Dakota NDT PZX1 Precision Ultrasonic Data Logging Thickness Gauge Instruction Manual

Dakota NDT PZX1 Precision Ultrasonic Data Logging Thickness Gauge

Product Information

Specifications

• Product Name: Dakota NDT PZX1-DL
• Type: Precision Ultrasonic Data Logging Thickness Gauge
• Manufacturer: Distributed by ABQ Industrial LP USA
• Website: https://www.abqindustrial.net
• Email: info@abqindustrial.net
• Telephone: +1 281-516-9292 / 888-275-5772
• eFax: +1 866-234-0451

Product Usage Instructions

Chapter Three: Principals of Ultrasonic Measurement

Understanding the fundamentals of ultrasonic measurement is crucial for accurate readings. Refer to this chapter for detailed information.

Chapter Four: Selecting the Measurement Mode

Learn how to choose the appropriate mode and transducer for your specific application to ensure precise measurements.

Chapter Five: Making Measurements

Instructions on performing probe zero and material calibration for accurate results.

Chapter Six: Through Paint Measurement

Discover how to conduct measurements through paint using multi-mode transducers.

Chapter Seven: Velocity Gauge

Utilize the velocity gauge feature, calibration to known thickness, and known velocity for enhanced measurements.

Chapter Eight: Additional Features

Explore the extra functionalities provided by the device for a comprehensive user experience.

Chapter Nine: Data Storage

Guidance on storing data efficiently for future reference and analysis.

Chapter Ten: Data Transfer & Power Options

Learn about transferring data and power options available for the device.

Frequently Asked Questions

• Q: How can I ensure accurate measurements with the PZX1-DL?
  • A: To ensure accuracy, carefully follow the instructions provided in the manual regarding measurement modes, transducer selection, and calibration procedures.
• Q: Can the PZX1-DL be used for measuring thickness through various coatings?
  • A: Yes, Chapter Six provides guidance on conducting measurements through paint using multi-mode transducers.

Distributed by: ABQ Industrial LP USA Tel: +1 281-516-9292 / 888-275-5772 eFax: +1 866-234-0451
Web: https://www.abqindustrial.net E-mail: info@abqindustrial.net
OPERATION MANUAL
Dakota NDT
PZX1-DL
Precision Ultrasonic Data Logging Thickness Gauge
Distributed by: ABQ Industrial LP USA Tel: +1 281-516-9292 / 888-275-5772 eFax: +1 866-234-0451
Web: https://www.abqindustrial.net E-mail: info@abqindustrial.net

CHAPTER ONE

INTRODUCTION

The Dakota NDT model PZX1-DL is a precision ultrasonic micrometer. Based on the same operating principles as SONAR, the PZX1-DL is capable of measuring the thickness of various materials with accuracy as high as 0.0001 inches, or 0.001 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 NDT 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 NDT
1500 Green Hills Road, #107 Scotts Valley, CA 95066 Tel: 831-431-9722 Fax: 831-431-9723 www.dakotandt.com
1.1 Disclaimer
While the PZX1-DL is a basic digital instrument, it is equipped with a number of measurement modes and transducer options for additional versatility. It is strongly recommended that the contents of this manual be read in its entirety to avoid erroneous measurements based on operator error. The user is solely responsible for proper use, setup 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 PZX1-DL 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. This feature is only used when using single element contact transducers. Refer to page 15 for a further explanation of this important feature.
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PZX1-DL Ultrasonic Thickness Gauge
2.3 CAL Key
The CAL key is used to enter and exit the PZX1-DL’s calibration mode. This mode is used to adjust the sound velocity value that the PZX1-DL 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 DATA Key
The DATA key accesses the data logging section of the PZX1-DL, which consists of 50 sequential (single column) files with 250 storage locations per file. Refer to page 42 for an explanation on the various calibration options.
2.5 CLR Key
The CLR key is used in conjunction with the data logging section to clear a single stored memory location. Refer to page 42 for an explanation on the various calibration options.
2.6 +/- Increment/Decrement Key’s
The +/- Keys are used to increment/decrement values, navigate menus, select menu options, and navigate data files and storage locations.
2.7 MODE Key
The MODE key toggles the measurement modes. If a delay line transducer (dLY) is selected from the PROB menu option, echo-echo (E-E) and interface-echo (I-E) modes will be toggled. If a contact transducer (Con) is selected, pulse- echo (P-E) and echo-echo (E-E) modes will be toggled. Finally, if the plastic transducer (PLAS) option is selected, the thickness options thin (thin) and thick (thK) will be toggled. The measurement modes and transducer styles offer the flexibility to address specific application scenarios. Refer to page 11 for an explanation on the various calibration options.
2.8 MENU Key
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The MENU key is used to access and set all of the additional features of the PZX1DL 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:

Gain

Matl

Scan

Alarm

Diff

Unit

Lite

Beep

Probe

VX

VLOW * Aluminum

On

On

On

English

On

On

Delay

On

LOW

Steel

Off

Off

Off

Metric

Off

Off

Plastic

Off

MED Stainless

Options Options Options Options

Contact

HIGH

Iron

Set Lo

Set

LOW

Lo

Nominal

Options **

VHI * Plexiglass

Set Hi

HIGH

Med

.12 5

PVC

High

.12 10

Plastic

.25 5

Poly Urea

.25 10

User 1

.37 5

User 2

.50 5

.50 10

• Displayed only when the contact transducer option has been selected.

** Diameter options are only available for contact transducers.

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

Navigating the Features in Menu

1. Press the 2) Press the

key once to enter the sub menu items. 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 PZX1-DL is currently in EDIT mode.

5. Press the

keys to toggle through the setting options.

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PZX1-DL Ultrasonic Thickness Gauge

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.

