Ametek USB Lab B.O.S.S. User manual

USB Lab B.O.S.S.
OS-100WX and OS-100WX-HD
USB Brinell Optical Scanning System
Operation Manual
®
Newage
hardness testing

This publication is protected by copyright, and all rights are reserved. No part
of it may be reproduced in any form without express written consent from
Newage Testing Instruments, Inc.
Newage Testing Instruments, Inc. reserves the right to alter designs, materials,
and specifications when conditions warrant, without notice.
Newage Testing Instruments, Inc. makes no representations or warranties,
either expressed or implied, with respect to this publication and accompanying
software and specifically disclaims any implied warranties of merchantability or
fitness for any particular purpose. This publication and accompanying software
are sold “as is”, and Newage Testing Instruments, Inc. will in no event be liable
for direct, indirect, incidental, or consequential damages resulting from any
defect, error, or failure to perform.
The software described in this publication is furnished under license and may
only be used in accordance with the terms of such license.
BOSS® is a registered trademark of Newage Testing Instruments, Inc.
Windows® is a registered trademark of Microsoft Corporation.
Newage Testing Instruments, Inc. is owned by AMETEK, a publicly traded
corporation. Neither the corporation nor AMETEK are affiliated, in any way, with
any other group or entity representing themselves or being referred to by the
philosophical term “New-Age.”
Newage Testing Instruments, Inc.
820 Pennsylvania Blvd, Feasterville
PA 19053 USA
Tel: [phone]; Fax: 215-354-
1803
[email protected]
www.hardnesstesters.com

SETUP AND BASIC OPERATION
1.1 Introduction................................................................................ 1
1.2 What’s Included .......................................................................... 1
1.3 System Requirements................................................................. 1
1.4 Principles of Operation ............................................................... 1
1.5 Lab B.O.S.S. Installation, Software, if required ......................... 2
1.6 Initial Software Startup................................................................ 3
1.7 Procedures for a Test Measurement........................................... 4
FILE FUNCTIONS
2.1 Create a New File........................................................................ 5
2.2 Open an Existing File .................................................................. 9
2.3 Close an Open File...................................................................... 9
BASIC SCREEN OPERATIONS
3.1 Screen Controls ........................................................................ 10
3.1.1 Result and Tolerance Display........................................ 10
3.1.2 Clear Last Button ........................................................... 10
3.1.3 Measurement Displays................................................... 11
3.1.4 Reports Selection .......................................................... 11
3.1.5 Test Axis........................................................................ 11
3.1.6 Load and Magnification Display .................................... 11
3.1.7 Status bar ..................................................................... 11
3.2 Making Measurements.............................................................. 11
3.2.1 Automatic Measuring..................................................... 12
3.2.2 Manual Measuring ......................................................... 12
3.3 Update Test Parameters .......................................................... 13
3.3.1 Changing Load and Magnification................................. 13
3.3.2 Test Block Verification/Calibration ................................. 14
3.3.3 Adjust Camera .............................................................. 15
3.3.4 Selection Line Control Functions................................... 15
3.3.5 Camera Gain ................................................................. 15
3.3.6 Camera Shift ................................................................. 15
3.3.7 Color Camera................................................................ 15
3.4 Full Screen Operation ............................................................... 16
3.5 Screen capture and Magnification............................................ 16
MENU BAR OPERATIONS
4.1 View Menu ................................................................................ 17
4.1.1 Advanced Statistics Software (Optional) ....................... 17
4.2 Setup Menu............................................................................... 18
4.2.1 Average Menu (Optional) ............................................... 18
4.2.2 Test Setup ...................................................................... 19
4.2.3 Tolerances...................................................................... 19
4.2.4 Scale Select ................................................................... 20
4.2.5 Communications Setup ................................................. 20
4.2.6 Select Settings............................................................... 20
4.3 Data Menu................................................................................. 21
4.3.1 Clear Last Test ............................................................... 21
4.3.2 Clear Test Number ......................................................... 21
4.3.3 Clear All Tests ................................................................ 21
4.3.4 Statistics ........................................................................ 22
4.3.5 Part Information ............................................................. 22
APPENDIX
A: Troubleshooting, Repairs............................................................ 24
B: File Layout .................................................................................. 25
C: B.O.S.S. Tether Option............................................................... 26
W: Limited Warranty........................................................................ 27

