Dakota MAX II User manual

OPERATION MANUAL
DAKOTA ULTRASONICS
MAX II
Ultrasonic Bolt Tension Monitor
P/N P-197-0002 Rev 1.0, June 2015

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TABLE OF CONTENTS
CHAPTER ONE INTRODUCTION......................................................................1
1.1 GENERAL DISCLAIMER..........................................................................................................1
1.2 SAFTEY................................................................................................................................1
1.3 WARRANTY..........................................................................................................................2
CHAPTER TWO ABOUT THIS MANUAL..........................................................3
2.1 NEW TO ULTRASONICS?.......................................................................................................3
2.2 NEW TO FASTENER MEASUREMENT?.....................................................................................3
2.3 MAX II OVERVIEW................................................................................................................3
2.4 TOP &SUBMENU REFERENCE ..............................................................................................6
CHAPTER THREE QUICK START GUIDE........................................................8
3.1 OVERVIEW...........................................................................................................................8
3.2 GETTING THE MAX II READY.................................................................................................8
3.3 SETTING UP THE MAX II.......................................................................................................8
3.4 CREATING A NEW GROUP TO STORE MEASUREMENTS ........................................................12
3.5 SETTING THE APPROXIMATE LENGTH..................................................................................19
3.6 MEASURING REFERENCE LENGTHS.....................................................................................22
3.7 MEASURING ELONGATIONS.................................................................................................23
CHAPTER FOUR KEYBOARD, MENU, & CONNECTOR REFERENCE........25
4.1 MENU KEY (OPERATION &SUB MENUS)..............................................................................25
4.2 CAL –MENU......................................................................................................................27
4.3 MATL (MATERIAL)–MENU .................................................................................................27
4.4 GEOM (GEOMETRY)–MENU..............................................................................................28
4.5 DISP (DISPLAY)–MENU.....................................................................................................29
4.6 TUNE –MENU...................................................................................................................30
4.7 GATES –MENU ................................................................................................................30
4.8 AUTO –MENU...................................................................................................................31
4.9 SETUP –MENU.................................................................................................................32
4.10 DATA –MENU.................................................................................................................32
4.11 UTIL (UTILITIES)–MENU..................................................................................................33
4.12 XFER (TRANSFER)–MENU..............................................................................................34
4.13 ON/OFF KEY...................................................................................................................34
4.14 FREEZE KEY ..................................................................................................................34
4.15 SETUPS KEY..................................................................................................................35
4.16 AUTO SET KEY...............................................................................................................35

4.17 DATA KEY ......................................................................................................................35
4.18 STORE KEY....................................................................................................................35
4.19 CLEAR KEY....................................................................................................................35
4.20 MEAS (MEASUREMENT MODE)KEY..................................................................................35
4.21 OK KEY...........................................................................................................................36
4.22 ESC KEY.........................................................................................................................36
4.23 WHEEL KEYS……………………………. ..........................................................................36
4.24 ENTER KEY ....................................................................................................................36
4.25 NAVIGATING THE HOT MENUS ..........................................................................................36
4.26 TOP &BOTTOM END CAPS...............................................................................................38
TRANSDUCER CONNECTOR......................................................................................................38
BATTERY COVERS (BACKUP)....................................................................................................38
USB TYPE BCONNECTOR .......................................................................................................38
RS-232 SERIAL CONNECTION (LEMO 1–5PIN) ......................................................................38
ALARMS CONNECTION (LEMO 1–5PIN)..................................................................................39
ANALOG OUTPUT (LEMO 1–5PIN) .........................................................................................39
POWER CONNECTOR (LEMO 1–2PIN)....................................................................................39
CHAPTER FIVE THEORY OF OPERATION ...................................................40
5.1 ULTRASONIC MEASUREMENT OF BOLTS..............................................................................40
5.2 FEATURES OF THE MAX II..................................................................................................40
5.3 ULTRASONIC WAVES ..........................................................................................................41
5.4 MEASUREMENT MODES......................................................................................................41
CHAPTER SIX BOLT PREPARATION............................................................43
6.1 USE OF ULTRASONIC COUPLANT ........................................................................................43
6.2 TRANSDUCER CONTACT REQUIREMENTS............................................................................43
6.3 BOLT END REFLECTORS.....................................................................................................45
CHAPTER SEVEN TRANSDUCER SELECTION............................................47
7.1 SELECTING THE TRANSDUCER............................................................................................47
CHAPTER EIGHT MEASURING SYSTEM ZERO (CALIBRATION)...............48
8.1 INTRODUCTION ..................................................................................................................48
8.2 CALIBRATION /ZERO MISNOMER.........................................................................................48
8.3 CREATING A GROUP TO DOCUMENT ZERO (CALIBRATION)DATA..........................................49
8.4 AUTO ZERO/CALIBRATION..................................................................................................57
8.5 USING A STANDARD BOLT ..................................................................................................62
8.6 CALIBRATION /ZERO BARS &TRIPLE SIDED GLASS BLOCK .................................................77
CHAPTER NINE TEMPERATURE COMPENSATION ....................................93
9.1 PURPOSE ..........................................................................................................................93

