Dakota Ultrasonics ZX-3 Operating Manual

OPERATION MANUAL

DAKOTA ULTRASONICS

ZZXX--33

Ultrasonic Thickness Gauge

P/N P-302-0002 Rev 1.10, March 2019

CONTENTS

CHAPTER ONE INTRODUCTION ...................................................................... 1

DISCLAIMER ......................................................................................................................... 1

1.1

CHAPTER TWO KEYPAD, MENU, DISPLAY & CONNECTORS ..................... 2

2.1

ON/OFF/ENTER KEY… ..................................................................................................... 2

2.2

PRB 0 KEY… ....................................................................................................................... 2

2.3

CAL KEY…. ......................................................................................................................... 3

GAIN KEY…. ....................................................................................................................... 3

2.4

2.5

SCAN KEY…. ...................................................................................................................... 3

2.6

+/- INCREMENT/DECREMENT KEY’S…. .................................................................................. 3

2.7

MATL KEY…. ...................................................................................................................... 3

2.8

MENU KEY… ...................................................................................................................... 3

2.9

THE DISPLAY ....................................................................................................................... 5

THE TRANSDUCER .............................................................................................................. 6

2.10

2.11

TOP END CAP .................................................................................................................... 8

CHAPTER THREE PRINCIPALS OF ULTRASONIC MEASUREMENT ........... 9

3.1

TIME VERSUS THICKNESS RELATIONSHIP ............................................................................... 9

3.2

SUITABILITY OF MATERIALS ................................................................................................... 9

RANGE OF MEASUREMENT AND ACCURACY ............................................................................ 9

3.3

3.4

COUPLANT ........................................................................................................................... 9

3.5

TEMPERATURE ................................................................................................................... 10

3.6

MEASUREMENT MODES ...................................................................................................... 10

CHAPTER FOUR SELECTING THE MEASUREMENT MODE ....................... 12

4.1

WHICH MODE & TRANSDUCER DO I USE FOR MY APPLICATION? ............................................ 12

CHAPTER FIVE MAKING MEASUREMENTS ................................................. 14

5.1

PROBE ZERO ...................................................................................................................... 14

5.2

MATERIAL CALIBRATION ..................................................................................................... 16

CHAPTER SIX ADDITIONAL FEATURES ....................................................... 23

6.1

GAIN .................................................................................................................................. 23

HIGH SPEED SCAN ............................................................................................................. 24

6.2

6.3

UNITS ................................................................................................................................ 24

6.4

LITE ................................................................................................................................... 25

6.5

ZERO ................................................................................................................................. 26

6.6 PROBE DIAMETER .............................................................................................................. 27

6.7

LOCK ................................................................................................................................. 28

6.8

FACTORY DEFAULTS .......................................................................................................... 29

APPENDIX A - VELOCITY TABLE .................................................................. 31

APPENDIX B- APPLICATION NOTES ........................................................... 33

CHAPTER ONE
INTRODUCTION

The Dakota Ultrasonics model ZX-3 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-3 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.

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 Corporation

1500 Green Hills Road, #107

Scotts Valley, CA 95066

Tel: [phone]

Fax: [phone]

www.dakotaultrasonics.com

1.1 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
rest solely with the user of the instrument. Other errors may occur from measuring
coated materials where the coating is insufficiently bonded to the material surface.
Irregular and inaccurate readings may result. Again, the user is responsible for
proper use and interpretation of the measurements acquired.

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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.

Once the gauge is initially powered on, this key will function as the ENTER key,
similar to a computer keyboard. This key will be used to select or set a menu option.

Note: Unit will automatically power off when idle for 5 minutes. All current settings
are automatically saved prior to powering off.

2.2 PRB 0 Key

The PRB 0 key is used to “zero” the ZX-3 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 14 for a
further explanation of this important feature.

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ZX-3 Ultrasonic Thickness Gauge

2.3 CAL Key

The CAL key is used to enter and exit the ZX-3's calibration mode. This mode is
used to adjust the sound velocity value that the ZX-3 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. This
provides increased linearity between transducers. Refer to page 16 for an
explanation on the various calibration options.

2.4 GAIN Key

The ZX-3 has an adjustable gain feature for additional versatility to control the overall

output of the gauge, to compensate for various materials and applications. There are
five gain settings (VLOW, LOW, MED, HIGH, VHI). The gain range is 40dB – 52dB
in 3dB increments. Refer to page 23 for details regarding the gain feature.

2.5 SCAN Key

The ZX-3 offers a high speed scan feature. This feature allows for scanning larger

areas on a given test material, while still offering reasonable representation of
thickness over the area scanned. Refer to page 24 for an explanation on the scan
feature.

2.6 +/- Increment/Decrement Key’s

The +/- Keys are used to increment/decrement values, navigate menus, and select
menu options.

2.7 MATL Key

The MATL Key is used to select a common basic material type from a short list of 9
materials and 2 programmable custom materials for calibration. Refer to page 16 for
an explanation on selecting a basic material type.