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Newage Testing Instruments, Inc.
SECTION 1: SETUP AND BASIC OPERATION
1.1 Introduction
Welcome to the Newage® Instruments Computer-Assisted Measurement System Program, a Windows™-based image
acquisition and measurement software for B.O.S.S.
®
(Brinell Optical scanning System). This software was developed to
enhance the capabilities of your hardness testers by allowing you to automate the measurement of test impressions, reduce
operator influence on test results, and transfer test results directly to a PC for real time, on-screen data management.
It is assumed that the operator has a basic understanding of Windows. If you are unfamiliar with how to use a PC, please
refer to your Windows manual for instructions.
The B.O.S.S. computer program is file based. All setup parameters
(such as hardness scale, tolerance limits, part information, etc.) are saved
with the individual file they are associated with.
1.2 What’s Included
The complete package consists of :
1 - Brinell scan head (see detail at right)
(regular "Lab Boss", or small nose "Lab Small")
1 - CD or flash drive with BOSS software and drivers
1 - Operation Manual
1.3 System Requirements
Computer: Windows XP or Windows 7 and USB-2 port
1.4 Principles of Operation
The B.O.S.S. System uses a scanning head attached to a computer to measure Brinell impression widths. The
B.O.S.S.- System is for accurate impression measurement, and data storage/printing only. It does not perform any
tests by itself. Operation of the hardness tester remains as described in it’s own operation manual. Please refer to it
for tester setup and operation.
The B.O.S.S. can be used in either manual or automatic mode. The Brinell impression is measured in both axes and
the value averaged and converted to a hardness value. The accuracy is affected by the surface condition of the test
specimen. Too rough a surface will cause the tester to report the reading is not good due to the surface condition.
"Lab Small" style
without removable
base
"Lab Small" style
with removable
base
Standard
"Lab Boss" style

2B.O.S.S.
(R) Operation Instructions
1.5 Lab B.O.S.S. Installation, Software, if required
Instructions for software installation, if necessary, on included media. See ReadMe. rtf file.

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Newage Testing Instruments, Inc.
1.6 Initial Software Startup
Setup automatically sets magnification to be Lab BOSS
1) Double click the icon to start the program.
2) The program will open up to the last file that was in use. If no data files have been created, the operator can
create a new file. (See Sec 2.1.1 Create a New File) Hardness test results will be added to the database of the
current open file.
FOR SMALL-NOSE SCAN HEAD BOSS:
If the unit has a small nose scan head (LAB SMALL), the objective must be changed in the Update Dialog Box from
Lab BOSS to Lab Small. Please refer to section 3.3.1 for details.
HD UNITS:
Do not select "HD BOSS" under magnification.

4B.O.S.S.
(R) Operation Instructions
1.7 Procedures for a Test Measurement
1.7.1 For Automatic Measurement
(Operator should also refer to following
sections for setting up new files)
Use your Brinell tester to perform a
test and create a test impression.
When you move the BOSS head into
position over the sample, the image
of the impression should appear on
the monitor. Click on the Measure
button on the right side of the
computer screen or click the button
on the scan head. The indicators
defining the indentation edge will
appear. If they are correctly placed,
accept the reading by clicking on the
Accept button. The reading will be
displayed with the scale designation
on the top left corner and, if
selected, the value converted to an
alternate scale. If the automatic
positioning of the indicators is not
accurate the operator can click the
right mouse button (with the cursor
inside the image area) to clear the
measurement indicators and restore a
live image, reposition the BOSS head
and press the measure button again
or perform a manual measurement.
(See below.) Press the Accept button
to complete the test. To see the test
recent measurement results, select
the View menu option(s) from the
main menu bar.
1.7.2 For Manual
Measurement
After a test has been made with the
tester and the image to be measured is
displayed on the monitor, the lines can
be manually positioned without using the Measure Button. The operator must make a judgement as to the
location of the edges of the impression and click the mouse at the top, bottom, right and left. The small X
mark on the center of the screen must fall within the area of the impression to be measured. Otherwise the
operator must use the forced positioning arrows near the top right of the screen. After the first line has been
placed, the image freezes on the screen. After positioning lines on the sides as well as the top and bottom,
accept the reading or click the right mouse button to return to the live image. To see the data select the View
menu option(s) from the main menu bar.
Manual Measurement
Automatic Measurement