9.2 MANUAL MODE ..................................................................................................................93
9.3 SEMI AUTOMATIC MODE.....................................................................................................95
9.4 AUTOMATIC MODE..............................................................................................................96
CHAPTER TEN BOLT MATERIAL CALIBRATION.........................................98
10.1 WHY CALIBRATE? ............................................................................................................98
10.2 VELOCITY CALIBRATION....................................................................................................98
10.3 STRESS FACTOR CALIBRATION........................................................................................102
10.4 TEMPERATURE FACTOR CALIBRATION.............................................................................106
CHAPTER ELEVEN LOAD MEASURMENT..................................................109
11.1 CALCULATING LOAD FACTOR..........................................................................................109
11.2 CALIBRATING LOAD FACTOR (FIELD CALIBRATION)..........................................................111
11.3 PERFORMING A FIELD CALIBRATION................................................................................112
CHAPTER TWELVE MEASUREMENT & WAVEFORM DISPLAY ...............127
12.1 QUANTITIES OF MEASUREMENT ......................................................................................127
12.2 DISPLAY VIEW OPTIONS .................................................................................................128
12.3 ADJUSTING THE DISPLAY................................................................................................134
12.4 GAIN..............................................................................................................................139
12.5 GATES...........................................................................................................................143
12.6 THRESHOLDS.................................................................................................................146
12.7 INTERPRETING THE WAVEFORM......................................................................................149
12.8 MANUALLY LOCATING THE ECHO ....................................................................................151
12.9 AUTOMATIC ECHO OPTIMIZATION....................................................................................153
12.10 UNLOADED LENGTH AND ELONGATION MEASUREMENTS................................................156
CHAPTER THIRTEEN ADDITIONAL FEATURES ........................................157
13.1 QUALITY/CORRELATION (TRANSDUCER PLACEMENT) ......................................................157
13.2 BRIGHTNESS..................................................................................................................157
13.3 COLOR...........................................................................................................................158
13.4 DIM................................................................................................................................160
13.5 GRAPHICS OPTIONS (LOOK &FEEL) ................................................................................161
13.6 PULSE ...........................................................................................................................162
13.7 PULSER VOLTAGE..........................................................................................................163
13.8 DAMPING .......................................................................................................................165
13.9 DIGITIZER ......................................................................................................................165
13.10 POLARITY ....................................................................................................................167
13.11 ALARM MODE...............................................................................................................168
13.12 ANALOG OUTPUT .........................................................................................................170
13.13 KEY CLICK ...................................................................................................................171
13.14 DATE &TIME................................................................................................................172