2.9 The Display

The PZX1-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 us:
A. Edit: 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.
B. Large 7 segment: The thickness measurement, velocity or alpha message will be displayed in this area.
C. Measurement Modes: This group of icons indicates which measurement mode the PZX1-DL is currently using. The modes are pulse-echo, echo-echo, interface- echo, and plastics (PLAS).
D. Stability/Repeatability Indicator: This is used in conjunction with the thickness measurement as a reference for the validity of the measurement. The PZX1-DL 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.
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E. Battery: Indicates the amount of battery life the PZX1-DL has remaining. F. Backlight : When this icon is illuminated, it indicates the backlight is on. 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 PZX1-DL 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 PZX1-DL. In P-E mode the options are VLOW, LOW, MED, HIGH, VHI, and LOW, MED, HIGH with modes E-E, I-E, and PLAS. MED is the default setting. 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. The plus/minus icon is illuminated when the DIFF (differential) feature is activated. 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 PZX1-DL, Refer to page 4 for a list. The PZX1-DL can be locked once calibrated, to avoid accidently changing the calibration. When this icon is illuminated, the PZX1-DL is in lock mode. Refer to page 40 for an explanation on locking the PZX1-DL. M. File/Loc: This area is exclusively for the data storage section of the PZX1DL. The icons and segment fields represent the current file open, and the current storage location in the file. Refer to page 42 for an explanation of the data storage feature in the PZX1-DL.
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2.10 The Transducer

PZX1-DL Ultrasonic Thickness Gauge

Delay Line

Contact

The Transducer is the “business end” of the PZX1-DL. It transmits and receives ultrasonic sound waves that the PZX1-DL uses to calculate the thickness of the material being measured. The transducer connects to the PZX1-DL using a single shielded coaxial cable with microdot connectors.

Delay Line Transducer
The single element delay line transducer is commonly used with the PZX1-DL for materials with an approximate range of 0.006″ to 1.00″ in steel. The measurement modes used with this style of transducer are echo-echo (E-E) and interface-echo (IE). Echo-echo mode will be used for the lower end of the measurement range, while interface-echo for the upper end of the measurement range. Interface-echo mode measures from the end of the delay line to the first return echo from the back wall of the material, while echo-echo measurements are made between the first and second return echoes from the back wall of the material. The frequency range for the versions Dakota commonly supply are from 10MHz to 20MHz.
The Delay line is fastened to the transducer with a retaining ring. A drop of couplant is applied between the delay line and transducer body. Refer to the diagram above. The couplant should be checked on a regular basis to keep it from drying out. To replenish, unscrew the retaining ring counterclockwise, separate the delay line from the body, `clean both surfaces’, apply a drop of couplant, and reassemble.

Delay Line Graphite Tip (For use with Plastics Mode)
The PZX1-DL has a special “PLAS” mode that uses the standard delay line transducer, as described above, but with a replaceable graphite delay tip. This mode and tip should be used when the velocity of the plastic material measured is similar to the velocity of the standard acrylic delay tip, and not achieving any signal/measurement. The graphite tip creates a `mismatch’ between the tip material and the plastic material measured.

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The Delay line is fastened to the transducer with a retaining ring. A drop of couplant is applied between the delay line and transducer body. Refer to the diagram above. The couplant should be checked on a regular basis to keep it from drying out. To replenish, unscrew the retaining ring counterclockwise, separate the delay line from the body, `clean both surfaces’, apply a drop of couplant, and reassemble.
Contact Transducer The single element contact style transducers are commonly used for materials with an approximate range of 0.040″ to the maximum range of the PZX1-DL rated in steel and depending on the transducers diameter and frequency. The frequency range is 5.0 to 10 MHz, with diameters available at 0.125, 0.250, 0.375 and 0.500 inches. The measurement modes used with this style of transducer are pulse-echo (P-E) and echo-echo (E-E).
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 PZX1-DL has been properly “zeroed” (see page 15), only if P-E mode is currently selected, 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 (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 PZX1DL 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.
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2.11 Top & Bottom End Caps