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Newage Testing Instruments, Inc.
SECTION 2: FILE FUNCTIONS
The Main Menu Bar at the top of the screen contains 5 selections: File, View, Setup, Data, and Help. They can be
accessed with the mouse by clicking on the selection. Click on one of them to open up it’s individual menu. The File
Menu consists of 7 different functions: New, Open, Close, Print, Print Preview, Print Setup, and Exit, as well as a listing of
the last 4 files that have been in use.
2.1 Create a New File
1) Select New from the File Menu. The Create a New Test File dialog box will appear.
2) Type in the name of the file (8 characters maximum) using the .csv extension and select the OK button (or press
Enter.)
3) You are prompted for what set of parameters to use. You can select USE-CURRENT-PARAMETERS to enter the
file parameters from the most recently used file; you are then prompted for a new comment. If you select to
ENTER-NEW- PARAMETERS you can set up a completely new set of parameters. (See Following Section.)
Finally, you can select to Retrieve Parameters. (Optional - appears grayed out when not activated.) When
activated you are prompted to enter the file name from which to retrieve the parameters. You are able to enter a
new comment for this selection also.
4) The next dialog box requires you to Select a New Scale. Choose one of the Primary Scales listed on the left by
highlighting it with the mouse. If you would like the test result automatically converted to another scale, highlight
one of the Converted Scales listed on the right .

6B.O.S.S.
(R) Operation Instructions
You will then be prompted for Data Part File Information. This information can be used to keep track of Part Number,
Description, Order Number, Comments, etc., related to this file. These headings will appear on printouts. Data entry
is not required. Select OK when done.
Clicking on the checkbox for “Prompted” will cause this window to appear after each test so the operator can enter relevant
data. Selecting "Sort by Prompt" will sort data in the printouts by the prompts so commented data can be readily identified.
Note: You may create custom headings by selecting the Field Names button, highlighting the name you wish to change,
and typing in the new heading. To make the new headings you’ve typed the default headings for all new files you
create, select Change Defaults. Use Defaults will revert headings you’ve just typed to the current default headings.

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The scale abbreviations which may be listed are:
HB = Brinell Scale for BOSS
DIA = Diameter Measurement for BOSS
INCH = Measurement in Inches
for linear measurement
MM = Measurement in Millimeters
for linear measurement
HRC = Rockwell C scale
HV = Vickers Scale for use with B.O.S.S.
HK = Knoop Scale for use with B.O.S.S.
HRB = Rockwell B scale
HRA = Rockwell A scale
HR15N, 30N, 45N = Rockwell N scales
HR15T, 30T, 45T = Rockwell T scales
HRD = Rockwell D scales
HRE = Rockwell E scales
Select OK when done.
NOTE: The scale cannot be changed for a data file that contains test results. The operator will be prompted to
change files if he tries to change scales with data in the file
5) After selecting the scale you will be prompted for
Average Mode. The operator may select to record
averages of multiple tests rather than the individual
tests. Enter a value into the Group Size. The radio
buttons on the remaining box are enabled. The
selections are as follows:
Keep All
The default setting. Returns the Average Mode to
the standard mode
Eliminate Highest and Lowest Values
When 3 or more tests are selected to be averaged
the system will remove the highest and lowest
values from the group average. For example, if the
average is set for 5, then 3 results will go into the
average. If an average of 2 is selected the average function has no effect.
Eliminate furthest from the average
Once the testing is completed the system calculates the average and removes the one test that is furthest from that
average. If an average of 2 is selected the average function has no effect
Eliminate if standard deviation exceeds [selection]
The operator is prompted to enter a maximum standard deviation value. When the testing is done the value farthest from
the standard deviation allowable is removed. If all the values fall within the standard deviation then none are removed.
6) After selecting the scale, you will be prompted to Set Tolerances. The program uses these settings for statistical