13.15 UPGRADE GAUGE ........................................................................................................173
13.16 FREEZE &CAPTURE.....................................................................................................174
13.17 STORAGE ....................................................................................................................175
CHAPTER FOURTEEN DATA STORAGE – SETUP, EDIT, & VIEW FILES 177
14.1 INTRODUCTION TO GROUP (SPREADSHEET)FORMAT.......................................................177
14.2 CREATING A NEW GROUP...............................................................................................177
14.3 STORING A READING ......................................................................................................180
14.4 VIEWING STORED READINGS...........................................................................................181
14.5 DELETING GROUPS (FILES)............................................................................................183
14.6 EDITING A GROUP (FILE)................................................................................................186
14.7 CHANGING THE ACTIVE FILE -OPEN................................................................................188
14.8 CLOSING AN ACTIVE FILE -CLOSE ..................................................................................190
CHAPTER FIFTEEN SETUPS – CREATE, STORE, EDIT, & RECALL........191
15.1 INTRODUCTION TO SETUPS.............................................................................................191
15.2 OPENING A SETUP .........................................................................................................191
15.3 SAVING A SETUP............................................................................................................192
15.4 DELETING A SAVED SETUP.............................................................................................195
15.5 USING THE DEFAULT SETUP...........................................................................................197
15.6 SELECTING A LANGUAGE................................................................................................198
CHAPTER SIXTEEN SOFTWARE, FILE TRANSFER, & UPGRADES ........200
16.1 COMPUTER SYSTEM REQUIREMENTS..............................................................................200
16.2 INSTALLING DAKVIEW.....................................................................................................200
16.3 COMMUNICATING WITH MAX II .......................................................................................200
16.4 USING THE XFER MENU (MAX II)...................................................................................201
16.5 SELECTING STORAGE DEVICE ........................................................................................201
16.6 COPYING FILES (SETUPS,DATA,&SCREENSHOTS) ........................................................202
16.7 UPGRADING THE MAX II.................................................................................................204

CHAPTER ONE
INTRODUCTION
The Dakota Ultrasonics model MAX II is used to measure the stretch (elongation,
load, stress and %strain) of a fastener under tension. This is accomplished
ultrasonically by sending an ultrasonic wave down the length of the fastener and
accurately measuring the change in transit time between an unloaded versus loaded
fastener/bolt, and calculating a physical stretch. The objective for using ultrasonics,
over conventional/mechanical methods is accuracy. Most conventional methods
refer to a torque value which has limited accuracy due to the coefficient of friction.
The coefficient of friction is difficult to determine, as it depends on the control and
application of lubrication.
The MAX II avoids the coefficient of friction entirely, using the transit time of a wave,
Hooke’s law, and Young’s modulus to accurately calculate the stretch on a bolt.
Since the MAX II cannot physically stretch a bolt, both conventional/mechanical
methods and the MAX II are complimentary and used in conjunction.
Dakota Ultrasonics maintains a customer support resource in order to assist users
with questions or difficulties not covered in this manual. Customer support may be
reached at any of the following:
Dakota Ultrasonics Corporation
1500 Green Hills Road, #107
Scotts Valley, CA 95066 USA
Telephone: [phone]
Facsimile: [phone]
www.dakotaultrasonics.com
1.1 General Disclaimer
The manual should be read and understood prior to using the MAX II. This operating
manual provides the user with all the general information necessary to use and adjust
the designed features. However, this manual is not a certified NDT/Bolting training
course, nor is it intended to be one. Training, according to company requirements, is
recommended. The responsibility for proper use of the instrument rests solely on the
user.
1.2 Safety
Using the MAX II while standing in water or in a wet environment can result in serious
electric shock, injury, and even death.
Operating the MAX II with damaged or inadequate cables and power source can
result in serious electric shock, injury, and even death.

Failure to read this manual and understand the proper operation of the MAX II can
result in inaccurate measurements, and lead to decisions which cause property
damage, personal injury, or even death.
Use of the MAX II for any other purpose, or in any other manner than described in
this manual invalidates the warranty and can result in serious electric shock, injury,
and even death.
1.3 Warranty
The Dakota Ultrasonics MAX II carries a two year limited warranty. The warranty only
applies to MAX II units being operated as described in this manual. Software and
hardware failures of the unit will be repaired or replaced at Dakota Ultrasonics
discretion. Dakota Ultrasonics will not be held liable for any damage caused,
interruption of business, loss of profits, etc., resulting from such failures. Dakota
Ultrasonics will not be liable to repair or replace a unit, which has been damaged,
used inappropriately, or subject to unauthorized repair by the purchaser.

