Checkline MX-1 User Manual

OPERATION MANUAL

P/N P

-

139

-

0002

Rev 1.

90,

January 2008

DAKOTA ULTRASONICS MODEL MX-1 ULTRASONIC THICKNESS GAUGE

Copyright  2008 Dakota Ultrasonics. All rights reserved.

No part of this publication may be reproduced, translated into another
language, stored in a retrieval system, or transmitted in any form or by any
means; electronic, mechanical, photocopying, recording, or otherwise,
without the prior written consent of Dakota Ultrasonics.

Every precaution has been taken in the preparation of this publication.
Dakota Ultrasonics assumes no responsibility for errors or omissions.
Neither is any liability assumed for damages resulting from the use of
information contained herein.

Any brand or product names mentioned herein are used for identification
purposes only, and are trademarks or registered trademarks of their
respective holders.

1500 Green Hills Road, #107

Scotts Valley, CA 95066 USA

Tel [phone] Fax [phone]

www.dakotaultrasonics.com

CONTENTS

MX-1 Ultrasonic Thickness Gauge

INTRODU CTION
OPERATION

THE KEYPAD
THE DISPLAY
THE TRANSDUCER
MAKING MEASUREMENTS
CONDITION AND PREPARATION OF SURFACES
PROBE ZERO
CALIBRATION

PROGRAMMING THE MX-1’S SOUND VELOCITY
TRANSDUCER SELECTION
APPENDIX A: PRODUCT SPECIFICATIONS
APPENDIX B: APPLICATION NOTES

1
3
3
5
7

8
10
11
12
12
14
17
19

APPENDIX C: SOUND VELOCITIES OF COMMON MATERIALS
WARRANTY INFORMATION

23
25

DISCLAIMER

Inherent in ultrasonic thickness measurement is the possibility that the
instrument will use the second rather than the first echo from the back
surface of the material being measured. This may result in a thickness
reading that is TWICE what it should be. Responsibility for proper use of
the instrument and recognition of this phenomenon rests solely with the
user of the instrument.

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INTRODUCTION

The Dakota Ultrasonics model MX-1 is a precision Ultrasonic
Micrometer. Based on the same operating principles as SONAR, the MX-1
is capable of measuring the thickness of various materials with accuracy as

high as ± 0.001 inches, or ± 0.01 millimeters. The principle advantage of
ultrasonic measurement over traditional methods is that ultrasonic
measurements can be performed with access to only one side of the
material being measured.

This manual is presented in three sections. The first section covers
operation of the MX-1, and explains the keypad controls and display. The
second section provides guidelines in selecting a transducer for a specific
application. The last section provides application notes and a table of
sound velocity values for various materials.

Dakota Ultrasonics maintains a customer support resource in order to
assist users with questions or difficulties not covered in this manual.
Customer support may be reached at any of the following:

• Dakota Ultrasonics, 1500 Green Hills Road, #107
Scotts Valley, CA 95066 USA

• Telephone: [phone]

• Facsimile: [phone]

• www.dakotaultrasonics.com

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MX-1 Ultrasonic Thickness Gauge

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OPERATION

The MX- 1 interacts with the operator through the membrane keypad
and the LCD display. The function s of the various keys on the keypad are
detailed below, followed by an explanation of the display and its various
symbols.

This key is used to turn the MX-1 on and off. When the gauge is turned
ON, it will first perform a brief display test by illuminating all of the
segments in the display. After one second, the gauge will display the
internal software version number. After displaying the version number, the
display will show "0.000" (or "0.00" if using metric units), indicating the
gauge is ready for use.

The MX- 1 is turned OFF by pressing the ON/OFF key. The gauge has
a special memory that retains all of its settings even when the power is off.

The gauge also features an auto-powerdown mode designed to conserve
battery life. If the gauge is idle for 5 minutes, it will turn itself off.

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The PRB- 0 key is used to "zero" the MX-1 in much the same way that a
mechanical micrometer is zeroed. If the gauge is not zeroed correctly, all
of the measurements that the gauge makes may be in error by some fixed
value. Refer to page 11 for an explanation of this important procedure.