PZX1-DL Ultrasonic Thickness Gauge

The top & bottom end panels are where all connections are made to the PZX1-DL. The diagram above shows the layout and description of the connectors:
Transducer Connector Refer to Diagram: The transducer connector and battery cover/probe zero disk are located on the PZX1-DL’s top end cap. The transducer connector is a Lemo “00”.
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 disk when the zero feature is set to the `manual’ option. 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 PZX1-DL. Note: Rechargeable batteries can be used, however they must be recharged outside of the unit in a standalone battery charger.
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 PZX1-DL to a standard USB type A port on a PC. The cable supplied with the PZX1-DL is a USB type C to a USB type A (pt# N-003-0330). See page 47 for information on connectivity. Note: This connector is also used to upgrade the PZX1-DL with the latest version of firmware.
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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. The accuracy of a thickness measurement therefore depends on having a consistent sound velocity. Some materials are not as consistent as others and accuracy will be marginal. For example, some cast materials are very granular and porous and as a result have inconsistent sound velocities. While there are many different ultrasonic techniques to measure thickness, which will be discussed below, all of them rely on using the sound velocity to convert from time to thickness.
3.2 Suitability of materials
Ultrasonic thickness measurements rely on passing a sound wave through the material being measured. Not all materials are good at transmitting sound. Ultrasonic thickness measurement is practical in a wide variety of materials including metals, plastics, and glass. Materials that are difficult include some cast materials, concrete, wood, fiberglass, and some rubber.
3.3 Range of measurement and accuracy
The overall measurement capabilities, based on the wide variety of materials, are determined by the consistency of the material being measured (homogeneity). The range of thickness that can be measured ultrasonically depends on the material type and surface, as well as the technique being used and the type of transducer and frequency. The range will vary depending on the type of material being measured.
Accuracy, is determined by how consistent the sound velocity is through the sound path being measured, and is a function of the overall thickness of the material. For example, the velocity in steel is typically within 0.5% while the velocity in cast iron can vary by 4%.
3.4 Couplant
All ultrasonic applications require some medium to couple the sound from the transducer to the test piece. Typically a high viscosity liquid is used as the medium. The sound frequencies used in ultrasonic thickness measurement do not travel through air efficiently. By using a liquid couplant between the transducer and test piece the amount of ultrasound entering the test piece is much greater.
3.5 Temperature
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PZX1-DL Ultrasonic 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.
Normal temperature range Most standard transducers will operate from 0F to 150F.
High temperature measurements Special transducers and couplants are available for temperatures above 150F with intermittent contact in some cases. It is necessary to cool the transducer by submerging it in water between measurements.
Modes and temperature errors In addition to errors caused by velocity changing with temperature, some modes (measurement techniques) are affected more than others. Multi-echo techniques offer temperature compensation to help minimize these errors.
3.6 Measurement Modes
This section will cover the different measurement modes of the PZX1-DL, the transducers required, and the reasons for using specific modes:
Pulse-Echo (P-E) Mode: Pulse-echo mode measures from the initial pulse (sometimes referred to as an artificial zero) to the first echo (reflection), and is only used if the transducer type is set to contact mode. In this mode, a manual zero using the disk (battery cover) will need to be performed prior to calibrating the PZX1-DL. The transducer is placed on the reference disk located on top of the PZX1-DL, and the PRB 0 key pressed to establish a zero point for the transducer connected.
Errors from surface coatings and temperature variations can occur in pulse- echo mode. Therefore, coatings should be removed, and frequent probe zero’s should be performed if experiencing temperature gradients.
Echo-Echo (E-E) Mode ­ Through paint
The echo-echo mode measures between the first and second return echoes/reflections. This mode is most commonly used with the high frequency delay line style transducers for thin materials, and will also eliminate compensate for temperature. This technique will also eliminate error due to epoxy based coated surfaces by eliminating the error from the coating and measuring only the second layer or base material without having to remove the coating. The disadvantage is that two return echoes are required to effectively measure the test material. As a result, the type and thickness of the coating will affect the ability to achieve a
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Dakota NDT successful measurement. Both delay line and contact style transducers can be used for through paint/coating measurements. Interface-Echo (I-E) Mode The interface-echo mode measures from the end of the “interface/delay line” to the first return echo/reflection. This mode can be used for thicker materials up to 1″, and for attenuative materials that don’t produce a sufficient second echo. The standard measuring range is approximately 0.060″ up to 1.00″ rated in steel, and offers temperature compensation for the heating and cooling of the transducer itself. Plastics (PLAS) Mode The plastics mode is a special setup for measuring thin plastics using a modified interface-echo mode. When the standard acrylic delay tip is similar in velocity to the plastic material measured, a return echo is not possible. Simply replacing the acrylic tip with our graphite tip and using the plastics’ mode will provide the necessary mismatch necessary to measure the plastic successfully. The approximate range is 0.005″ up to 0.300″ depending on the type of plastic measured. This mode additionally offers temperature compensation for the heating and cooling of the transducer.
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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. Thicker cast iron and plastics applications will generally require lower frequencies depending on the material type and thickness. Frequencies from 5MHz to 10MHz are common. Larger diameters offer greater penetration power based on the size of the crystal.
Thin Materials & Tough Access Areas The high frequency delay line transducers are suitable when measuring thinner consistent materials that pass sound easily, such as steel, aluminum, titanium, etc. They offer temperature compensation with a suitable range up to 1″ depending on the delay line used. Replaceable cone tip options are also useful for difficult access areas and diameters.
Thru Paint & Coatings It’s common that users will be faced with applications where the material will be coated with some type of protective paint or other epoxy based material. Since the velocity of the coating is approximately 3 times slower than that of steel, pulse-echo mode will produce an error if not removed. However, echo-echo mode can be used with either delay line or contact style transducers to eliminate the error from the coating, and measure only the base material. High damped or high frequency transducers are most suitable for echo-echo measurement mode.
Plastics Thin plastics are best suited using the delay line transducer with either the acrylic delay tip in echo-echo or interface-echo modes. If the plastic measured is similar in velocity to the acrylic tip and not measuring adequately, the replaceable graphite tip and plastics mode will serve as the best option. Thicker plastics will generally require a lower frequency contact style transducer for additional penetration. Increasing the diameter of the transducer will also offer greater output.
High temperature High temperature applications will require a special delay line material that isn’t as absorptive of temperature.
Noisy Material Materials such as titanium, stainless steel, and aluminum may have inherent surface noise issues (mirroring effect). This can be avoided using a high frequency delay line transducer in either echo-echo or interface- echo modes. If using a contact style transducer, a high frequency option should be considered.
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Dakota NDT Restricted access Measuring materials with extreme curvatures or restricted access are best suited for higher frequencies and smaller diameter transducers or tip options.
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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 PZX1-DL for field use. In pulse-echo mode the probe zero must be performed on the reference disk (battery disk) attached to the top of the instrument. This compensates for variation in the transducer. In all modes the sound velocity must be determined. The sound velocity is used to convert the transit time to a physical length. The sound velocity can be selected from the material chart at the end of this manual, or for greater precision determined by measuring and calibrating from a known thickness of the actual material. To enter the velocity from a table, look up the material on the chart in the appendix of this manual and refer to the section below on Calibration to a Known Velocity. To determine the velocity of a single sample, refer to the Material Calibration section on page 16. When measuring curved materials, it’s more accurate to calibrate from two test points, one at the minimum limit of the target thickness and one at the maximum limit. In this case the reference disk is not used, and considered a `two-point’ calibration described on page 19.
5.1 Probe zero
A probe zero is only necessary if a contact style transducer is used in pulse- echo mode, and the contact option is enabled in the menu. A probe zero should be done prior to calibrating the instrument, and done on a periodic basis when a temperature gradient is an issue. If the PZX1-DL is not zeroed correctly, all measurements will be in error by some fixed value. In order to perform a probe zero, you must be in pulseecho mode.
Setting the zero point of the PZX1-DL is important for the same reason that setting the zero on a mechanical micrometer is important. It must be done prior to calibration, and should be done throughout the day to account for any temperature changes in the probe. If the PZX1-DL is not zeroed correctly, all the measurements taken may be in error by some fixed value. The zero can only be performed with the measurement mode set to pulse-echo (P-E). Therefore, if the PZX1-DL is to use the echo-echo (E-E) measurement mode and a manual zero is being performed, the PZX1-DL will argue by briefly displaying the message “nO prB0″ (no probe zero), and automatically switch modes to pulse-echo (P-E) where a zero can be performed.
The procedure to zero the transducer is outlined as below:
Performing a Manual Probe Zero (On Block)
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1. Apply a drop of couplant on the transducer and place the transducer in steady contact with the disk (battery cover) located at the top of the unit to obtain a measurement.