3
CHAPTER TWO
ABOUT THIS MANUAL
This chapter is intended to help you make the best use of this manual. Readers may
have different knowledge of ultrasonic bolt measurement and may find parts of this
manual repetitive or unnecessary.
2.1 New To Ultrasonics?
There are a variety of ultrasonic applications currently being utilized in today’s
industry. For example weld inspection, thickness measuring, immersion testing of
flaws, etc. The use of ultrasound to measure forces in fasteners is relatively new
compared to the previously mentioned traditional applications.
Ultrasonic measurement of bolts provides an extremely accurate means of
determining fastener load, provided the correct techniques are utilized. As a new
user, careful consideration of this entire manual is highly recommended.
2.2 New to fastener measurement?
Assuming you are familiar with ultrasonics, but unfamiliar with fastener measurement,
the chapters on transducer selection and the theory of operation can be skipped
entirely.
The MAX II measures load on the fastener by measuring the amount the fastener
stretches. As load is applied to the fastener, it stretch’s just as a spring would
stretch. The stretch is proportional to the load while the load is less than the elastic
limit of bolt. By measuring the stretch of the fastener and knowing the physical
properties of the fastener, the load of the fastener can be calculated. The MAX II
measures the fastener stretch by ultrasonically measuring the change in length.
Be sure to setup and experiment with a test fixture of some kind as a means of
becoming familiar with your MAX II.
2.3 MAX II Overview

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In order to understand how to operate the MAX II, it’s best to start off with an
understanding of what it is we’re looking at exactly. The MAX II has a lot of great
features, tools, and flexibility to assist you with all of your bolting applications. Let’s
have a brief look at the screens you’ll be looking at most often:
A. Repeatability/Stability Indicator – Indicates the reliability of the measured
bolt length. When all the vertical bars are fully illuminated and the last digit on
the digital thickness value is stable, the MAX II is reliably measuring the same
value on a consistent basis.
B. Battery Icon – Indicates the amount of battery life the MAX II has remaining.
C. Temperature – Indicates the current temperature of either the temperature
sensor, or manual value entered.

MAX II Bolt Tension Monitor
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D. Alarm – Indicates that the alarm feature has been activated and currently in
use.
E. RF A-Scan Display (split screen) – Displays the radio frequency sound wave
reflection returned the opposite end of the bolt being measured. The RF view
displays both the positive and negative cycles.
F. Quantity – Displays the current quantity setting used (elongation, load, stress,
strain or time).
G. Digital Measurement – Display in inches, millimeters, KSI, KIPS, %strain,
time (nanoseconds).
H. Rectified A-Scan Display – Displays either the positive or negative half cycle
wave reflection returned from the opposite end of the bolt being measured,
depending on the polarity selected.
I. Time & Date – Feature to display either the time, date, or both time and date
on the main measurement screen.
J. Hot Menu items – We call this menu section our “hot menu”, as these items
are the most commonly adjusted features, requiring quick access from the
user. They can be displayed and scrolled by pressing the MEAS key at any
time. The MEAS key advances forward and the ESC key backwards to the
next hot menu item. Alternatively, the UP,DOWN, LEFT and RIGHT
arrow keys on the left button wheel can be used to either scroll through the
sub menu items, or advance to the next HOT MENU items list. There are 4
HOT MENU lists that contain the most commonly adjusted items from the
tabbed menus, and in the same order as the tabbed menus. Note: Some of
the lists contain multiple tabbed menu items in order to condense the number
of HOT MENU lists.
K. Units – Displays the current measurement units being used (English, Metric).
L. Gain & Step Size – The gain and increment step size can be continuously
used and adjusted at any time using the UP and DOWN arrow keys on
the right button wheel to scroll the value, and the GAIN key to activate the
Digit Edit screen to adjust the step size.
M. Scan Bar – Another view of bolt length in a deflection style horizontal bar.
This is a visual tool that would enable the user the ability to see the length
from a graphics perspective.
N. Large Digital Measurement – Display in inches, millimeters, KSI, KIPS,
%strain, time (nanoseconds).
O. Feature Status Bar – Indicates the features currently enabled and in use in
the following order:
Measurement Mode
Alarm
Capture (screen shots)
Quantity
Temperature

