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Summary of Contents for DAKOTA ULTRASONICS Z-304-0001
- Page 1 OPERATION MANUAL DAKOTA ULTRASONICS Data Logging Ultrasonic Thickness Gauge P/N P-304-0002 Rev 1.10, March 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 ….......................... 3 2.4 DATA K …... - Page 4 7.1 G ..........................28 7.2 H ......................29 PEED 7.3 A ..........................30 LARM 7.4 D ........................31 IFFERENTIAL 7.5 U ..........................32 NITS 7.6 L ........................... 33 7.7 B ..........................34 7.8 Z ..........................35 7.9 V (VX) ........................36 ELOCITY 7.10 P ......................
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Page 5: Chapter One Introduction
CHAPTER ONE INTRODUCTION The Dakota Ultrasonics model ZX-5 DL 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 DL 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: Cal Key
ZX-5 DL Ultrasonic Thickness Gauge 2.3 CAL Key The CAL key is used to enter and exit the ZX-5 DL's calibration mode. This mode is used to adjust the sound velocity value that the ZX-5 DL will use when calculating thickness. - Page 8 Dakota Ultrasonics Menu Feature Items: Gain Scan Alarm Diff Unit Lite Beep Zero Probe VLOW English Manual .18 5 Metric Auto .25 5 Options Options Options .25 7 HIGH Set Lo .5 0 3 Nominal Set Hi .50 5 High Here’s a quick overview of navigating through the various features in MENU:...
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Page 9: The Display
ZX-5 DL Ultrasonic Thickness Gauge 2.9 The Display The ZX-5 DL 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 DL is currently calibrated too. This area is also used for alpha messages in the menu and edit modes. - Page 11 ZX-5 DL Ultrasonic Thickness Gauge The transducer must be used correctly in order for the ZX-5 DL to produce accurate, reliable measurements. Below is a short description of the transducer, followed by instructions for its use. This is a bottom view of a typical transducer. The two semicircles of the wear face are visible, as is the barrier separating them.
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Page 12: Top End Cap
Dakota Ultrasonics If the Stability Indicator has fewer than five bars darkened, or the numbers on the display seem erratic, first check to make sure that there is an adequate film of couplant beneath the transducer, and that the transducer is seated flat against the material. - Page 13 ZX-5 DL 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 DL to a standard USB type A port on a PC. The cable supplied with the ZX-5 DL 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 DL 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 DL 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 DL Ultrasonic Thickness Gauge 3) Press the key to perform the manual zero. “PRB0” will briefly be displayed on the screen, indicating the zero calculation is being performed. 5.2 Material Calibration In order for the ZX-5 DL to make accurate measurements, it must be set to the correct sound velocity of the material being measured. - Page 22 Dakota Ultrasonics 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. 3) Press the key to set the velocity value and return to the measurement screen.
- Page 23 ZX-5 DL Ultrasonic Thickness Gauge 2) 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 reading is stable and the repeatability indicator in the top left corner of the display is fully lit and stable.
- 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 DL 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 DL would offer a reasonable approximation of the thickness.
- Page 27 ZX-5 DL 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 DL includes a function to convert the unit into a dedicated velocity gauge. With this feature enabled, the ZX-5 DL 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 DL 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 DL a ‘known thickness’ on the material or part will be used. -
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 DL 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 DL 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 DL Ultrasonic Thickness Gauge 2) Use the keys to scroll through the items/features until the GAIN feature is being displayed. 3) Press the key to edit the gain setting. The edit icon will be illuminated and flashing. 4) Use the keys to scroll to the five gain options (VLOW, LOW, MED, HIGH, VHI). -
Page 34: Alarm
Dakota Ultrasonics 3) Press the key to edit the scan setting. The edit icon will be illuminated and flashing. 4) Use the keys to toggle scan on/off. Note: Pressing the key prior to pressing the key will abort to the measurement screen without saving changes. -
Page 35: Differential
ZX-5 DL Ultrasonic Thickness Gauge 4) Use the keys to toggle alarm on/off/beep. 5) When the desired ALRM status is displayed, press the key to set the status and edit the LO limit option. 6) Use the keys to scroll the LO limit value to the target value. Note: Pressing the key prior to pressing the key will abort to the... -
Page 36: Units
