Dakota NDT ZX-6DL Operation Manual
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Dakota NDT ZX-6DL Operation Manual

Ultrasonic multi-echo data logging thickness gauge
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OPERATION MANUAL
Dakota NDT
Z
X
6
-
D
L
Z
X
6
-
D
L
Ultrasonic Multi-Echo Data
Logging Thickness Gauge
P/N P-306-0004
Rev 1.00, January 2024

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  • Page 1 OPERATION MANUAL Dakota NDT Ultrasonic Multi-Echo Data Logging Thickness Gauge P/N P-306-0004 Rev 1.00, January 2024...

  • Page 2: 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 DATA K …...
  • Page 3 CHAPTER EIGHT ADDITIONAL FEATURES ..........31  8.1 G ..........................31  8.2 H ......................32  PEED 8.3 A ..........................33  LARM 8.4 D ........................34  IFFERENTIAL 8.5 U ..........................35  NITS 8.6 L ........................... 36  8.7 B ..........................37  8.8 Z ..........................

  • Page 4: Chapter One Introduction

    CHAPTER ONE INTRODUCTION The Dakota NDT model ZX6-DL is a basic dual element thickness gauge with through paint measurement capability, and the ability to locate blind surface pitting and internal defects/flaws in materials. Based on the same operating principles as SONAR, the ZX6-DL is capable of measuring the thickness of various materials with accuracy as high as ...

  • Page 5: 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 6: Data Key

    ZX- 6 DL Ultrasonic Multi-Mode Thickness Gauge 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. This provides increased linearity between transducers. Refer to page 19 for an explanation on the various calibration options.

  • Page 7: The Display

    Dakota NDT VLOW Aluminum English Manual .18 5 Steel Metric Auto .18 5 Stainless Options Options Options .25 5 HIGH Iron Set Lo .25 7 Nominal Plexiglass Set Hi .50 3 High .50 5 Plastic Poly Urea User 1 User 2 Here’s a quick overview of navigating through the various features in MENU:...
  • Page 8 ZX- 6 DL Ultrasonic Multi-Mode Thickness Gauge The ZX6-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 A.

  • Page 9: The Transducer

    Dakota NDT I. Small 14 Segment: Displays the current gain setting of the ZX6-DL. MED is the default, with the options of VLOW, LOW, MED, HIGH, VHI (40dB to 52db gain range with MED at 46dB). J. Units: This combination of icons are illuminated in different sequences to inform the user what measurement units are currently being displayed in the large 7 segment area.
  • Page 10 ZX- 6 DL Ultrasonic Multi-Mode 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.

  • Page 11: Top & Bottom End Caps

    Dakota NDT (size or frequency) for the material being measured. See page 14 for information on transducer selection. While the transducer is in contact with the material that is being measured, the ZX6- DL will perform four measurements every second, updating its display as it does so.
  • Page 12 ZX- 6 DL Ultrasonic Multi-Mode Thickness Gauge type C to a USB type A (pt# N-003-0330). See page 49 for information on connectivity. Note: This connector is also used to upgrade the ZX6-DL with the latest version of firmware.

  • Page 13: 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 14: Measurement Modes

    ZX- 6 DL Ultrasonic Multi-Mode Thickness Gauge 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 15 Dakota NDT surface of the test material does not have to be as flat in order to obtain good measurements. Dual element transducers are normally used in pulse-echo mode for finding defects, and in echo-echo mode for through coating measurements.
  • Page 16 ZX- 6 DL Ultrasonic Multi-Mode Thickness Gauge Dual Element Transducer in Echo to Echo mode...

  • 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 ZX- 6 DL Ultrasonic Multi-Mode Thickness Gauge Thin materials Pulse echo mode and a high frequency transducer is commonly used for these types of applications. The most common transducers are the 7.5MHz and 10MHz models with extra resolution. The higher frequencies provide greater resolution and a lower minimum thickness rating overall.

  • 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 ZX6-DL for field use. An automatic or manual zero must always be performed. The auto zero is an ‘off block’...
  • Page 20 ZX- 6 DL Ultrasonic Multi-Mode Thickness Gauge 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: Performing an Auto Probe Zero (Off Block) 1) Press the key to perform the auto zero.

  • Page 21: Material Calibration

    Dakota NDT 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 ZX- 6 DL Ultrasonic Multi-Mode Thickness Gauge 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 Dakota NDT 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 ZX- 6 DL Ultrasonic Multi-Mode Thickness Gauge 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.
  • Page 25 Dakota NDT 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 ZX- 6 DL Ultrasonic Multi-Mode Thickness Gauge 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 ZX6-DL would offer a reasonable approximation of the thickness.
  • Page 27 Dakota NDT 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 5) When the desired MATL setting is displayed, press the key to set the material velocity and return to the measurement screen.

  • Page 28: Chapter Six Through Paint Measurement - Multi Mode

    CHAPTER SIX THROUGH PAINT MEASUREMENT - MULTI MODE 6.1 Introduction Through paint measurement is accomplished by measuring the time between two repeat echoes from the back surface of the material. Since both of these back wall echoes travel the same path through the paint or coating, the thickness of the coating is subtracted out of the measurement so that only the actual material thickness is measured.
  • Page 29 Dakota NDT Note: Be sure that a probe zero and “one point calibration”, or a “two point calibration” has been performed prior to this procedure. 1) Press the key to toggle between the measurement modes; pulse-echo (P-E) and echo-echo (E-E) at any time.

