OPERATION MANUAL DAKOTA ULTRASONICS MODEL MX-5 DL ULTRASONIC THICKNESS GAUGE P/N P-115-0002 Rev.1.
Dakota Ultrasonics Copyright 2008 Dakota Ultrasonics. All rights reserved. No part of this publication may be reproduced, translated into another language, stored in a retrieval system, or transmitted in any form or by any means; electronic, mechanical, photocopying, recording, or otherwise, without the prior written consent of Dakota Ultrasonics. Every precaution has been taken in the preparation of this publication. Dakota Ultrasonics assumes no responsibility for errors or omissions.
MX-5 DL Ultrasonic Thickness Gauge CONTENTS I NTRODUCTION 1 OPERATION 3 THE KEYPAD 3 THE DISPLAY 7 THE TRANSDUCER 9 MAKING MEASUREMENTS 10 CONDITION AND PREPARATION OF SURFACES 12 PROBE ZERO 13 CALIBRATION 14 UNITS, BACKLIGHT , SCAN MODE, ALARM MODE, DIFF 18 MODE, BEEPER, RS232 PORT & DATA LOGGER TRANSDUCER SELECTION 30 APPENDIX A: PRODUCT SPECIFICATIONS 34 APPENDIX B: APPLICATION NOTES 36 APPENDIX C: SOUND VELOCITIES OF COMMON MATERIALS 40 W ARRANTY I NFORMATION 42 DISCLAIMER
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MX-5 DL Ultrasonic Thickness Gauge INTRODUCTION The Dakota Ultrasonics model MX-5 DL is a precision Ultrasonic Micrometer. Based on the same operating principles as SONAR, the MX-5 DL 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.
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MX-5 DL Ultrasonic Thickness Gauge OPERATION The MX-5 DL interacts with the operator through the membrane keypad and the LCD display. The functions of the various keys on the keypad are detailed below, followed by an explanation of the display and its various symbols. The Keypad This key is used to turn the MX-5 DL on and off. When the tool is turned ON, it will first perform a brief display test by illuminating all of the segments in the display.
Dakota Ultrasonics The PRB-0 key is used to "zero" the MX-5 DL in much the same way that a mechanical micrometer is zeroed. If the tool is not zeroed correctly, all of the measurements that the tool makes may be in error by some fixed value. Refer to page 13 for an explanation of this important procedure. The CAL key is used to enter and exit the MX-5 DL's calibration mode. This mode is used to adjust the sound-velocity value that the M X-5 DL will use when calculating thickness.
MX-5 DL Ultrasonic Thickness Gauge The UP arrow key has three functions. When the MX-5 DL is in calibration mode, this key is used to increase numeric values on the display. An auto-repeat function is built in, so that when the key is held down, numeric values will increment at an increasing rate. When MODE is activated, the UP arrow key scrolls through the various features and settings of the MX-5 DL.
Dakota Ultrasonics The MEM key enables/disables the data logging feature of the MX-5 DL. This key is used in conjunction with the UP/DOWN arrows, SEND, AND CLR keys (hi-lighted in green). The combination of these keys control the data logging features of the MX-5 DL. Refer to the section on data logging page 24. The CLR key is specifically used with the data logging feature of the MX-5 DL. This key clears the contents of an entire file, or individual storage locations.
MX-5 DL Ultrasonic Thickness Gauge The Display The numeric portion of the display consists of 4 complete digits preceded by a leading "1", and is used to display numeric values, as well as occasional simple words, to indicate the status of various settings. When the MX-5 DL is displaying thickness measurements, the display will hold the last value measured, until a new measurement is made. Additionally, when the battery voltage is low, the entire display will begin to flash.
Dakota Ultrasonics When the IN symbol is on, the MX-5 DL is displaying a thickness value in inches. The maximum thickness that can be displayed is 19.999 inches. When the MM symbol is on, the MX-5 DL is displaying a thickness value in millimeters. If the displayed thickness exceeds 199.99 millimeters, the decimal point will shift automatically to the right, allowing values up to 1999.9 millimeters to be displayed.