The IN/MM key is used to switch back and forth between English and
Metric units. This key may be used at any time, whether the gauge is

displaying a thickness (IN or MM) or a velocity value (IN/µs or M/s).

The BACKLIGHT key switches the display backlight between three
available settings. OFF will be displayed when the backlight is switched
off. AUTO will be displayed when the backlight is set to automatic mode,
and ON will be displayed when the backlight is set to stay on. In the AUTO

setting, the backlight will illuminate when the MX- 1 is actually making a
measurement.

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The Display

The numeric portion of the display consists of 4 complete digits
preceded by a leading "1", and is used to display numeric values, as well
as occasional simple words, to indicate the status of various settings.
When the MX-1 is displaying thickness measurements, the display will hold

the last value measured, until a new measurement is made. Additionally,

when the battery voltage is low, the entire display will begin to flash.
When this occurs, the batteries should be replaced.

These eight vertical bars form the Stability Indicator. When the MX-1 is
idle, only the left -most bar and the underline will be on. When the gauge is
making a measurement, six or seven of the bars should be on. If fewer

than five bars are on, the MX- 1 is having difficulty achieving a stable
measurement, and the thickness value di splayed will most likely be
erroneous.

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When the IN symbol is on, the MX-1 is displaying a thickness value in
inches. The maximum thickness that can be displayed is 19.999 inches.

When the MM symbol is on, the MX- 1 is displaying a thickness value in
millimeters. If the displayed thickness exceeds 199.99 millimeters, the
decimal point will shift automatically to the right, allowing values up to

1999.9 millimeters to be displayed.

When the IN symbol is on, in conjunction with the /µs symbol, the MX-1
is displaying a sound-velocity value in inches- per-microsecond.

When the M symbol is on, in conjunction with the /s symbol, the MX- 1
is displaying a sound-velocity value in meters-per-second.

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The Transducer

The transducer is the "business end" of the M X-1. It transmits and
receives the ultrasonic sound waves which the MX-1 uses to calculate the

thickness of the material being measured. The transducer connects to the
MX-1 via the attached cable, and two coaxial connectors. When using

transducers manufactured by Dakota Ultrasonics, the orientation of the
dual coaxial connectors is not critical: either plug may be fitted to either
socket in the MX-1.

The transducer must be used correctly in order for the MX- 1 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
wearface 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. When the transducer is placed

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against the material being measured, it is the area direct ly beneath the
center of the wearface that is being measured.

This is a top view of a typical transducer. Press against the top with the
thumb or index finger to hold the transducer in place. Moderate pressure is
sufficient, as it is only necessary to keep the transducer stationary, and the
wearface seated flat against the surface of the material being measured.

Making Measurements

In order for the transducer to do its job, there must be no air gaps
between the wear-face and the surface of the material being measured.
This is accomplished with the use of a "coupling" fluid, commonly called
"couplant". This fluid serves to "couple", or transmit, the ultrasonic sound
waves from the transducer, into the material, and back again. Before
attempting to make a measurement, a small amount of couplant should be
applied to the surface of the material being measured. Typically, a single
droplet of couplant is sufficient.

After applying couplant, press the transducer (wearface down) firmly
against the area to be measured. The Stability Indicator should have six or
seven bars darkened, and a number should appear in the display. If the
MX-1 has been properly "zeroed" (see page 11) and set to the correct

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sound velocity (see page 12), the number in the display will indicate the
actual thickness of the material directly beneath the transducer.

If the Stability Indicator has fewer than five bars darkened, or the
numbers on the display seem er ratic, 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. If the condition persists, it
may be necessary to select a different transducer (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 being measured, the
MX-1 will perform four measurements every second, upda ting its display as

it does so. When the transducer is removed from the surface, the display
will hold the last measurement made.

IMPORTANT

Occasionally, a small film of couplant will be drawn out between the
transducer and the surface as the transducer is removed. When this
happens, the MX-1 may perform a measurement through this couplant film,
resulting in a measurement that is larger or smaller than it should be. This
phenomenon is obvious when one thickness value is observed while the
transducer is in place, and another value is observed after the transducer is
removed.