2.8 MENU Key

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The MENU key is used to access and set all of the additional features of the ZX-3

that are not at the top level of the keypad with a dedicated key. The features and
setting are outlined in the table below:

Menu Feature Items:

Unit Lite Zero Probe

English On Manual .187

Metric Off Auto .250

Options .500

Lo

Med

High

Here’s a quick overview of navigating through the various features in MENU:

Navigating the Features in Menu

1) Press the key once to enter the sub menu items.

2) Press the keys to toggle through the features.

3) To enable or edit the status of any feature, press the key.

4) The edit icon will start blinking to indicate that the ZX-3 is currently in EDIT

mode.

5) Press the keys to toggle through the setting options.

6) Press the key to accept changes and return to the top level of

features, or the key at any time to abort changes and return the

measurement screen.

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ZX-3 Ultrasonic Thickness Gauge

2.9 The Display

The ZX-3 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
us:

Note: This display is used for multiple gauge models in the ZX & PZX series. As a
result, some of the icons and segments that are illuminated during boot up, may not
be applicable to your specific model, and will never be illuminated during operation.
The icons and segments that will be used with the ZX-3 are shown in the diagram
above.

A. Edit:

B. Large 7 segment: The thickness measurement, velocity or alpha message

C. Measurement Modes: This icon indicates the measurement mode. The ZX-

D. Stability/Repeatability Indicator:

E. Battery: Indicates the amount of battery life the ZX-3 has remaining.

F. Backlight :
G. Small 7 Segment:

This icon will be displayed, and blinking, to let a user know when they

are in an edit mode to change a value or setting.

will be displayed in this area.

3 operates exclusively in pulse-echo (P-E) mode only.

This is used in conjunction with the

thickness measurement as a reference for the validity of the measurement.

The ZX-3 takes multiple measurements per second, and when all the vertical

bars are illuminated, it’s a reference that the same thickness value is reliably
being measured multiple times per second.

When this icon is illuminated, it indicates the backlight is on.

The material velocity, speed the sound wave travels

through a given medium/material, is displayed in this area, informing the user

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Dakota Ultrasonics

what material the ZX-3 is currently calibrated too. This area is also used for

alpha messages in the menu and edit modes.

H. Units: This combination of icons are illuminated in different sequences to

inform the user what measurement units are currently being displayed in the
small 7 segment area.

I. Small 14 Segment: Displays the current gain setting of the ZX-3. 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.

K. Small 14 Segment: The material type is displayed in this area. If it is set to a

value of one of the materials in our material list, it will be displayed in alpha
characters indicating the material type. Otherwise it will be set to CUST,
indicating custom material type.

L. Features: The icons illuminated in this row across the bottom of the LCD

display which features are currently enabled. For a complete list of the menu

features in the ZX-3, Refer to page 3 for a list. The ZX-3 can be locked once

calibrated, to avoid accidently changing the calibration. When this icon is

illuminated, the ZX-3 is in lock mode. Refer to page 28 for an explanation on
locking the ZX-3.

2.10 The Transducer

The Transducer is the “business end” of the ZX-3. It transmits and receives
ultrasonic sound waves that the ZX-3 uses to calculate the thickness of the material
being measured. The transducer connects to the ZX-3 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 ZX-3.

The transducer must be used correctly in order for the ZX-3 to produce accurate,

reliable measurements. Below is a short description of the transducer, followed by
instructions for its use.

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ZX-3 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.
When the transducer is placed against the material being measured, it is the area
directly beneath the center of the wear face 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 wear face seated flat
against the surface of the material being measured.

Measuring

In order for the transducer to do its job, there must be no air gaps between the wear­face 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
transfer, 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 (wear face 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 ZX-3 has been properly

"zeroed" (see page 14) and set to the correct sound velocity (see page 16), 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 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. If the condition persists, it may be necessary to select a different transducer

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(size or frequency) for the material being measured. See page 12 for information on
transducer selection.

While the transducer is in contact with the material that is being measured, the ZX-3

will perform four measurements every second, updating its display as it does so.
When the transducer is removed from the surface, the display will hold the last
measurement made.

2.11 Top End Cap

The top end cap is where all connections are made to the ZX-3. The diagram above

shows the layout and description of the connectors:

Transducer Connectors

Refer to Diagram: The transducer connectors and battery cover/probe zero disk are

located on the ZX-3’s top end cap. The transducer connectors are of type Lemo

“00”.

Note: There is no polarity associated with connecting the transducer to the ZX-3, it
can be plugged into the gauge in either direction.

Probe Zero Disk & Battery Cover

Refer to Diagram: The Battery cover is the large round disk shown in the diagram.

Note: This same disk is also used as a probe zero reference disk. Simply remove

the cover when replacing the batteries (2 AA cells). When performing a manual
probe zero function, simply place the transducer on disk making firm contact.
Important: Be sure the battery polarity is correct, which can be found on the back
label of the ZX-3.

Note: Rechargeable batteries can be used, however they must be recharged outside
of the unit in a standalone battery charger.

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