MX-5 DL Ultrasonic Thickness Gauge The Transducer The transducer is the "business end" of the MX-5 DL. It transmits and receives ultrasonic sound waves that the M X-5 DL uses to calculate the thickness of the material being measured. The transducer connects to the MX-5 DL via the attached cable, and two coaxial connectors. When using transducers manufactured by Dakota Ultrasonics, the orientation of the dual coaxial connectors is not critical: either plug may be fitted to either socket in the MX-5 DL.
Dakota Ultrasonics This is a top view of a typical transducer. Press against the top with the thumb or index finger to hold the transducer in place. Moderate pressure is sufficient, as it is only necessary to keep the transducer stationary, and the wearface seated flat against the surface of the material being measured. Making Measurements In order for the transducer to do its job, there must be no air gaps between the wear-face and the surface of the material being measured.
MX-5 DL Ultrasonic Thickness Gauge 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 30 for information on transducer selection.
Dakota Ultrasonics Condition and Preparation of Surfaces In any ultrasonic measurement scenario, the shape and roughness of the test surface are of paramount importance. Rough, uneven surfaces may limit the penetration of ultrasound through the material, and result in unstable, and therefore unreliable, measurements. The surface being measured should be clean, and free of any small particulate matter, rust, or scale.
MX-5 DL Ultrasonic Thickness Gauge Probe Zero Setting the Zero Point of the MX-5 DL is important for the same reason that setting the zero on a mechanical micrometer is important. If the tool is not "zeroed" correctly, all of the measurements the tool makes will be in error by some fixed number. When the MX-5 DL is "zeroed", this fixed error value is measured and automatically corrected for in all subsequent measurements.
Dakota Ultrasonics At this point, the MX-5 DL has successfully calculated it's internal error factor, and will compensate for this value in any subsequent measurements. When performing a "probe-zero", the MX-5 DL will always use the sound-velocity value of the built-in probe-disc, even if some other velocity value has been entered for making actual measurements.
MX-5 DL Ultrasonic Thickness Gauge Calibration to a known thickness NOTE: This procedure requires a sample piece of the specific material to be measured, the exact thickness of which is known, e.g. from having been measured by some other means. 1) Make sure the M X-5 DL is on. 2) Perform a Probe-Zero (refer to page 13) 3) Apply couplant to the sample piece. 4) Press the transducer against the sample piece, making sure that the transducer sits flat against the surface of the sample.
Dakota Ultrasonics Calibration to a known velocity NOTE: This procedure requires that the operator know the soundvelocity of the material to be measured. A table of common materials and their sound-velocities can be found in Appendix C. 1) Make sure the M X-5 DL is on. 2) Press the CAL key to enter calibration mode. If the IN (or MM) symbol is flashing, press the CAL key again, so that the IN/µs (or M/s) symbols are flashing.
MX-5 DL Ultrasonic Thickness Gauge Two Point Calibration NOTE: This procedure requires that the operator has two known thickness points on the test piece that are representative of the range to be measured. 1) Make sure the M X-5 DL is on. 2) Perform a Probe-Zero (refer to page 13) 3) Apply couplant to the sample piece. 4) Press the transducer against the sample piece, at the first/second calibration point, making sure that the transducer sits flat against the surface of the sample.
Dakota Ultrasonics thickness values that were entered in step 7. The MX-5 DL is now ready to perform measurements within this range. MX-5 DL Modes Changing Units IN / MM The MX-5 DL has the ability to display measurements in both the English (IN) and Metric (MM) systems. The following steps outline the procedure for changing units: 1) Press ON/OFF key to power up the MX-5 DL. 1) Press the MODE key to activate features and settings. 2) Press the UP or Down arrow keys to scroll to the unIt symbol.
MX-5 DL Ultrasonic Thickness Gauge The Back light The back light of the MX-5 DL can be set to three different positions on/off/auto. The following steps outline the procedure for changing the settings of the back light: 1) Press ON/OFF key to power up the MX-5 DL. 5) Press the MODE key to activate features and settings. 6) Press the UP / Down arrow keys to scroll to the LItE symbol. 7) Press the SEND key to toggle the status of the back light on/off/auto.