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.

5.2 Material Calibration
In order for the PZX1-DL to make accurate measurements, it must be set to the correct sound velocity of the material being measured. Different types of materials have different inherent sound velocities. For example, the velocity of sound 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 amount.
The One Point calibration is the simplest and most commonly used calibration method – optimizing linearity over large ranges. The Two Point calibration allows for greater accuracy over small ranges by calculating both the probe zero, as well as the material velocity. The PZX1-DL provides three simple methods for setting the soundvelocity outlined below:
Known Velocity
If the material velocity is known, it can be manually entered into the PZX1-DL, rather than have the PZX1-DL calculate the velocity value using a known thickness of the same material type. The steps for entering the velocity are outlined below:
Using a Known Material Velocity
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PZX1-DL Ultrasonic Thickness Gauge

1. With the transducer free from contact with the material, press the

key

to display the current velocity.

2. Use the value.

keys to scroll the velocity to the known target

Note: The longer the keys are pressed and held, the faster the value will increment/decrement.

Note: Pressing the

key prior to pressing the

routine without saving any changes.

key will abort the cal

3. Press the

key to set the velocity value and return to the measurement

screen. The new velocity value will be shown at the top of the display.

Known Thickness
Often times the exact sound velocity of a material is unknown. However, a sample with one or two known thicknesses can be used to determine the sound velocity. As previously discussed, the PZX1-DL has a one or two point calibration option. The one point calibration option is most suited for linearity over large ranges. When using the one point option, the calibration should be perform on the thickest side of the measurement range for the best linearity for that range. For example, if the measurement range is .100″ (2.54mm) to 1.0″ (25.4mm), the user should calibrate on a known thickness sample close to 1.0″ (25.4mm). Note: It’s always handy to carry a set of mechanical calipers to use in conjunction with the PZX1-DL for calibration of various materials in the field:
One Point Calibration

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Note: Be sure that a probe zero has been performed prior to performing this calibration procedure.

1. Physically measure an exact sample of the material, or a location directly on the material to be measured, using a set of calipers or a digital micrometer.
   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. Be sure that the reading is stable and the repeatability indicator in the top left corner of the display is fully lit and stable.

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.

Note: Pressing the

key prior to pressing the

routine without saving any changes.

key will abort the cal

5. Once the known thickness value is being displayed, press the display the calculated material velocity edit screen.

key to

Note: The calculated velocity can be edited, if needed, by pressing the keys to scroll and edit the velocity value.

6. Press the

key to set the calculated material velocity and return to the

measurement screen.

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PZX1-DL Ultrasonic Thickness Gauge
Note: CHECK YOUR CALIBRATION! Place the transducer back on the calibration point and verify the thickness. If the thickness is not correct, repeat the steps above.
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’ andvelocity value. If the two point option is used, a probe zero is not required. For example, if the measurement range was .080″ (2.03mm) to .250″ (6.35mm), two known samples or locations on the test material would be needed for the minimum and maximum boundaries of the test range. Using the range above, a one point calibration would be performed at .250″ (6.35mm) and a two point calibration at .080” (2.03mm), or something close to the min/max values of the measurement range. Note: The PZX1-DL also offers the capability of setting the probe zero’ to use any reference standard as theprobe zero’ standard. For clarification, if it’s desired to use a one inch reference of a specific material type as the zero’ reference, performing the first point of a two-point calibration sets the internal zero of the PZX1-DL. This should be used only in manual probe zero mode “on block”. This can be done inall’ measurement modes to correct the zero or offset as needed/required. The following steps outline this procedure:
Two Point Calibration

1. Physically measure a minimum and maximum calibration point of the exact sample material, or locations directly on the material to be measured, using a set of calipers or a digital micrometer.
   Note: A sample or location on the test piece should be used as close to the minimum and maximum thickness of the test range to minimize error and improve linearity.
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2. Apply a drop of couplant on the transducer and place the transducer in steady contact with either the minimum or maximum 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.

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.

Note: Pressing the

key prior to pressing the

routine without saving any changes.

key will abort the cal

5. Once the known thickness value is being displayed, press the

key to

display “1 of 2”, which sets the zero value and returns to the measurement

screen.

Note: The internal zero of the PZX1-DL is now set. The procedure above can be used in all measurement modes to set the internal zero or offset of the PZX1-DL to use any reference standard as the `probe zero’ standard if desired.

6. Repeat steps 2-4 on the second test point/location.

7. Press the

key to display the calculated velocity edit screen.

Note: The calculated velocity can be edited, if needed, by pressing the keys to scroll and edit the velocity value.

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PZX1-DL Ultrasonic Thickness Gauge

8. Press the

key to set the calculated material velocity and return to the

measurement screen.

Note: CHECK YOUR CALIBRATION! Place the transducer back on the calibration points. The thickness readings should now match the known 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 PZX1-DL would offer a reasonable approximation of the thickness. There are 9 common materials and 2 user programmable settings available. It’s important to note that these velocities will not always be an exact representation of the material being tested. Use these values only if a close approximation is acceptable. Follow the steps below to select a basic material type:
Selecting a Basic Material Type

1. Press the

key to access the menu items/features.

2. Use the

keys to scroll through the items/features until the

MATL feature is being displayed.

3. Press the

key to edit the material setting. The edit icon will be

illuminated and flashing.

Note: Pressing the

key prior to pressing the

key will abort to the

measurement screen without saving any changes.

21

Dakota NDT 4) Use the

keys to scroll through the material options.

