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

USB Lab B.O.S.S.
OS-400WX and OS-400WX-LS USB
Brinell Optical Scanning System
Operation Manual
®

We:
of
METEKe
MEASUREMENT & CALIBRATION TECHNOLOGIES DIVISION
DECLARATION OF CONFORMITY
Ametek, Inc.
8600 Somerset Drive
Largo, FL 33773,
USA,
In accordance with the following Directive(s):
2004/108/EC The Electromagnetic Compatibility Directive
Hereby declare that:
The following Newage Brinell Optical Scanning System (Newage is a brand name owned by Ametek,
Inc)
Machine Part No.
B.O.S.S. OS-300\VE-7 & OS-300\VE-LS7
Serial Number: 1000 and up
Are in conformity with the applicable requirements of the following documents
Ref. No.
EN 61010-1:2010
Title
Safety Requirement for Electrical Equipment for measurement, control and laboratory use. General requirements
Name:
Position:
Done at
On
Douglas Tilghman
Division Vice President, Engineering
8600 Somerset Drive, Largo, Florida 33773, USA
March 21, 2013 Document ref. No. ER-428
The technical documentation for the machinery is available from:
Name:
Position:
Address:
Joel Frie
Division Vice President & Business Unit Manager
Ametek, Inc. Gydevang 32, 3450 Lillerod, Denmark

EUROPEAN DECLARATION OF CONFORMITY
NAME. ADDRESS OF MANUFACTURER AND LOCATION OF TECHNICAL CONSTRUCTION FILE
Ametek. Inc.
8600 Somerset Drive
Largo, FL 33773, USA, PHONE: [phone], FAX: [phone]
DESCRIPTION OF EQUIPMENT
Product:
Models: Newage, Brinell Optical Scanning System 8.O.S.S.: OS-300WE-7 & OS-300WE-LS7
Effective Date: August 2013
Serial Number: 1000 & IO0GS to 99990
HARMONIZED STANDARDS USED
A sample of this product has been assessed against the essential health and safety requirements of the Low Voltage and the
EMC Directives listed below. Based on conformity with the listed directives, Ametek, Inc. declares the products mentioned
above are in compliance with the following:
Machinery Directive 2006-42-EC
BS EN 61010-1: 2010 Safety Requirement for Electrical Equipment
This declaration of conformity is the result of testing and evaluation performed by PSE, Product Safety Engineering approved
CE testing laboratories and by Ametek, Inc. Newage is a brand name owned by Ametek, Inc.
Division Vice President, Engineering
Ametek, Inc.
8600 Somerset Drive, Largo, Florida 33773, USA
[phone] or Email: [e-mail] or FAX: [phone]
EUROPEAN SIGNATORY
Joel Frie
Division Vice President & Business Unit Manager
Ametek, Inc.
Gydevang 32,3450 Lillerod
Denmark
[phone] or Email: [e-mail] orFAX: [phone]
C•r11Uc•1• Nun,b9n 1•1•.01
Douglas Tilghman

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. 820 PennsylvaniaBlvd,
Feasterville PA 19053 USA
Tel: [phone]; Fax: 215-354-
1803
[e-mail] www.hardnesstesters.com
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.”

1SETUP AND BASIC OPERATION 1
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 3
1.6 Initial Software Startup 4
1.7 Procedures for a Test Measurement 5
2FILE FUNCTIONS 8
2.1 Create a New Test File 8
3ADDITIONAL SCREEN OPERATIONS 10
3.1 APPENDIX A: TROUBLESHOOTING, REPAIRS 16
3.2 REPAIRS AND SHIPPING INSTRUCTIONS 17
3.3 APPENDIX C: B.O.S.S. TETHER OPTION 18
3.4 APPENDIX W: LIMITED WARRANTY 19

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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
Standard
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
"Lab Boss" style
"Lab Small" style
without removable
base
"Lab Small" style
with removable
base
1.3 System Requirements
Computer: Windows 7, Windows 10 or Windows 11 and (2)USB-2 ports, Is PC only has one port a bus will be needed to have 2 USB
ports available just for installation.
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

B.O.S.S.(R) Operation Instructions
2
specimen. Too rough a surface will cause the tester to report the reading is not good due to the surface condition.

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1.5 Lab B.O.S.S. Installation, Software, if required
Instructions for software installation are on the USB drive provided with system.

B.O.S.S.(R) Operation Instructions
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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.

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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. Centerthe
impressionnearthemiddleoftheimage.Click
on theRedMeasurebuttonontherightsideof
thecomputerscreenorclicktheRedButton
onthescanhead.Theeightindicatorsdefining
theindentationedgewillappear.Iftheyare
correctlyplaced,acceptthereadingbyclicking
ontheRedbuttonasecondtimeor pressing
theAcceptbuttononthescreen.Thereading
willbedisplayedwiththescaledesignationon
thetop 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.