Dakota Ultrasonics In normal operation, the MX-5 DL performs and displays four measurements every second, which is quite adequate for single measurements. In Scan Mode, however, the tool performs sixteen measurements every second. While the transducer is in contact with the material being measured, the MX-5 DL is keeping track of the lowest measurement it finds. The transducer may be "scrubbed" across a surface, and any brief interruptions in the signal will be ignored.
MX-5 DL Ultrasonic Thickness Gauge Using the Beeper 1) Press ON/OFF key to power up the unit. 2) Press MODE key to activate features and settings. 3) Press the UP or DOWN arrow keys to scroll to bEEP. 4) Press the SEND key to toggle the status of the beeper on/off. 5) Press the MODE key once again to return to measurement mode. Alarm Mode 1) Press ON/OFF key to power up the MX-5 DL. 2) Press the MODE key to activate features and settings. 3) Mode will start with ALAr feature and current status.
Dakota Ultrasonics Differential Mode In the Quality Control environment, it is sometimes necessary to know the difference between a nominal (target) thickness value and an actual thickness value. This feature is also included in the MX-5 DL. With the Differential Mode enabled, the MX-5 DL will display the positive or negative difference from an entered nominal value. The following steps outline the procedure for setting up this feature: Differential Mode 1) Press ON/OFF key to power up the MX-5 DL.
MX-5 DL Ultrasonic Thickness Gauge 7) Press the SEND key to select the desired nominal value and return to mode menu. 8) Press the MODE key once again to return to measurement mode. RS232 Serial Port & The Data Logger The MX-5 DL is equipped with an RS232 serial port. Using the accessory cable (part# N-306-0010), the MX-5 DL has the ability to connect to a computer, or external storage device.
Dakota Ultrasonics 4) Set the communications software COMM port to the port number that the M X-5 DL is connected - direct comm1, comm 2, etc. 5) Proceed to the section USING THE DATA LOGGER. Note: Communications software packages generally have the ability to capture the screen data to a common text file. This text file, containing the measurements, can then be imported into any common spreadsheet program (i.e. Excel, Quattro Pro, Lotus123) for further reporting requirements.
MX-5 DL Ultrasonic Thickness Gauge Note: • The display will flash FILE / F-01 (or the last file used) symbol. Remember, there are 10 files F-01 thru F-10. 3) Press the SEND key to enter file setup. Using the Data Logger (con't) • The current file will be diplayed ( F-01, F-03, etc. ) 4) Press the UP / DOWN arrow keys to scroll to the file ( 1-10 ) that will be used to record the measurements. 5) Press the SEND key once again to select the file.
Dakota Ultrasonics Note: • The data logger will automatically advance to the next storage location in sequential order. 9) Repeat step 8 as required. Clearing a Storage Location The user may require a storage location, that is currently full, be over written. This procedure is outlined in the following steps: Note: § Assuming the steps in Using The Data Logger have been completed, and step 8 is being repeated. 1) Press the UP / DOWN arrow keys to move to the location to be over written.
MX-5 DL Ultrasonic Thickness Gauge Clearing an Entire File The user may require the contents of an entire file be completely cleared of all measurements. This would allow the user to start a new list of measurements starting at storage location L001. The procedure is outlined in the following steps: 1) Press the ON/OFF key to power up the MX-5 DL. 2) Press the MEM key to activate the data logging functions and settings. 3) Press the SEND key to enter file setup.
Dakota Ultrasonics 7) Press the SEND key to select the clear file option. The symbol ( CLr? ) will be displayed. 8) Press the CLR key to confirm and clear the contents of the entire file. 9) Press the MEM key, at any time, to exit the data logging functions and return to measurement mode. Clearing all Files 1) Press the ON/OFF key to power up the MX-5 DL. 2) Immediately press the CLR key. CLr? Will be displayed. 3) Press the CLR key once again to clear all files.
MX-5 DL Ultrasonic Thickness Gauge 5) Press the SEND key to send all data files to the computer. 6) Press the MEM key to exit the data logging functions and return to measurement mode. Printing a File The user may wish to print an individual file to a serial printer or computer. A file can, very simply, be printed to a communications program on a PC ( i.e. Windows 3.1 - Terminal, Window 95/98 HyperTerminal ), and then printed.