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Condition and Preparation of Surfaces

In any ultrasonic measurement scenario, the shape and roughness of
the test surface are of paramount importance. Rough, uneven surfaces
may limit the penetration of ultrasound through the material, and result in
unstable, and therefore unreliable, measurements. The surface being
measured should be clean, and free of any small particulate matter, rust, or
scale. The presence of such obstruction s will prevent the transducer from
seating properly against the surface. Often, a wire brush or scraper will be
helpful in cleaning surfaces. In more extreme cases, rotary sanders or
grinding wheels may be used, though care must be taken to prevent
surface gouging, which will inhibit proper transducer coupling.

Extremely rough surfaces, such as the pebble-like finish of some cast
irons, will prove most difficult to measure. These kinds of surfaces act on
the sound beam like frosted glass on light, the beam becomes diffused and
scattered in all directions.

In addition to posing obstacles to measurement, rough surfaces
contribute to excessive wear of the transducer, particularly in situations
where the transducer is "scrubbed" along the surface. Transducers should
be inspected on a regular basis, for signs of uneven wear of the wearface.
If the wearface is worn on one side more than another, the sound beam
penetrating the test material may no longer be perpendicular to the material
surface. In this case, it will be difficult to exactly locate tiny irregularities in
the material being measured, as the focus of the soundbeam no longer lies
directly beneath the transducer.

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Probe Zero

Setting the Zero Point of the MX- 1 is important for the same reason that
setting the zero on a mechanical micrometer is important. If the gauge is
not "zeroed" correctly, all of the measurements the gauge makes will be in

error by some fixed number. When the MX-1 is "zeroed", this fixed error
value is measured and automatically corrected for in all subsequent
measurements. The MX- 1 may be "zeroed" by performing the following
procedure:

Performing a Probe-Zero

1) Make sure the MX- 1 is on.

2) Plug the transducer into the MX- 1. Make sure that the connectors
are fully engaged. Check that the wearface of the transducer is
clean and free of any debris.

3) On the top of the MX- 1, above the display, is the metal probe-disc.
Apply a single droplet of ultrasonic couplant to the face of this disc.

4) Press the transducer against the probe- disc, making sure that the
transducer sits flat against the surface of the probe-disc. The
display should show some thickness value, and the Stability
Indicator should have nearly all its bars illuminated.

5) While the transducer is firmly coupled to the probe-disc, press the

PRB-0 key on the keypad. The MX-1 will display "Prb0" while it is
calculating its zero point.

6) Remove the transducer from the probe- disc.

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At this point, the MX-1 has successfully calculated it's internal error

factor, and will compensate for this value in any subsequent
measurements. When performing a "probe-zero", the MX-1 will always use

the sound-velocity value of the built-in probe-disc, even if some other
velocity value has been entered for making actual measurements. Though
the MX-1 will remember the last "probe-zero" performed, it is generally a
good idea to perform a "probe-zero" whenever the gauge is turned on, as
well as any time a different transducer is used. This will ensure that the
instrument is always correctly zeroed.

Calibration

In order for the MX- 1 to make accurate measurements, it must be set to
the correct sound-velocity for the material being measured. Different types
of material have different inherent sound-velocities. For example, the
velocity of sou nd through steel is about 0.233 inches-per-microsecond,
versus that of aluminum, which is about 0.248 inches-per-microsecond. If
the gauge is not set to the correct sound-velocity, all of the measurements
the gauge makes will be erroneous by some fixed percentage.

Programming the Sound Velocity

Since the MX-1 is a fixed velocity gauge, the correct sound velocity for
the material being measured must be programmed into the gauge via the
serial port on the bottom of the unit. Approximate sound velocities for
common materials can be found in appendix C.

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Programming the MX-1

1) Connect the serial cable (Part No. N-306-0010) to a COM port on
a computer and to the RS232 connector located on the bottom of
the MX-1. Remove and replace the rubber plug before and after

programming.

2) Assuming that DakView2 PC software is installed and running,
select the MX-1 icon from the DakView2 gauge selector icons. A

window will appear with the title “MX-1 Velocity Upload Utilty”.