ALUMINUM (2024)
STEEL (4340)

in/µs m/s 0.250 6350 0.233 5918

STAINLESS (303) 0.223 5664

CAST IRON

0.180 4572

PLEXIGLASS

0.106 2692

PVC

0.094 2388

POLYSTYRENE 0.092 2337

POLYURETHANE 0.070 1778

USER PROGRAMMABLE

5. When the desired MATL setting is displayed, press the material velocity and return to the measurement screen.

key to set the

Note: Pressing the

key prior to pressing the

key will abort to the

measurement screen without saving any changes.

6. If USR1 or USR2 were selected, the velocity edit screen will be displayed and edit icon illuminated and flashing.

7. Use the

keys to scroll to the desired material velocity.

Note: The longer these keys are held, the faster the velocity value is incremented.

8. When the desired velocity setting is displayed, press the material velocity and return to the measurement screen.

key to set the

22

PZX1-DL Ultrasonic Thickness Gauge

9. Note: Pressing the

key prior to pressing the

key will abort to

the measurement screen without saving any changes.

23

CHAPTER SIX

THROUGH PAINT MEASUREMENT

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. This avoids having to scrape or remove the coating from materials prior to inspection. The primary purpose of thru paint measurement is to determine the actual/nominal material thickness without error from the coating. Finally, this mode will only work for typical epoxy based coatings.
6.2 Multi Mode Transducers
The multi echo measurement technique does have restrictions on the type of transducers it can use successfully. The key requirement is that the transducers are “high damped”, which refers to the duration of how long the transducer rings. In order to improve the low end measurement range, being able to measure thin materials, the cycles of ring must be limited so they don’t interfere with the internal gating.
Since the PZX1-DL is a basic easy to operate gauge without the adjustability you’d get using an advanced A-Scan scope, echo-echo mode is subject to limitations depending on type and thickness of the coating, as well as the type of transducer used.
The procedure for activating the through paint (E-E) measurement mode is outlined as follows:
Echo-Echo Multi Mode
Note: Be sure that a probe zero (if using a contact transducer) and “one point calibration”, or a “two point calibration” has been performed prior to this procedure.
24

PZX1-DL Ultrasonic Thickness Gauge

1. Press the

key to toggle between the measurement modes, for a given

transducer type (contact or delay line), to echo-echo (E-E) mode.

Note: An icon will be illuminated in the top left portion of the display to indicate
the measurement mode the PZX1-DL is currently using.

25

CHAPTER

SEVEN VELOCITY GAUGE

7.1 Velocity Gauge (VX)
The PZX1-DL includes a function to convert the unit into a dedicated velocity gauge. With this feature enabled, the PZX1-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. This is primarily useful for rudimentary “nodularity” testing, as the velocity can be associated with density and used to determine the hardness/strength of a given material. A casting manufacturer would typically use this feature to control their processes and make sure the density/hardness is sufficient for each part and batch within a specified tolerance.
Using this feature will require calibration on a “known” thickness that will remain consistent at a specific location on a group of parts. The test will always be performed at the same location for all parts in the group. The velocity will be determined, and either accepted or rejected depending on the specified tolerances.
The procedure for enabling this feature is outlined below:
Velocity Gauge Option

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 velocity gauge setting. The edit icon will be

illuminated and flashing.

4. Use the

keys to toggle velocity on/off.

Note: Pressing the

key prior to pressing the

measurement screen without saving changes.

key will abort to the

26

PZX1-DL Ultrasonic Thickness Gauge

5. When the desired VX setting is displayed, press the status and return to the measurement screen.

key to set the

7.2 Calibration to a known thickness
In order to calibrate the PZX1-DL 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.
The procedure is outlined as follows:

Calibration ­ Known Thickness

Note: Be sure that a probe zero has been performed prior to performing this calibration procedure.

1. Physically measure an exact sample of the material, or a location directly on the material to be measured, using a set of calipers or a digital micrometer.

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.

3. Press the

key to enter the calibration edit screen displaying the

current velocity IN /s (M /s) value. The edit icon will be illuminated and

flashing.

4. Press the

key again to edit the known thickness value. The edit icon

will be illuminated and flashing and the units will be IN or MM, indicating

thickness.

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Dakota NDT

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

routine without saving any changes.

key will abort the cal

6. Once the known thickness value is being displayed, press the

key to

return to the measurement screen and display the calculated material

velocity.

Note: The known thickness value that was used to calibrate will be displayed in the top right corner of the display for confirmation.

7.3 Calibration to a known velocity
The velocity can also be directly edited and set to a target velocity value that was previously determined from a reference standard at an earlier time. The procedure for directly entering the velocity is outlined below:
Calibration ­ Known Velocity
Note: Be sure that a probe zero has been performed prior to performing this calibration procedure. Note: This procedure requires that the operator know the sound-velocity of the material to be measured. A table of common materials and their soundvelocities can be found in Appendix A.
28

PZX1-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.

2. Press the

key to enter the calibration edit screen displaying the

current velocity IN /s (M /s) value. The edit icon will be illuminated and

flashing.

3. Use the

keys to scroll to the known velocity value.

Note: Pressing the

key prior to pressing the

routine without saving any changes.

key will abort the cal

4. Once the known velocity value is being displayed, press the display the calculated thickness based on known velocity.

key to

5. Press the

key to return to the measurement screen and begin making

measurements.

Note: The known velocity value that was entered will be displayed, and the thickness value calculated will appear in the top right corner of the display for confirmation.