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Velocity (material)
P. Temperature – Depending on the display view selected full/split screen, the
temperature will be displayed in either of two different locations on the screen.
Q. Digital Measurement – In full screen view, the measurement will be displayed
in either of two different locations (full/split screen).
R. RF A-Scan Display (full screen) – Displays the radio frequency sound wave
reflection returned the opposite end of the bolt being measured. The RF view
displays both the positive and negative cycles.
2.4 Top & Submenu Reference
The following table is a quick menu reference guide. The MAX II has 11 top level
menu titles, and multiple submenu items as illustrated below. The MAX II also has 4
‘hot menu’ subsets of the same menu structure. These are the most commonly
adjusted submenu items from each of the top level menus. They can be quickly
accessed from the main measurement screen by pressing the LEFT and RIGHT
arrow keys multiple times using the left button wheel, and pressing the UP and
DOWN arrow keys on the left button wheel to select the appropriate submenu item.
Refer to Chapter Four for additional definitions and information on the keypad and
menu items.
1
st
Main Hot Menu
Additional Hot Menus
Note: “Log” is also listed in the 1
st
main Hot Menu, and is used to access data storage if no log file is
currently open, or display log or grid file if open.
Start >>
CAL MATL GEOM DISP TUNE GATES AUTO SETUP
ZERO MODE UNITS QUANTITY VIEW GAIN POLARITY AUTO SET OPEN
ZERO TYPE LOAD FACTOR BRIGHTNESS PULSE GATE 1 APPROX LEN SAVE
MEASURE
ZERO
VELOCITY LOAD OFFSET COLORS PULSER
VOLTAGE
THRESHOLD 1 MEASURE
MODE
DELETE
LOAD CAL
MODE
STRESS
FACTOR
AREA DIM DAMPING GATE 2 DEFAULT
SETUP
LOAD CAL
CALC
TEMP COEF EFFECTIVE
LEN
DELAY DIGITIZER THRESHOLD 2
WIDTH GATE 3 LANGUAGE
RECT WAVE THRESHOLD 3
DETECT MARK

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>> End
DATA UTILS XFER
NEW TEMP MODE BACKUP
SETUPS
EDIT ALARM COPY DATA
OPEN ALARM LOW COPY
SCREENS
CLOSE ALARM HIGH UPGRADE
GAUGE
DELETE ONE
FILE
ANALOG
OUTPUT
CAPTURE TO
FILE
DELETE ALL
DATA
KEY CLICK STORAGE
SET DATE ABOUT
SUMMARY SHOW DATE

8
CHAPTER THREE
QUICK START GUIDE
3.1 Overview
This section demonstrates the basic procedures for setting up and measuring bolts
using the MAX II. More in depth explanations pertaining to the individual functions
and features can be found in the chapters that follow.
Here we go!
3.2 Getting the MAX II ready
Making all the connections
In order to get the MAX II ready for operation; the following connections must
be made:
1) Remove the MAX II from the carrying case.
2) Connect the transducer cable to the transducer, and plug the lemo
connector into the gauge.
3) If a temperature sensor is being used, connect the sensor to the MAX II.
3.3 Setting up the MAX II
Please Read: In this section the MAX II will be setup in its simplest form. Remember
this is only a quick start guide to get the user up and measuring bolts. Before we
setup the gauge to measure basic elongation, the following assumptions must be
made: A preset material type will be used. The user will not be re-measuring the
fasteners at a later date to monitor relaxation of the joint over time. This eliminates
the need for an instrument zero/calibration. All these assumptions will be answered
and explained in detail in the chapters that follow.
Selecting the Quick Start Setup