8B.O.S.S.
(R) Operation Instructions
calculations and for HI, LO, and OK indications for individual test results.
When the Advanced Statistics Option has been purchased the X-Bar/R
Chart uses these settings to plot the “high” and “low” test results as red
points on the graph; “acceptable” test results are plotted as green points.
You may also set a low warning and high warning number - those test
results are indicated by a gray color on the Advanced statistics output.
The “Warning” test results do not affect statistical calculations.
Select the desired button, key in the hardness value, and select OK when
done. Repeat this sequence for tolerance setting.
When the Acknowledgment Required box is checked the operator will
have to acknowledge every time an out-of-tolerance result is produced.
The operator can also enter the default error-checking value to limit the
relative size of the two axes on the Vickers scale.
Operators may also adjust the default tolerance setting that controls the
allowable difference between the two Vickers axis widths. Any value may
be entered.
NOTE: Entering or leaving the values of zero will deactivate the Tolerance
function. All readings will then be assigned OK status.
After setting the tolerance values, select OK to proceed.
7) Next the operator is given a chance to update the test parameters:
load and camera objective. It is important to select the proper parameters
for the scale that the test was performed in on the hardness tester.
Otherwise the final measured test result will be incorrect.
To change the default values, click on the arrows with your mouse. A
selection of all the possible values will appear. For each scale the operator
has selected the available selections that appear in these selections for the
load, time and magnification will change.
When testing with a Regular BOSS unit the operator must use “Lab
BOSS” for the magnification and with a Small-nose BOSS the operator
must use the “Lab Small” selection.
8) Finally the operator has the opportunity to enter a comment. This
comment applies to the entire setup file and is used on reports.

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Newage Testing Instruments, Inc.
2.1.1 Create a New File - Pin Brinell Testing (Optional feature)
If the operator is using the BOSS for testing
impressions from the Pin Brinell, the DIA
scale should be selected, then the
conversion must be PIN for the Pin Brinell.
The next pop-up provides the opportunity
to select the pin type: D, E, F, G, or H pins,
the type of indenter, standard or Carbide
(STD, CAR) and the configuration of the
tester, Impact or Clamp (IMPACT, STATIC)
and the material (STEEL or IRON). When
setup of the PIN-scale is complete,
proceed like any other scale.
2.2 Open an Existing File
1) Select Open from the File Menu.
2) Choose the desired file to open by highlighting it from the list on the left with the mouse or by typing in the file name.
3) Open the file by selecting the OK button or by double clicking on the file name in the list.
NOTE: If the file you want to open is one of the 4 files listed in the File Menu, simply click on it or press the
corresponding number key to open it.
NOTE: If you open a new file with another file already open, the current file will be automatically saved and closed.
2.3 Close an Open File
1) Select Close from the File Menu. The file is immediately closed leaving the program still running and on-
screen. The operator may then select a new file or exit the program.
NOTE: The operator cannot exit the program by double clicking in the upper left corner of the screen. He must
use the FILE/Exit routine

10 B.O.S.S.
(R) Operation Instructions
SECTION 3: BASIC SCREEN OPERATIONS
The buttons on the main screen are used for:
• basic testing
• calibration and screen setup
• accessing certain user adjustable parameters
The main screen has many controls. A brief description is as follows
NOTE: Select 2x for BOSS HD
3.1 Screen Controls
3.1.1 Result and Tolerance Display
Displays the current test result, any tolerances set in the main menu under
Setup, and the test result converted to another scale (If a conversion value
was selected). The current test result displays green if it is within tolerances,
yellow is within warning tolerances and red if outside of tolerances. If no
tolerances are setup the result is displayed in white.
3.1.2 Clear Last Button
This selection acts the same as Data Menu Function - Clear Last Test.

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3.1.3 Measurement Displays
These displays show the current distance between the lines in the horizontal
and vertical axes. If HK, IN or MM scales are selected, only one axis is
shown for HB or Diameter, only D is shown.
3.1.4 Reports Selection
This function is the same as the View menu selection from the top menu. It
will display the currently selected reports. (Refer to Section 4.1.)
3.1.5 Test Axis
Between the Measure and Accept Buttons is a display of the test axis the
program is set to measure. If the operator encounters impressions or
structures that need to measured in another axis, or in a different number of
axes, he must select the button indicated with the question mark to change
the axis selection. Note: it is possible to force incorrect measurements through changing the number of axes
so be careful. This selection changing to a new default if the operator changes scales.
3.1.6 Load and Magnification Display
This display (at left) shows the currently selected test values for the
scale being used. The operator has an opportunity to change these
values when setting up a new file. It is important to make any
necessary changes through the Update Button if the operator has
changed any parameters on the test being made prior to the beading.
False test results can be obtained by failing to set these parameters
correctly.
3.1.7 Status bar
The bottom right corner of the screen has a menu bar that shows the current selections for: file name, test
scale, and test number.
3.2 Making Measurements
The first step is to orient the grain on the test sample to the scan head. The grain,
if any should run from lower left to upper right. A diagram on the screen provides
a reminder