Dakota Ultrasonics 7) Press the UP / DOWN arrow keys to scroll to the flashing Prnt / F05 ( The file chosen ), or LISt (tape printer) symbol. 8) Press the SEND key to print the contents of the file. 9) Press the MEM key, at any time, to exit the data logging functions and return to measurement mode. TRANSDUCER SELECTION The MX-5 DL is inherently capable of performing measurements on a wide range of materials, from various metals to glass and plastics.
MX-5 DL Ultrasonic Thickness Gauge more energy into the material being measured than a small emitting area. Thus, a so-called "1/2-inch" transducer will emit a stronger signal than a "1/4-inch" transducer. • Absorption and Scattering As ultrasound travels through any material, it is partly absorbed. If the material through which the sound travels has any grain structure, the sound waves will experience scattering.
Dakota Ultrasonics When it is necessary to measure on surfaces that are exceedingly hot, high temperature transducers must be used. These transducers are built using special materials and techniques that allow them to withstand high temperatures without damage. Additionally, care must be taken when performing a "Probe-Zero" or "Calibration to Known Thickness" with a high temperature transducer. See Appendix B for more information on measuring materials with a high temperature transducer.
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Dakota Ultrasonics APPENDIX A Product Specifications Physical Weight: 10 ounces Size: 2.5W x 4.75H x 1.25D inches (63.5W x 120.6H x 31.75D mm). Operating Temperature: -20 to 120 °F (-20 to 50 °C) Case: Extruded aluminum body / nickel plated aluminum end caps. Keypad Sealed membrane, resistant to water and petroleum products. Power Source Two “AA” size, 1.5 volt alkaline or 1.2 volt NiCad cells. 200 hours typical operating time on alkaline, 120 hours on NiCad. Display Liquid-Crystal-Display, 4.5 digits, 0.
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Dakota Ultrasonics APPENDIX B Application Notes • Measuring pipe and tubing When measuring a piece of pipe to determine the thickness of the pipe wall, orientation of the transducers is important. If the diameter of the pipe is larger than approximately 4 inches, measurements should be made with the transducer oriented so that the gap in the wearface is perpendicular (at right angle) to the long axis of the pipe.
MX-5 DL Ultrasonic Thickness Gauge 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 a calibration procedure (refer to page 14) on a sample piece of known thickness, which is at or near the temperature of the material to be measured. This will allow the MX-5 DL to correctly calculate the velocity of sound through the hot material.
Dakota Ultrasonics An additional important consideration when measuring laminates, is that any included air gaps or pockets will cause an early reflection of the ultrasound beam. This effect will be noticed as a sudden decrease in thickness in an otherwise regular surface. While this may impede accurate measurement of total material thickness, it does provide the user with positive indication of air gaps in the laminate.
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Dakota Ultrasonics APPENDIX C Sound Velocities of some Common Materials Material sound velocity in/us Aluminum Bismuth Brass Cadmium Cast Iron Constantan Copper Epoxy resin German silver G lass, crown G lass,flint Gold Ice Iron Lead Magnesium Mercury Nickel Nylon Paraffin Platinum Plexiglass Polystyrene Porcelain PVC Quartz glass Rubber, vulcanized Silver Steel, common Steel, stainless Stellite Teflon Tin Titanium Tungsten Zinc W a ter 40 m/s 0.250 0.086 0.173 0.109 0.180 0.206 0.184 0.100 0.187 0.
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Dakota Ultrasonics WARRANTY INFORMATION • Warranty Statement • Dakota Ultrasonics warrants the MX-5 DL against defects in materials and workmanship for a period of five years from receipt by the end user. Additionally, Dakota Ultrasonics warrants transducers and accessories against such defects for a period of 90 days from receipt by the end user.
MATERIAL SAFETY DATA SHEET N/A = not applicable or not available (To comply with 29 CFR 1910.1200) SECTION 1 – PRODUCT IDENTIFICATION NFPA Hazardous Materials Identification System (est) Health……………………0 Flammability…………….0 Reactivity………………..0 Product Name: SOUNDSAFE Generic Name: Ultrasonic Couplant Manufacturer: Sonotech, Inc. 774 Marine Dr.