3) Under the Preset Velocity heading are two options. The first
option is a test box with a velocity number displayed. The text box
is editable. To change the velocity, click in the text field and type in
the appropriate velocity number. The second option is a list box
with a material type displayed. To change the material type, click
the down arrow located to the right of the list box. Use the arrows
or slider bar to scroll through the available material types. Click on
a material to select it.

4) To select the units (english or metric), click on the radio button
located to the left of the units title. A black dot will appear in the
button when selected.

5) Click on the Program Gauge button located in the top right of the
window. A pop up window will be display with the following
message “Turn on gauge power”. Press the ON/OFF button on the
MX-1 to download the velocity. The MX-1 will display the new
velocity.

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TRANSDUCER SELECTION

The MX- 1 is inherently capable of performing measurements on a wide
range of materials, from various metals to glass and plastics. Different
types of material, however, will require the use of different transducers.
Choosing the correct transducer for a job is critical to being able to easily
perform accurate and reliable measurements. The following paragraphs
highlight the important properties of transducers, which should be
considered when selecting a transducer for a specific job.

Generally speaking, the best transducer for a job is one that sends
sufficient ultrasonic energy into the material being measured such that a
strong, stable echo is received by the MX- 1. Several factors affect the
strength of ultrasound as it travels. These are outlined below:

• Initial Signal Strength

The stronger a signal is to begin with, the stronger its return echo
will be. Initial sign al strength is largely a factor of the size of the
ultrasound emitter in the transducer. A large emitting area will send
more energy into the material being measured than a small emitting
area. Thus, a so-called "1/2-inch" transducer will emit a stronger signal
than a "1/4-inch" transducer.

• Absorption and Scattering
As ultrasound travels through any material, it is partly absorbed. If

the material through which it travels has any grain structure, the sound
waves will also experience scattering. Both of these effects reduce the

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strength of the waves, and thus, the MX-1's ability to detect the
returning echo.

Higher frequency ultrasound is absorbed and scattered more than

ultrasound of a lower frequency. While it may seem that using a lower
frequency transducer might be better in every instance, low frequencies
are less directional than high frequencies. Thus, a higher frequency
transducer would be a better choice for detecting the exact location of
small pits or flaws in the material being measured.

• Geometry of the Transducer
The physical constraints of the measuring environment sometimes

determine a transducer's suitability for a given job. Some transducers
may simply be too large to be used in tightly confined areas. Also, the
surface area available for contacting with the transducer may be limited,
requiring the use of a transducer with a small wearface. Measuring on
a curved surface, such as an engine cylinder wall, may require the use
of a transducer with a matching curved wearface.

• Temperature of the Material
When it is necessary to measure on surfaces that are exceedingly

hot, high temperature transducers must be used. These transducers
are built using special materials and techniques that allow them to
withstand high temperatures withou t damage. Additionally, care must
be taken when performing a "Probe-Zero" or "Calibration to Known
Thickness" with a high temperature transducer. See Appendix B for
more information on measuring materials with a high temperature
transducer.

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Selection of the proper transducer is often a matter of tradeoffs between
various characteristics. It may be necessary to experiment with a variety of
transducers in order to find one that works well for a given job. Dakota
Ultrasonics can provide assistance in choosing a transducer, and offers a
broad selection of transducers for evaluation in specialized applications.

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Physical

Weight: 10 ounces
Size: 2.5W x 4.75H x 1.25D inches
(63.5W x 120.7H x 31.8D mm).

Operating Temperature: -20 to 120 °F (-20 to 50 °C)
Case: Extruded aluminum body / nickel plated aluminum end
caps.

MX-1 Ultrasonic Thickness Gauge

APPENDIX A

Product Specifications

Keypad

Sealed membrane, resistant to water and petroleum products.

Power Source

Two “AA” size, 1.5 volt alkaline or 1.2 volt NiCad cells. 20 0 hours
typical operating time on alkaline, 120 hours on NiCad.

Display

Liquid-Crystal-Display, 4.5 digits, 0.500 inch high numerals. LED
backlight.