B.O.S.S.(R) Operation Instructions
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1.7.2 Manual Measurement
To take a manual measurement of
the impression. Place the Scan Head
over the impression and center it on
the screen. Use the mouse and left
click near the edge of the impression.
You will place measurement lines at
the 12, 3, 6, and 9 o’clock positions
on the impressions.
Manual
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. 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.
Line can be re-positions with the mouse
and also by clicking on the arrow keys on the computer keyboard. A ccept the reading or click the right mouse
button to return to the live image.
1.7.3 Aligning Surface texture to Scan Head
For Standard BOSS Scan Heads it is important 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. This enables
the Special lighting to minimize the surface texture and read
impressions on less-than-ideal surfaces more accurately.
This is much less critical on Small Nose Scan Heads. The lighting is
different, Made for smaller impressions and smoother surfaces.
There is a Visual reminder on the Measurement Screen to remind the
operator to correctly orient the Scan Head

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Measurement Text Box
Once a new set of measurements started a measurement” text box will appear on the
measurement screen. This will show the readings taken with the last measurement shown on
top. This Box can be dragged to any location on the screen and sized to fit your needs. You
can also set the readings shown by clicking in the “Show Last” section and typing in the
number required.
At any time clicking on the Red Button on the BOSS Scan Head the software
will return to the Measurement Screen

B.O.S.S.(R) Operation Instructions
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2 FILE FUNCTIONS
The Menu Bar onthe right side of the screen contains 4 selections: New Test File, Parameters, Export, and Preferences.
used to create files and change on screen functions. They can be accessed with the mouse by clicking on the
selection. Click on one of them to open up its individual menu. The New Test File consists of 4 different functions:
General, Part Ifo, Scale, and Measurement.
2.1 Create a New Test File
1) Select New Test File. This Create Test box will open with General Highlighted. You can create a new file of open an existing
file.
2) Type in the name of the file on the “Name line”
3) You can add a Work Order or File Comment that will appear on the report. The company name will be the Report header.
4) Clicking on “Store images in data file”will store an image file of each impression measured when the measurement is accepted.
5) Select “Next”to continue.

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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 . The software will default to PART#,
you can add additional lines, up to ten, by clicking on the + icon. Type in the Name, Value can be added later.
High light the line and click on the “Waste-Can” to delete lines . 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.
.

B.O.S.S.(R) Operation Instructions
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6) The next dialog box requires you to Select the Scale to measure. 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,
Click on the “Calculate Converted Scale”. Then highlight one of the Converted Scales listed on the right.
The scale abbreviations which are listed
H BW - Brinell Scale
DIA - Diameter Measurement of
impression
INCH = Measurement in Inches
for linear measurement
MM = Measurement in Millimeters
for linear measurement
PIN –Scale for measurement for
impressions made with a Newage Pin Brinell tester
Converted Scales
HRC - Rockwell C scale
HV = Vickers Scale
HK = Knoop Scale
HRB = Rockwell B scale
HRA = Rockwell A scale
HR15N, 30N, 45N = Rockwell N scales
HR15T, 30T, 45T = Rockwell T scales
HRD = Rockwell D scale
HRE = Rockwell E scales
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

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To advance, click NEXT to “Measurement” tab. The
operator may select to record averages of multiple
tests rather than the individual tests. Enter a value
into the Group Size. The buttons on the remaining
selections are enabled. The selections are as
follows:
Keep All
The default setting. Uses all measurement.
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.
Set Tolerance; After “Average” , you can seta Tolerances. The program uses these settings to showgreenforgoodreading
and Redfor badreadings.

B.O.S.S.(R) Operation Instructions
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and for HI, LO, and OK indications for individual test results. 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 statistics output.
The “Warning” test results do not affect statistical calculations.
When the Acknowledgment Required box is checked the operator will
have to acknowledge every time an out-of-tolerance result is produced.
NOTE: Entering or leaving the values of zero will deactivate the Tolerance
function. Allreadings will then be assigned OK status.
After setting the tolerance values, select Finish to proceed
Detect Elliptical Impressions
Click here to enter an out of roundness setting of ether 0.1 or 0.2 mm per ASTM recommendations.
Test Load
Use the arrow on the right to display all the available
Scales, 10/500 or 10/3000. Select load and indenter size to
be used.
.

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2.1.1 Create a New File - Pin Brinell Testing (Optional feature)
If the BOSS is to beusedfor measuring impressionsfromthePin Brinell,thePINscaleshouldbe
selected,
The TestLoadmenuwill nowincludeallthevariationsofPINdesignationsandindenter combinations, for
exampleF-STD-IM-STl, for “F” Pins, Standard Indenter, Impact method, measuring steel.
2.1.2 Open an Existing File
1) Select New Test File, Click “ Open”. All test files will be list. Click on file to choose from the File Menu.
NOTE: When you open a new file with another file already open, the current file will be automatically
saved and closed.

B.O.S.S.(R) Operation Instructions
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3 ADDITIONAL SCREEN OPERATIONS
Paramete r –These are the same functions for setting measuring conditions that are found under “New Test
File”. Some functions such as Tolerance can be changed after measurements are made. Others such as Scale,
Average, etc. will be grayed out once a file has measured data in it.
Export – There are three functions concerning exporting reports under Export.
- Report –This function allows selecting what report format is used. Selecting Preview will allow the
operator to see the report on the screen.
- Advanced –This function allows you to create a custom report using third party design software,
not included by Newage.
- Image –Allows exporting of Measurement data.
Preferences –The selections under Preferences are concerning how the BOSS screen
appears.
General
Location - Allows selection of which file folder test files and data is stored.
Demo Mode - Settings for Demo mode. You can select from several Test
images or save you own for Demonstrating the function of the
BOSS.
View
Measurement Axis –Should always be set for 2 Axis for Brinell
impression measurement. Additional use of these setting is shown
in Inch and MM measurement instructions later in manual
Line –Set the color and size of the measurement marks in this section.
Different colors allow for best contrast against the background color of
the parts being measured.
Lighting –Set the type of Scan Head you have. See images at beginning
of manual for two Scan Head types available.
Zoom –Allows setting of screen magnification from 0.5 to 2.0X
magnifications.
Number Format –Setting the of number of decimal places used when displaying
Impression sizes in MM. Most common is 2.
Theme
Dark / Light, setting for over all look of screen, ether black or white background.