29

CHAPTER

EIGHT ADDITIONAL FEATURES

8.1 Gain
The gain, or amplification of the return echoes, can be adjusted in the PZX1-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. Not enough gain may result in intermittent detection. If you turn it up too much, you can’t hear the music clearly. If it’s turned down too much, you can’t hear it at all.
The PZX1-DL has the option of using and selecting three different transducer types; contact, delay line, and plastics. The contact transducers, in pulse- echo (P-E) and echo-echo (E-E), as well as delay line style transducers in interface-echo (I-E) and echo-echo (E-E) use automatic gain control (AGC) and fixed time dependent gain (TDG). They have three gain settings (LOW, MED, HIGH) with a 3dB cut/boost to the dynamic range of the AGC. Plastics (PLAS) mode, ` thin setting only’, uses a manual gain with five settings (VLOW, LOW, MED, HIGH, VHI) in 3dB increments, while the delay line style transducers use automatic gain control (AGC), and have 3 gain settings (LOW, MED, HIGH), similar to the contact and delay line style probes.
The PZX1-DL has been optimized for the MED gain setting for all common applications. It should be operated in this mode as standard. However, some applications may require the lower or higher gain settings. When? The low settings may be necessary for noisy or granular cast materials. How do I know when to lower the gain? If the reading becomes sporadic and won’t settle down or resolve on a thickness value because the material is either very noisy or granular. Setting the gain to a lower less sensitive level, would potentially offer improved stability. How do I know when to increase the gain? When a material is difficult to penetrate or pass sound through. This could be due to the material type, overall thickness, the transducer diameter and frequency, or a combination of all the above. Turning the gain up for additional output could improve the ability to obtain a successful measurement. In any case, the selectable gain settings offer improved versatility to resolve and overcome potential application issues.
Note: When the pulse-echo (P-E), echo-echo (E-E),or plastics (PLAS) “thick plastic setting option” measurement modes are selected for either contact, delay line, or plastics modes, The automatic gain control (AGC) is enabled. The dynamic range of the AGC can be adjusted with the following options (LOW, MED, HIGH), with MED still being the optimized standard setting as above.
The procedure for adjusting the gain is outlined as follows:
30

PZX1-DL Ultrasonic Thickness Gauge
GAIN

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 and flashing.

key to edit the gain setting. The edit icon will be illuminated

4. Use the

keys to scroll through the gain settings in PLAS

“thin setting” (VLOW, LOW, MED, HIGH, VHI), or P-E, E-E, I-E, PLAS “thick

setting” (LOW, MED, HIGH) until the desired setting is being displayed.

Note: Pressing the

key prior to pressing the

measurement screen without saving changes.

key will abort to the

5. Press the

key to set the gain and return to the measurement screen.

Note: Pressing the

key prior to pressing the

measurement screen without saving changes.

key will abort to the

8.2 High Speed Scan
The High Speed Scan feature of the PZX1-DL increases the overall repetition rate to a maximum of 140Hz with a high speed screen refresh rate of 25 times a second. This allows for making scanned passes over an arbitrary length of the test material, while still maintaining a reasonable representation of thickness over the area or region scanned. The alarm (ALRM) feature, with high and low limits, can be used in conjunction with high speed scan.
The procedure to use the scan feature is outlined below:

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Dakota NDT

High Speed Scan

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 and flashing.

key to edit the scan setting. The edit icon will be illuminated

4. Use the

keys to toggle scan on/off.

Note: Pressing the

key prior to pressing the

measurement screen without saving changes.

key will abort to the

5. When the desired SCAN setting is displayed, press the status and return to the measurement screen.

key to set the

8.3 Alarm
The Alarm feature of the PZX1-DL provides a method of setting tolerances, or limits, for a particular application requirement. This feature may be used for a variety of 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. There are two limit values HI/LO, that can be set according to specified tolerances.
The procedure to use the alarm feature is outlined below:

ALARM

32

PZX1-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

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.

5. When the desired ALRM status is displayed, press the status and edit the LO limit option.

key to set the

6. Use the value.

keys to scroll the LO limit value to the target

Note: Pressing the

key prior to pressing the

key will abort to the

measurement screen without saving changes to the LO limit value.

7. When the target LO limit is displayed, press the and advance to setting HI limit option.

key to set the value

8. Use the

keys to scroll the HI limit 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 HI limit value.

9. When the target HI limit is displayed, press the and return to the measurement screen.

key to set the value

8.4 Differential
33

Dakota NDT
The Differential Mode of the PZX1-DL provides the user with the ability to set a nominal value, according to what the expected thickness should be, and measure the +/- difference from the nominal value entered. This feature is typically used in QA incoming inspections on pipes, plate stock, coils, etc.
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.

3. Press the

key to edit the differential status. The edit icon will be

illuminated and flashing.

4. Use the

keys to toggle differential on/off.

5. When the desired DIFF setting is displayed, press the status and edit the NOMINAL value.

key to set the

6. Use the value.

keys to scroll the NOMINAL value to the target

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 return to the measurement screen.

key to set the value and

34

PZX1-DL Ultrasonic Thickness Gauge
8.5 Units
The PZX1-DL will operate in both English (inches) or Metric (millimeters) units. In either option the resolution (RES) can be set to LOW (.001in/.01mm), or HIGH (.0001in/.001mm).
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 and flashing.

key to edit the units setting. The edit icon will be illuminated

4. Use the

keys to toggle English or Metric units.

Note: Pressing the

key prior to pressing the

measurement screen without saving changes.

key will abort to the

5. When the desired UNIT setting is displayed, press the units and edit the RES (resolution) option.

key to set the

6. Use the

keys to scroll the RES (LOW, HIGH) options.

7. When the desired RES setting is displayed, press the resolution and return to the measurement screen.

key to set the

8. Note: Pressing the

key prior to pressing the

the measurement screen without saving changes.

35

key will abort to

Dakota NDT
8.6 Lite
The PZX1-DL uses a custom glass segmented display that is equipped with a backlight for use in low light conditions. The options are on/off/auto, where the auto setting 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.

3. Press the and flashing.

key to edit the light setting. The edit icon will be illuminated

4. Use the

keys to toggle status on/off/auto.

Note: Pressing the

key prior to pressing the

measurement screen without saving changes.

key will abort to the

5. When the desired LITE setting is displayed, press the status and edit the BRT (brightness) option.

key to set the

6. Use the options.

keys to scroll through the BRT (LO, MED, HI)

7. When the desired BRT setting is displayed, press the brightness and return to the measurement screen.
   36

key to set the

PZX1-DL Ultrasonic Thickness Gauge

8. Note: Pressing the

key prior to pressing the

the measurement screen without saving changes.

key will abort to

8.7 Beep
The PZX1-DL also has a feature to use the internal beeper, most commonly used with the alarm feature, for the key strokes on the keypad. When enabled, pressing any of the keys on the keypad will sound the beeper.
The procedure to enable the keyboard beeper feature is outlined below:

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.

