millimeters) units. The procedure to select the units is outlined as below: Units 1) Press the key to access the menu items/features. - Page 38 Dakota Ultrasonics only lights the display when the gauge is coupled to the material and receiving a measurement. The steps below outline how to toggle the options: Backlight 1) Press the key to access the menu items/features. 2) Use the keys to scroll through the items/features until the LITE feature is being displayed.
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Page 39: Zero
ZX-5 Ultrasonic Thickness Gauge 7.8 Zero There are two transducer zeroing options available in the ZX-5; auto and manual. The AUTO zero can be performed automatically without using a reference standard to zero the gauge (off block), while the MANUAL option requires a reference standard like the battery disk at the top of the gauge (on block). -
Page 40: Probe Diameter
Dakota Ultrasonics feature is generally used for basic “nodularity” testing, as velocity is a key part of density for determining hardness. An example might be casting manufacturers where the density/hardness will determine the strength of the material. When this feature is enabled, the ZX-5 is operating in reverse to the standard option of the gauge. -
Page 41: Lock
ZX-5 Ultrasonic Thickness Gauge The PROB feature was added to improve linearity when using a specific probe diameter. The default standard setting is (.250”), and works reasonably well using a general correction curve for all of our dual element transducers in our range. However, selecting the exact diameter of the transducer being used will offer additional linearity (accuracy). -
Page 42: Factory Defaults
Dakota Ultrasonics altered, as well as any of the individual features in the gauge. The only keys that are always unlocked are the power and probe zero keys, as these must remain unlocked for measurement functionality. The procedure to enable/disable the lock feature is outlined below:... - Page 43 ZX-5 Ultrasonic Thickness Gauge Note: Once the measurement screen is displayed the can be released. 2) Press the keys to scroll through the factory setting options. 3) Make a note of the “MEDI” & “ZERO” settings prior to performing a reset. These values will need to be entered back in the gauge following the reset.
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Page 44: Chapter Eight Connectivity & Power
CHAPTER EIGHT CONNECTIVITY & POWER 8.1 Connectivity The ZX-5 is equipped with a USB-C connector and offers serial over USB using a CDC (Communications Data Class) and software wedge to transfer data into common text editors and spreadsheet software programs as needed. The ZX-5 does not have any internal memory to store data, but is used to connect to external storage devices such as SPC data collectors and PC based software programs. - Page 45 ZX-5 Ultrasonic Thickness Gauge Right click on the CDC device as illustrated above, and select “update driver”. The following window will appear: Select “browse my computer” and navigate to the directory where the driver was saved on your PC and install the driver. When the installation is completed, the following window will be displayed:...
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Page 46: Line Power
Dakota Ultrasonics Open device manager again to reference the communications port assigned to the CDC device, it will be displayed to the right of the CDC device. Now that the driver has been successfully installed, a ‘keyboard wedge’ with serial communications... -
Page 47: Appendix A- Velocity Table
APPENDIX A- VELOCITY TABLE Material sound velocity sound velocity in/us Aluminum 0.2510 6375 Beryllium 0.5080 12903 Brass 0.1730 4394 Bronze 0.1390 3531 Cadmium 0.1090 2769 Columbium 0.1940 4928 Copper 0.1830 4648 Glass (plate) 0.2270 5766 Glycerine 0.0760 1930 Gold 0.1280 3251 Inconel 0.2290... - Page 48 Dakota Ultrasonics 0.1310 3327 Titanium 0.2400 6096 Tungsten 0.2040 5182 Uranium 0.1330 3378 Water 0.0580 1473 Zinc 0.1660 4216 Zirconium 0.1830 4648...
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Page 49: Appendix B- Application Notes
APPENDIX B- APPLICATION NOTES Measuring pipe and tubing When measuring a piece of pipe to determine the thickness of the pipe wall, orientation of the transducers is important. The transducer should be oriented so that the gap (sound barrier) in the wear face is perpendicular (at a right angle) to the length (long axis) of the tubing, allowing both sides of the transducer to make the same amount of contact. - Page 50 Dakota Ultrasonics the probe be left in contact with the surface for as short a time as needed (intermittent contact) to acquire a stable measurement. Measuring laminated materials Laminated materials are unique in that their density (and therefore sound-velocity) may vary considerably from one piece to another. Some laminated materials may even exhibit noticeable changes in sound-velocity across a single surface.
- Page 51 Additionally, Dakota Ultrasonics warrants transducers and accessories against such defects for a period of 90 days from receipt by the end user. If Dakota Ultrasonics receives notice of such defects during the warranty period, Dakota Ultrasonics will either, at its option, repair or replace products that prove to be defective.