Dakota Ultrasonics 1) Press the key to access the menu items/features. 2) Use the keys to scroll through the items/features until the DIFF feature is being displayed. 3) Press the key to edit the differential status. The edit icon will be illuminated and flashing. -
Page 37: Lite
ZX-5 DL Ultrasonic Thickness Gauge 1) Press the key to access the menu items/features. 2) Use the keys to scroll through the items/features until the UNIT feature is being displayed. 3) Press the key to edit the units setting. The edit icon will be illuminated and flashing. -
Page 38: Beep
Dakota Ultrasonics 3) Press the key to edit the light setting. The edit icon will be illuminated and flashing. 4) Use the keys to toggle status on/off/auto. Note: Pressing the key prior to pressing the key will abort to the measurement screen without saving changes. -
Page 39: Zero
ZX-5 DL Ultrasonic Thickness Gauge 2) Use the keys to scroll through the items/features until the BEEPER feature is being displayed. 3) Press the key to edit the beeper setting. The edit icon will be illuminated and flashing. 4) Use the keys to toggle the beeper on/off. -
Page 40: Velocity (Vx)
Dakota Ultrasonics 3) Press the key to edit the zero setting. The edit icon will be illuminated and flashing. 4) Use the keys to select the auto/man option. Note: Pressing the key prior to pressing the key will abort to the measurement screen without saving changes. -
Page 41: Probe Diameter
ZX-5 DL Ultrasonic Thickness Gauge 2) Use the keys to scroll through the items/features until the VX feature is being displayed. 3) Press the key to edit the setting. The edit icon will be illuminated and flashing. 4) Use the keys to select the on/off option. -
Page 42: Lock
Dakota Ultrasonics 3) Press the key to edit the diameter setting. The edit icon will be illuminated and flashing. 4) Use the keys to select the diameter option. Note: Pressing the key prior to pressing the key will abort to the measurement screen without saving changes. -
Page 43: Factory Defaults
ZX-5 DL Ultrasonic Thickness Gauge 7.12 Factory Defaults The ZX-5 DL can be reset to factory defaults at any time to restore the original gauge settings. This should only be used if the gauge is not functioning properly, or perhaps multiple features have been enabled and a clean start is needed. The procedure to reset the gauge is outlined below: Factory Reset 1) With the ZX-5 DL powered off, press and hold down the... - Page 44 Dakota Ultrasonics...
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Page 45: Chapter Eight Data Storage
CHAPTER EIGHT DATA STORAGE 8.1 Introduction The ZX-5 DL is equipped with a basic and convenient sequential style data logger that’s intuitive to operate. By ‘sequential’ meaning a single column of 250 measurements and a total of 40 individual files, for a total storage capacity of 10,000 measurements. -
Page 46: Storing A Measurement
Dakota Ultrasonics 4) When the desired FILE is displayed, press the key to open the file and return to the measurement screen. Note: The FILE and LOC (location) will be displayed in lower left portion of the measurement screen. 8.3 Storing a Measurement Now that a file has been selected and opened, the ZX-5 DL is ready to store measurements. -
Page 47: Clearing A File
ZX-5 DL Ultrasonic Thickness Gauge (memory) in the top right corner of the display. If the key is pressed to store another measurement at that location, FULL will briefly be displayed on the screen indicating a measurement has already been stored at that location. -
Page 48: Clear All Files
Dakota Ultrasonics 6) Press the key to display the confirmation screen. CLR? will be displayed, as well as a flashing Yes/No option. 7) Press the key for YES, and the key for NO. The edit icon will be illuminated and flashing. - Page 49 ZX-5 DL Ultrasonic Thickness Gauge 3) Press the key to display the confirmation screen. CLR ALL is displayed, as well as a flashing Yes/No option. 4) Press the key for YES, and the key for NO. The edit icon will be illuminated and flashing. Note: Pressing the key prior to pressing the key will abort to the...
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Page 50: Chapter Nine Data Transfer & Power Options
CHAPTER NINE DATA TRANSFER & POWER OPTIONS 9.1 Connectivity The ZX-5 DL is connected to a PC with a USB-C to USB Type A cable, supplied with the kit (part# N-003-0330). The gauge has a file system and the PC will recognize it as an external hard disk, or thumb drive. -
Page 51: Line Power
ZX-5 DL Ultrasonic Thickness Gauge Now that the files have been located and are accessible, they can either be opened from the ZX-5 DL’s memory, or copied to another location/folder on your PC. To accomplish this, simply ‘drag and drop’ files in a new folder on your PC, or on your desktop. -
Page 52: 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 53 ZX-5 DL Ultrasonic Thickness Gauge 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 54: 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 55 ZX-5 DL Ultrasonic Thickness Gauge 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.
- Page 56 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.