4. Use the

keys to toggle the beeper on/off.

Note: Pressing the

key prior to pressing the

measurement screen without saving changes.

key will abort to the

5. When the desired BEEP setting is displayed, press the status and return to the measurement screen.

key to set the

37

Dakota NDT
8.8 Probe Type
The PZX1-DL can use three different probe/transducer styles for different application requirements. The styles are; CONTACT, DELAY LINE, and plastics PLAS. The corresponding option `must’ be selected to match the type of transducer connected to the PZX1-DL in order for the gauge to operate correctly.
The procedure to select the probe type is outlined below:
Probe

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 and flashing.

key to edit the probe type. The edit icon will be illuminated

4. Use the option.

keys to select the contact/delay line/plastics

Note: Pressing the

key prior to pressing the

measurement screen without saving changes.

key will abort to the

5. When the desired PROB type is displayed, press the type and return to the measurement screen.

key to set the

Note: If the `contact’ option was selected, the diameter and frequency of the contact style transducer must be selected in order to operate correctly.

6. Use the

keys to select the diameter & frequency (.12 5,

.12 10, .25 5, .25 10, .37 5, .50 5, .50 10 inches).

38

PZX1-DL Ultrasonic Thickness Gauge

Note: Pressing the

key prior to pressing the

measurement screen without saving changes.

key will abort to the

7. When the desired PROB diameter is displayed, press the the diameter and return to the measurement screen.

key to set

8.9 Velocity (VX)
When the velocity setting (VX) is enabled, the PZX1-DL will display the material velocity as the primary measurement quantity instead of dimensional thickness. The 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 PZX1-DL is operating in reverse to the standard option of the gauge. Only the one point’ calibration can be used with this feature active, and a manual or auto zero is still required. The PZX1-DL can be calibrated by entering the known velocity or entering the know thickness of the material at a given position on the test material. Refer to themaking measurements’ section on page 26 for a complete explanation of the zero and one point calibration procedure.
The procedure to enable the velocity feature is outlined below:

Velocity Gauge

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 flashing.

key to edit the setting. The edit icon will be illuminated and

39

Dakota NDT

4. Use the

keys to select the on/off option.

Note: Pressing the

key prior to pressing the

measurement screen without saving changes.

key will abort to the

5. When the desired VX setting is displayed, press the status and return to the measurement screen.

key to set the

8.10 Lock
The lock feature was built into the PZX1-DL for the purpose of locking the operators out of editing any of the gauge settings, for purposes of consistency between operators. When the lock feature is enabled, the gauge calibration functionality cannot be 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:

Lock

1. With the PZX1-DL powered off, press and hold down the

key while

powering the PZX1-DL on display.

. The lock icon will be illuminated on the

2. To unlock the PZX1-DL repeat step one, but hold down the

key

while powering the PZX1-DL on

.

8.11 Factory Defaults
40

PZX1-DL Ultrasonic Thickness Gauge The PZX1-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 PZX1-DL powered off, press and hold down the

and

keys while powering the PZX1-DL on

.

Note: Once the measurement screen is displayed the

and

can be

released.

41

CHAPTER

NINE DATA STORAGE

9.1 Introduction
The PZX1-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. These files can then be transferred to a PC using the USB-C to USB type A cable included in the kit. When PZX1-DL is connected to a PC, it will show up in the list of drives as an external hard drive, or “thumb” drive. Open the external gauge drive, and copy the files to and from the gauge and PC.
The file format is .csv (comma separated) and can be opened using any text editor, spreadsheet editor, or Dakota’s proprietary PC software supplied with the gauges. Only files with at least one measurement stored in the file will appear in the external drive folder.
9.2 Opening a Data File
Open Data File

1. Press the

key to access the data files and display the current file open.

2. Press the

key to edit which file to open. The edit icon will be

illuminated and flashing.

3. Use the

keys to scroll through the files.

Note: Pressing the

key prior to pressing the

key will abort to the

measurement screen without saving any changes.

4. When the desired FILE is displayed, press the return to the measurement screen. 42

key to open the file and

PZX1-DL Ultrasonic 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 PZX1-DL is ready to store measurements. The following procedure outlines this process:
Storing Data

1. Use the measurement.

keys to scroll to the desired location to store a

2. Press the

key to store a measurement and advance to the next

location (LOC).

3. Repeat steps 1 and 2 as needed.

Note: If an area exists where a measurement cannot be obtained successfully,

press the

key to store OBST (obstruction) in the location. Pressing the

again will clear the location.
Note: If a measurement has been previously stored in a location, scrolling to that location will display the measurement currently stored, and show MEM

(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

43

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 new measurement.

key will now store the

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.
The following procedure outlines this process:

Clear File

1. Press the

key to access the data files and display the current file open.

2. Press the

key to edit which file will be cleared. The edit icon will be

illuminated and flashing.

3. Use the

keys to scroll to the file that will be cleared.

4. When the desired FILE is being displayed, press the file to be cleared.

key to select the

5. Use the

keys to scroll to CLR (clear).

6. Press the

key to display the confirmation screen. CLR? will be

displayed, as well as a flashing Yes/No option.

44

PZX1-DL Ultrasonic Thickness Gauge

7. Press the

key for YES, and the

will be illuminated and flashing.

key for NO. The edit icon

Note: Pressing the

key prior to pressing the

measurement screen without clearing the file.

key will abort to the

8. Press the

key to confirm Yes/No selection and return to the

measurement screen.

Note: If Yes was selected a BUSY message will briefly be displayed confirming the file is being cleared.

9.5 Clear All Files
If a number of files in the PZX1-DL contain old data, or data that has been previously downloaded, clearing all the files might prove an efficient option.
The following procedure outlines this process:
Clear Files

1. Press the 2) Use the

key to access the data files and display the current file open. keys to scroll to the CLR ALL option.

3. Press the

key to display the confirmation screen. CLR ALL is

displayed, as well as a flashing Yes/No option.