  • Page 30: Chapter Seven Velocity Gauge

    CHAPTER SEVEN VELOCITY GAUGE 7.1 Velocity Gauge (VX) The ZX6-DL includes a function to convert the unit into a dedicated velocity gauge. With this feature enabled, the ZX6-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 31: Calibration To A Known Thickness

    Dakota NDT 5) When the desired VX setting is displayed, press the key to set the status and return to the measurement screen. 7.2 Calibration to a known thickness In order to calibrate the ZX6-DL a ‘known thickness’ on the material or part will be used.

  • Page 32: Calibration To A Known Velocity

    ZX- 6 DL Ultrasonic Multi-Mode Thickness Gauge 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 33 Dakota NDT 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.

  • Page 34: Chapter Eight Additional Features

    CHAPTER EIGHT ADDITIONAL FEATURES 8.1 Gain The gain, or amplification of the return echoes, can be adjusted in the ZX6-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 35: High Speed Scan

    Dakota NDT 1) Press the key to access the menu items/features. 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.

  • Page 36: Alarm

    ZX- 6 DL Ultrasonic Multi-Mode Thickness Gauge 1) Press the key to access the menu items/features. 2) Use the keys to scroll through the items/features until the SCAN feature is being displayed. 3) Press the key to edit the scan setting. The edit icon will be illuminated and flashing.

  • Page 37: Differential

    Dakota NDT 2) Use the keys to scroll through the items/features until the ALRM feature is being displayed. 3) Press the key to edit the alarm status. The edit icon will be illuminated and flashing. 4) Use the keys to toggle alarm on/off/beep.

  • Page 38: Units

    ZX- 6 DL Ultrasonic Multi-Mode Thickness Gauge The steps below outline how to enable and enter the nominal value to use this feature: Differential 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.

  • Page 39: Lite

    Dakota NDT The procedure to select the units is outlined as below: Units 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.

  • Page 40: Beep

    ZX- 6 DL Ultrasonic Multi-Mode Thickness Gauge 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. 3) Press the key to edit the light setting. The edit icon will be illuminated and flashing.

  • Page 41: Zero

    Dakota NDT Beeper 1) Press the key to access the menu items/features. 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.

  • Page 42: Velocity (Vx)

    ZX- 6 DL Ultrasonic Multi-Mode Thickness Gauge 1) Press the key to access the menu items/features. 2) Use the keys to scroll through the items/features until the ZERO feature is being displayed. 3) Press the key to edit the zero setting. The edit icon will be illuminated and flashing.

  • Page 43: Probe Diameter & Frequency

    Dakota NDT 1) Press the key to access the menu items/features. 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.

  • Page 44: Lock

    ZX- 6 DL Ultrasonic Multi-Mode Thickness Gauge 1) Press the key to access the menu items/features. 2) Use the keys to scroll through the items/features until the PROB feature is being displayed. 3) Press the key to edit the diameter/frequency setting. The edit icon will be illuminated and flashing.

  • Page 45: Factory Defaults

    Dakota NDT 1) With the ZX6-DL powered off, press and hold down the key while powering the ZX6-DL on . The lock icon will be illuminated on the display. 2) To unlock the ZX6-DL repeat step one, but hold down the...
  • Page 46 ZX- 6 DL Ultrasonic Multi-Mode Thickness Gauge 4) Press the keys to scroll “REST” (reset). 5) Press the key to edit the reset option. 6) Press the keys to toggle YES, followed by pressing to reset the gauge. 7) Repeat the steps above to set “MEDI” & “ZERO” back to their original settings noted in step three above.

  • Page 47: Chapter Nine Data Storage

    CHAPTER NINE DATA STORAGE 9.1 Introduction The ZX6-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 48: Storing A Measurement

    ZX- 6 DL Ultrasonic Multi-Mode Thickness Gauge Note: The FILE and LOC (location) will be displayed in lower left portion of the measurement screen. 9.3 Storing a Measurement Now that a file has been selected and opened, the ZX6-DL is ready to store measurements.

  • Page 49: Clearing A File

    Dakota NDT displayed on the screen indicating a measurement has already been stored at that location. Pressing the key will clear the previously stored measurement from the location. Pressing the key will now store the new measurement. 9.4 Clearing a File If a file contains a large number of previously stored measurements, and has already been downloaded, the file will need to be cleared of its measurements.

  • Page 50: Clear All Files

    ZX- 6 DL Ultrasonic Multi-Mode Thickness Gauge 7) 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 measurement screen without clearing the file. 8) Press the key to confirm Yes/No selection and return to the measurement screen.
  • Page 51 Dakota NDT 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 measurement screen without clearing the files.

  • Page 52: Chapter Ten Data Transfer & Power Options

    CHAPTER TEN DATA TRANSFER & POWER OPTIONS 10.1 Connectivity The ZX6-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 53: Line Power

    Dakota NDT accomplish this, simply ‘drag and drop’ files in a new folder on your PC, or on your desktop. If you have a specific software package associated with .CSV files, like a spreadsheet editor, they can automatically be opened by ‘double clicking’ one of the active files in the folder.

  • Page 54: 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...
  • Page 55 Dakota NDT 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...

  • Page 56: 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 57 Dakota NDT 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 58  Warranty Statement  Dakota NDT warrants the ZX6-DL against defects in materials and workmanship for a period of five years from receipt by the end user. Additionally, Dakota NDT warrants transducers and accessories against such defects for a period of 90 days from receipt by the end user.

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