12 B.O.S.S.
(R) Operation Instructions
3.2.1 Automatic Measuring
The measure button always appears when the scale is selected for HB or DIA. Press the Measure Button to
automatically perform the measurement of the Brinell impression. With the BOSS system, after the measuring
indicators are displayed, if they are not properly positioned, press the right mouse
button to clear the indicators and return to a live image. Press the Accept Button to
enter the reading. The impression must fall within all four quadrants or he will not
be able to automatically position all the measurement marks. (See at right.) Then
the operator will need to use the positioning arrows near the top right of the screen.
When the Measure
Button is selected the
selection marks show
the identified edge of
the test sample. The
diameter is
automatically displayed in addition to the hardness value (unless the diameter is selected in the scale selection
as the primary scale in which case the diameter measurement appears in the measurement display and result
display) If the selection marks are not accurately positioned in automatic mode the operator must right click on
the mouse to clear the selection and re-measure. Otherwise the operator must select the Accept Button
3.2.2 Manual Measuring
With the B.O.S.S. the linear measurement the lines can be manually
positioned without using the Measure Button. The operator must make a
judgement as to the location of the edges of the impression and click the
mouse at the top, bottom, right and left. The impression must fall within all
four quadrants or he will not be able to automatically position all the
measurement marks. (See at right.) Then the operator will need to use the
positioning arrows near the top right of the screen. (See Section 3.8)
NOTE: After the auto-measure or after the first line has been placed, the
image of the impression is captured on the screen (no longer a live
image). The other lines can be placed or adjustments to the
measurement made to the captured image. Accept the reading or click
the right mouse button to return to the live image.
Manual Selection Marks
Automatic Selection
Marks

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3.3 Update Test Parameters
3.3.1 Changing Load and Magnification (under Update Button)
The Update button at the left of the screen allows the operator to view and change selected test parameters that the
computer uses to determine the hardness value: the load and magnification (current selections for load and
magnification can be seen under the UPDATE button).
To change the selection, click on the UPDATE button then the pull down
selection for LOAD. In these pull-downs the operator can click on the
Load, Load Time, or the Magnification selections with the mouse to
change to another option. A list of all the possibilities for each is displayed
in a drop-down list.
Note separate settings for Lab
BOSS and Lab Small
Lab BOSS,
BOSS HD,
Lab Small,
and
Lab SMALL HD

14 B.O.S.S.
(R) Operation Instructions
3.3.2 Verification/Changing Calibration (under Update Button)
IMPORTANT NOTE: Whenever the scan head part of the B.O.S.S. is swapped
out or repaired, it must be calibrated to the computer.
1) Using the B.O.S.S. calibration block, place the scan head on the test block
so it fits into the circular footprint provided. This footprint helps to reduce
scratching on the indentation which can lead to reduced calibration
accuracy. Orient the test head so the grain appears to be running in the
correct direction on the monitor.
2) Use the mouse to click on the measurement points or select the measure
button.
3) Compare the numbers in the measurement window on the right side of the
screen to the actual dimensions of the test block. If they are within 0.02 mm
the system does not need calibration. If calibration is needed, see the
following.
4) Select the Calibrate Button under the Update button on the left of the main
screen. The program will then prompt for a password.
5) Key in the actual dimension. Select F1 OK when done. The number in the
measurement window on the right side of the screen will change to indicate
the corrected number.
6) When finished, select F1 OK to complete the procedure.
B.O.S.S. STYLES
(see previous page)
When testing in Brinell scales with
the regular BOSS unit you must use
the “Lab‑Boss” setting for the
objective. With the small nose BOSS
you must use the "Lab Small”. These
settings are marked on the display.
B.O.S.S.
Calibration Block
Calibrate Button as seen
after pressing the
Update Button
"Lab Small" style
without removable
base
"Lab Small" style
with removable
base
Standard
USB "Lab Boss" style