Measuring

Range: 0.025 to 19.999 inches (0.63 to 500 millimeters)
Resolution: 0.001 inch (0.01 millimeter)

Accuracy: ±0.001 inch (0.01 millimeter), depends on material

and conditions

Sound Velocity Range: 0.0492 to 0.3930 in/µs (1250 to 10000m/s)

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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. If the diameter of the pipe
is larger than approximately 4 inches, measurements should be made with
the transducer oriented so that the gap in the wearface is perpendicular (at
right angle) to the long axis of the pipe. For smaller pipe diameters, two
measurements should be performed, one with the wearface gap
perpendicular, another with the gap parallel to the long axis of the pipe.
The smaller of the two displayed values should then be taken as the
thickness at that point.

Perpendicular Parallel

• Measuring hot surfaces

The velocity of sound through a substance is dependant upon its
temperature. As materials heat up, the velocity of sound through them
decreases. In most applications with surface temperatures less than about

200°F (100 °C), no special procedures must be observed. At temperatures

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above this point, the change in sound velocity of the material being
measured starts to have a noticeable effect upon ultrason ic measurement.

At such elevated temperatures, it is recommended that the user perform
a calibration procedure (refer to page 11) on a sample piece of known
thickness, which is at or near the temperature of the material to be

measured. This will allow the MX-1 to correctly calculate the velocity of
sound through the hot material.

When performing measurements on hot surfaces, it may also be
necessary to use a specially constructed high -temperature transducer.
These transducers are built using materials which can withstand high
temperatures. Even so, it is recommended that the probe be left in contact
with the surface for as short a time as needed to acquire a stable
measurement. While the transducer is in contact with a hot surface, it will
begin to heat up itself, and through thermal expansion and other effects,
may begin to adversely affect the accuracy of measurements.

• 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. The only way to reliably measure such materials is
by performing a calibration procedure on a sample piece of known
thickness. Ideally, this sample material should be a part of the same piece
being measured, or at least from the same lamination batch. By calibrating
to each test piece individually, the effects of variation of sound-velocity will
be minimized.

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An addition al important consideration when measuring laminates, is that
any included air gaps or pockets will cause an early reflection of the
ultrasound beam. This effect will be noticed as a sudden decrease in
thickness in an otherwise regular surface. While this may impede accurate
measurement of total material thickness, it does provide the user with
positive indication of air gaps in the laminate.

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in/us

m/s

Aluminum

0.250

6350

Brass

0.173

4394

Cast Iron

0.180

(apprx)

4572

Copper

0.184

4674

Epoxy resin

0.100

(apprx)

2540

Glass, crown

0.223

5664

Gold

0.128

3251

Iron

0.232

5893

Magnesium

0.228

5791

Nylon

0.102

(apprx)

2591

Platinum

0.156

3962

Polystyrene

0.092

2337

PVC

0.094

2388

Rubber, vulcanized

0.091

2311

Silver

0.142

3607

Steel, stainless

0.223

5664

Teflon

0.056

1422

Titanium

0.240

6096

Zinc

0.166

4216

APPENDIX C

Sound Velocities of some Common Materials

Material sound velocity

Bismuth 0.086 2184
Cadmium 0.109 2769
Constantan 0.206 5232

German silver 0.187 4750
Glass,flint 0.168 4267
Ice 0.157 3988
Lead 0.085 2159
Mercury 0.057 1448

Nickel 0.222 5639
Paraffin 0.087 2210
Plexiglass 0.106 2692
Porcelain 0.230 (apprx) 5842
Quartz glass 0.222 5639

Steel, common 0.233 5918
Stellite 0.275 (apprx) 6985
Tin 0.131 3327
Tungsten 0.210 5334
Water 0.058 1473

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WARRANTY INFORMATION

• Warranty Statement •

Dakota Ultrasonics warrants the MX-1 against defects in materials and
workmanship for a period of five years from receipt by the end user. 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.

Should Dakota Ultrasonics be unable to repair or replace the product within a
reasonable amount of time, the customer's alternative exclusive remedy shall be refund
of the purchase price upon return of the product.

• Exclusions •

The above warranty shall not apply to defects resulting from: improper or
inadequate maintenance by the customer; unauthorized modification or misuse; or
operation outside the environmental specifications for the product.