MAX II Bolt Tension Monitor
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1) Press the ON/OFF key to power up the MAX II.
2) Press the MENU key once to activate the menu items tab. Press the MENU
key multiple times to tab right and the ESC key multiple times to tab left until
the SETUP menu is highlighted and displaying the submenu items.
Alternatively, press the LEFT and RIGHT arrow keys multiple times
using the left button wheel.
3) Use the UP and DOWN arrow keys multiple times using the left button
wheel to scroll through the sub menu items until OPEN is highlighted.
4) Press the ENTER key to display the list of setups.
5) Press the UP and DOWN arrow keys multiple times using the left
button wheel to scroll through the setup list until the QUICK START setup is
highlighted.
6) Press the ENTER key to display the confirmation screen.
7) Press the OK key to select the setup and return to the menu screen, or ESC
to cancel the selecting the setup.

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Selecting the Units
Note: The Quick Start setup, selected in the previous section, automatically
defaults to english units – inches. Follow the procedure below to change the
units to metric, if needed.
1) Press the MENU key multiple times to tab right and the ESC key multiple
times to tab left until the MATL menu is highlighted and displaying the
submenu items. Alternatively, press the MENU key once, followed by
pressing the LEFT and RIGHT arrow keys multiple times using the left
button wheel to scroll the tabbed menus.
2) Use the UP and DOWN arrow keys to scroll through the sub menu items
until UNITS is highlighted.
3) Press the LEFT and RIGHT arrow keys multiple times using the right
button wheel to scroll through the unit options IN (inches), IN HR (inches hi
resolution), MM (millimeters), and MM HR (millimeters hi resolution).
Note: The high-resolution options display an additional digit of resolution to the
measurement. This mode is typically used when measuring very short bolts
with very little elongation.
Selecting the Material Type

MAX II Bolt Tension Monitor
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This section allows the user the ability to select a material from a list of preset
material types. Keep in mind that we are measuring elongation only. If your
material is not in the list, select a similar material type. When measuring in
elongation mode, the measurement consists of a difference equation only
(Loaded Length – Unloaded Length = Length). Therefore, it doesn’t matter if
the ultrasonic length is different from the actual physical length, because the 
Length will be the same. Example: 2.0080” physical loaded length – 2.0000”
physical unloaded length = 0.0080” Length which is equivalent to 2.1080”
ultrasonic loaded length – 2.1000” ultrasonic unloaded length = 0.0080” 
Length.
1) Press the UP and DOWN arrow keys multiple times using the left
button wheel to scroll through the sub menu items until TYPE is highlighted.
2) Press the ENTER key to display the list material types.
3) Press the UP and DOWN arrow keys multiple times using the left
button wheel to scroll through the material list until the appropriate type is
highlighted.
4) Press the ENTER key to display the confirmation screen.
5) Press the OK key to select the type and return to the menu screen, or ESC
to cancel selecting the material type.

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3.4 Creating a New Group to Store Measurements
Now that the MAX II is all setup, this section will explain how to get started measuring
unloaded initial lengths. In order to do this, we need to create a group that contains
bolts. A group can have up to 250 bolts, each bolt containing 1 reference length (L-
REF), and up to 51 elongations. Keep in mind that the MAX II uses a group to store
measurements and all gauge settings at the time of measurement.
Creating a Group Name
1) Press the MENU key once to activate the menu items tab. Press the MENU
key multiple times to tab right, and the ESC key multiple times to tab left,
until the DATA menu is highlighted and displaying the submenu items.
Alternatively, press the MENU key once, followed by pressing the
LEFT and RIGHT arrow keys multiple times using the left button wheel to
scroll the tabbed menus.
Note: Pressing the key will automatically open the DATA tabbed menu.
2) Press the UP and DOWN arrow keys multiple times using the left
button wheel to scroll through the sub menu items until NEW is highlighted.
3) Press the ENTER key to display the New Group Edit Box.
4) Press the UP and DOWN arrow keys multiple times using the left
button wheel to scroll through the new Group List Items until NAME is
highlighted.
5) Press the ENTER key to activate the Alpha Edit Box.