45

Dakota NDT

4. Press the

key for YES, and the

will be illuminated and flashing.

key for NO. The edit icon

Note: Pressing the

key prior to pressing the

measurement screen without clearing the files.

key will abort to the

5. Press the

key to confirm Yes/No selection and return to the

measurement screen.

Note: If Yes was selected a BUSY message will briefly be displayed confirming the files are being cleared.

46

CHAPTER TEN

DATA TRANSFER & POWER OPTIONS 10.1 Connectivity

The PZX1-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. It functions very similar to a cell phone or camera. Opening the external disk folder will display only the files that currently have data stored in them, and while the other files are physically in the directory, they are hidden until they contain data. The PZX1-DL has a maximum of 40 total files with 250 sequential readings per file.
10.2 Opening a File
The data files are stored as a .CVS (comma separated) text file, which is a very basic generic text file structure. It can be conveniently opened using any standard text editor, spreadsheet or database program. The data can easily be copied, moved or imported into reports created by a variety of software packages. With the gauge turned on and connected to your PC a drive called “ultrasonics” will appear in your list of devices:
Open the external drive to view the files.
10.3 Copying/Opening Files
Now that the files have been located and are accessible, they can either be opened from the PZX1-DL’s memory, or copied to another location/folder on your PC. To
47

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 bydouble clicking’ one of the active files in the folder. Alternatively, you can specify what software package you’d like them opened with by right clicking’ on a specific file and using theopen with’ option in the menu.

Spreadsheet

Text Editor

10.4 Line Power
The PZX1-DL can be powered using the standard USB-C to USB-A data cable (N003-0330), by connecting directly to a USB port on your computer, or using a standard cell phone power adapter directly to an outlet. This is a convenient way to power the gauge for specific bench top applications in a factory line environment.
Note: If USB is being displayed on the display, the PZX1-DL is currently in download/transfer mode. This can be bypassed by pressing any key to abort the transfer mode, and return to actively measuring and using line power.

48

APPENDIX A VELOCITY TABLE

Material

sound velocity in/us

sound velocity m/s

Aluminum Beryllium Brass Bronze Cadmium Columbium Copper Glass (plate) Glycerine Gold Inconel Iron Cast Iron Lead Magnesium Mercury Molybdenum Monel Nickel Nylon Platinum Plexiglas Polystyrene PVC Quartz glass Rubber vulcanized Silver Steel (1020) Steel (4340) Steel Stainless” Teflon

0.2510 0.5080 0.1730 0.1390 0.1090 0.1940 0.1830 0.2270 0.0760 0.1280 0.2290 0.2320 0.1800 0.0850 0.2300 0.0570 0.2460 0.2110 0.2220 0.1060 0.1560 0.1060 0.0920 0.0940 0.2260 0.0910 0.1420 0.2320 0.2330 0.2230 0.0540

(approx) (approx)

6375 12903 4394 3531 2769 4928 4648 5766 1930 3251 5817 5893 4572 2159 5842 1448 6248 5359 5639 2692 3962 2692 2337 2388 5740 2311 3607 5893 5918 5664 1372

49

Dakota NDT
Tin Titanium Tungsten Uranium Water Zinc Zirconium

0.1310 0.2400 0.2040 0.1330 0.0580 0.1660 0.1830

3327 6096 5182 3378 1473 4216 4648

50

APPENDIX BAPPLICATION NOTES
Measuring hot surfaces
The velocity of sound through a substance is dependent on its temperature. As materials heat up, the velocity of sound through them decreases. In most applications with surface temperatures less than about 200F (100C), no special procedures must be observed. At temperatures above this point, the change in sound velocity of the material being measured starts to have a noticeable effect upon ultrasonic measurement.
At such elevated temperatures, it is recommended that the user perform calibration on a sample piece of known thickness, which is at or near the temperature of the material to be measured. This will allow the PZX1-DL to correctly calculate the velocity of sound through the hot material.
Expansion and contraction of the transducer based on temperature, and a varying temperature gradient, will also affect the measurement in a pulse-echo (P-E) measurement mode. It is recommended that a “transducer zero” be performed often to account for the delay line changing length and adversely affecting the accuracy of the measurements.
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 (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. 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. If the variation is relatively close, averaging the sound velocities to minimize error is another option.
51

Dakota NDT An additional important consideration when measuring laminates is that many included air gaps or pockets which 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. Measuring through paint & coatings Measuring through paints and coatings are also unique, in that the velocity of the paint/coating will be significantly different from the actual material being measured. A perfect example of this would be a mild steel pipe with .025″ of coating on the surface. Where the velocity of the steel pipe is .2330 in/sec, and the velocity of the paint is .0850 in/sec. If the user is calibrated for mild steel pipe and measures through both materials, the actual coating thickness will appear to be approximately 3 times thicker than it actually is, as a result of the differences in velocity. This error can be eliminated by using a special echo-echo (E-E) mode to perform measurements for applications such as these. In echo-echo mode, the paint/coating thickness will be eliminated entirely and only the steel or base metal measured.
52

Distributed by: ABQ Industrial LP USA Tel: +1 281-516-9292 / 888-275-5772 eFax: +1 866-234-0451
Web: https://www.abqindustrial.net E-mail: info@abqindustrial.net
WARRANTY INFORMATION
Warranty Statement Dakota NDT warrants the PZX1-DL against defects in materials and workmanship for a period of two 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. If Dakota NDT receives notice of such defects during the warranty period, Dakota NDT will either, at its option, repair or replace products that prove to be defective. Should Dakota NDT 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 NDT makes no other warranty, either express or implied, with respect to this product. Dakota NDT 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 NDT and arrange for servicing of the product. Retain proof of purchase in order to obtain warranty service. For products that require servicing, Dakota NDT 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 NDT for details of the services available, and to arrange for non-warranty service.
Distributed by: ABQ Industrial LP USA Tel: +1 281-516-9292 / 888-275-5772 eFax: +1 866-234-0451
Web: https://www.abqindustrial.net E-mail: info@abqindustrial.net

References

• Dakota NDT - Ultrasonic solution in Corrosion Inspection, Flaw Detection and Bolt Tension

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