Dakota Ultrasonics makes no other warranty, either express or implied, with respect
to this product. Dakota Ultrasonics specifically disclaims any implied warranties of
merchantability or fitness for a particular purpose. Some states or provinces do not
allow limitations on the duration of an implied warranty, so the above limitation or
exclusion may not apply to you. However, any implied warranty of merchantability or
fitness is limited to the five-year duration of this written warranty.

This warranty gives you specific legal rights, and you may also have other rights
which may vary from state to state or province to province.

• Obtaining Service During Warranty Period •

If your hardware should fail during the warranty period, contact Dakota Ultrasonics
and arrange for servicing of the product. Retain proof of purchase in order to obtain
warranty service.

For products that require servicing, Dakota Ultrasonics may use one of the following
methods:

- Repair the product

- Replace the product with a re-manufactured unit

- Replace the product with a product of equal or greater performance

- Refund the purchase price.

• After the Warranty Period •

If your hardware should fail after the warranty period, contact Dakota Ultrasonics for
details of the services available, and to arrange for non-warranty service.

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MATERIAL SAFETY DATA SHEET

N/A = not applicable or not available (To comply with 29 CFR 1910.1200)

SECTION 1 – PRODUCT IDENTIFICATION

Product Name: SOUNDSAFE
Generic Name: Ultrasonic Couplant
Manufacturer: Sonotech, Inc.
774 Marine Dr., Bellingham, WA 98225
[phone]

SECTION 2 – HAZARDOUS INGREDIENTS

This material does not contain any ingredients having

known health hazards in concentrations greater than 1%.

This material does not contain any known or suspected

carcinogens.

SECTION 4 – FIRE AND EXPLOSION

HAZARD DATA

Flash Point : none
Upper Exposure Limit: none
Lower Exposure Limit: none
Special Fire Fighting Procedures : N/A
Extinguishing media: N/A
Unusual Fire and Explosion Hazards : none

NFPA Hazardous Materials

Identification System (est)

Health……………………0
Flammability…………….0
Reactivity………………..0

SECTION 3 – PHYSICAL DATA

(nominal)

Boiling Point: >220 °F pH: 7.35 – 7.9
Freezing Point: <20°F Acoustic Imp.: 1.726x10
Vapor Pressure: N/A Vapor Density: N/A
Evaporation Rate: N/A Specific Gravity: >1.02
Solubility in Water: complete
Appearance and Odor: water white, opaque gel;
bland odor

6

SECTION 5 – REACTIVITY DATA

Stability: Stable
Conditions to Avoid: none
Incompatibility (Materials to Avoid): none known
Hazardous Polymerization: will not occur
Hazardous Decomposition or Byproducts: none known

SECTION 6 – HEALTH HAZARD AND FIRST AID DATA

Routes of Entry :
Skin: not likely Ingestion: not normally
Eyes: not normally Inhalation: no
Effects of Overexposure: Acute: May cause temporary

1

eye irritation

Chronic: none expected

SECTION 7 – STORAGE AND HANDLING

INFORMATION

Precautions to be taken in handling and storage: Store
between 20°F and 120 °F. Spills are slippery and should

be cleaned up immediately.
Steps to be taken in case material is released or spilled:
Pick up excess for disposal. Clean with water.
Waste disposal method: Dispose of in accordance with
federal, state, and local regulations.

1

SOUNDSAFE contains only food grade and cosmetic grade ingredients.

SONOTECH, INC.

Toll Free: 1-800-458-4254

774 Marine Dr., Bellingham, WA 98225

Telephone: [phone]

First Aid Procedures :
Skin: Remove with water if desired.
Eyes: Flush with water for 15 minutes.
Ingestion: For large quantities, induce vomiting and

call a physician.

Inhalation: N/A

SECTION 8 – CONTROL MEASURES

Respiratory Protection: not required
Ventilation: not required
Protective Gloves : on individuals demonstrating

sensitivity to SOUNDSAFE
Eye Protection: as required by working conditions
Other Protective Equipment : not required

Fax: [phone]