DeFelsko PosiTector 200 User manual

Instruction Manual v. 3.1
Ultrasonic Coating Thickness Gage
Standard
and
Advanced
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Table of Contents
Table of Contents
Introduction ......................................................... 4
Quick Start .......................................................... 4
Certification ......................................................... 5
Probes ................................................................. 7
How to Measure .................................................. 8
Calibration, Verification and Adjustment ............. 9
Menu Operation .................................................. 10
Cal Settings Menu ............................................... 11
Zero ................................................................ 11
Set Range ...................................................... 11
Thickness ....................................................... 12
Polyurea ......................................................... 12
Cal Lock ......................................................... 12
Cal Reset ....................................................... 12
Setup Menu ......................................................... 13
Reset .............................................................. 13
Gage Info ....................................................... 14
Graphics ......................................................... 14
Layers ............................................................ 16
Memory Management ......................................... 18
Standard Models Menu .................................. 18
Advanced Models Menu ................................ 19
Annotate ......................................................... 20
Display ........................................................... 21
Summaries ..................................................... 22
Screen Capture .............................................. 22
Accessing Stored Measurement Data ................ 23
PosiSoft Desktop Manager (PDM) ................. 23
PosiSoft.net .................................................... 24
PosiSoft Mobile .............................................. 25
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Connect Menu ..................................................... 26
Sync Now ....................................................... 26
Auto Sync ....................................................... 26
USB Drive ...................................................... 26
Bluetooth ........................................................ 28
Bluetooth Wireless Printer ............................. 29
WiFi ................................................................ 29
Updates .......................................................... 32
Application Notes ................................................ 33
Measuring on rough surfaces ........................ 33
Measuring on dense (hard) surfaces ............. 34
Measuring total thickness (multi-layers applications) ..... 34
Troubleshooting - General................................... 34
Gage does not turn on ................................... 34
Gage powers up but fails to stay on .............. 34
Gage readings are lower than expected ........ 34
Gage readings are higher than expected ...... 35
Gage does not yield accurate or consistent results ...... 35
Gage displays an error message ................... 35
Gage displays dashed line “----” .................... 35
and emits low-tone buzz ...................... 35
Power Supply / Battery Indicator ........................ 36
Rechargeable Batteries ...................................... 36
Additional Accessories ........................................ 36
Coating Thickness Standards ........................ 38
Technical Data .................................................... 39
Probe Details & Specifications........................ 39
Operating Temperature Range....................... 39
Size / Weight.................................................. 39
Returning For Service ......................................... 40
Warranty .............................................................. 40
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Introduction
Introduction
PosiTector 200 Kit Contents
- PosiTector body (Standard or Advanced)
- PosiTector probe (200 B, C or D)
- Protective rubber cap for Probe
- Protective lens shield
- Wrist strap
- 3 AAA alkaline batteries
- Quick Guide instruction booklet
- Protective rubber holster
- Nylon carrying case with shoulder strap
- Belt clip for rubber holster and carrying case
- USB Cable
- 4 ounce (118 ml) bottle ultrasonic couplant
- Precision Plastic Shims
- 2500 microns (100 mils) Polystyrene Block (C & D Probe only)
- Certificate of Calibration traceable to NIST
- PosiSoft.net account
- Two (2) year warranty on Body and Probe
The PosiTector 200 is a hand-held Coating Thickness Gage that
uses a non-destructive ultrasonic principle to measure coating
thickness on a wide variety of substrates. It consists of a body
(Standard or Advanced) and a probe (see Probes pg. 7).
The PosiTector 200 powers-up when the center navigation button
is pressed. To preserve battery life, the Gage powers down
after approximately 5 minutes of no activity. All settings are
retained.
1. Remove the protective rubber cap from the probe.
2. Power-up Gage by pressing the center navigation button.
3. Zero the probe. (see pg. 11)
4. Adjust to a known thickness, if necessary. (see pg. 12)
5. Measure the part. (see pg. 8)
Quick Start
Quick Start
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Certification
All PosiTector 200 probes include a Certificate of Calibration. For
organizations with re-certification requirements, instruments may
be returned at regular intervals for calibration.
DeFelsko recommends that customers establish calibration
intervals based upon their own experience and work environment.
Based on our product knowledge, data and customer feedback, a
one year calibration interval from either the date of calibration, date
of purchase, or date of receipt is a typical starting point.
Wrist Strap
We recommend attaching and wearing the
supplied wrist strap.
1
2
Protective Lens Shield
The LCD is covered with a thin plastic film for protection against
fingerprints and other marks during shipment. This film, while
usually removed before using the Gage, can be left in place to
protect against paint overspray or debris. Replacements can be
purchased.
Protective Cap
PosiTector 200 gages ship with a protective rubber cap over the
probe. Remove this cap prior to use. Replace it when the Gage is
not in use to protect the probe.
Couplant
Couplant is required to propagate ultrasound into the coating.
Water is a good couplant for smooth coatings. Use the supplied
glycol gel for rougher coatings. While it is unlikely that the
couplant will damage the finish or leave a stain on the surface, we
suggest testing the surface by using the couplant on a sample. If
testing indicates that staining has occurred, a small amount of
water can be used instead of couplant. Consult the Material Safety
Data Sheet available on our website and your coating supplier if
you suspect the couplant may damage the coating. Other liquids
such as liquid soap may also be used.
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Typical Display
Current
Measurement
Unit of
Measurement
thou/mils
Battery
Icon
Factory Calibration
settings in use.
USB Port
LCD
Display
Probe
Connector
PosiTector Body
200 B probe
200 C probe
200 D probe
2.1
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Probes
Probes
To disconnect a probe from a body, power-down the
Gage and slide the plastic probe connector horizontally
(in the direction of the arrow) away from the body.
Reverse these steps to attach a new probe.
When powered-up the PosiTector automatically
determines what type of probe is attached and does a
self-check.
Additionally, the PosiTector accepts a number of probe types
including magnetic and eddy current coating thickness, surface
profile, environmental and ultrasonic wall thickness probes.
Perform the latest software Updates (pg. 32) to ensure probe
compatibility with your Gage. For the latest information on probe
PosiTector 200 probes are available for measuring a
wide variety of coating thickness applications.
B probe - 13 to 1000 microns (0.5 to 40 mils)
Ideal for polymer coatings on wood, plastic, composites, etc.
C probe - 50 to 3800 microns (2 to 150 mils)
Ideal for thicker coatings on concrete, fiberglass, etc.
D probe - 50 to 5000 microns (2 to 200 mils) - Polyurea
- 50 to 7600 microns (2 to 300 mils) - Other Coatings
Ideal for thick or soft (attenuative) coatings
Range limits apply to polymer coatings only.
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The PosiTector 200 probe emits a high frequency sound pulse
that travels into the coating via a coupling gel and reflects from
ANY surface that is different in density. Coating thickness readings
are obtained by measuring the time taken for the ultrasonic signal
to propagate from the probe to the coating/substrate interface and
back. The travel time is divided by two and multiplied by the
velocity of sound in the coating to obtain the thickness of the
coating.
Ultrasonic Thickness
Ultrasonic Thickness
Theory of Operation
Theory of Operation
Couplant
Probe
Coating 1
Substrate
Coating 2
The PosiTector 200
interprets the largest
“echo” within the
selected range as the
coating/coating or
coating/substrate echo.
How to Measure
How to Measure
1. Remove the protective rubber cap from probe.
2. Power-up Gage by pressing the center navigation
button.
3. Apply couplant (see pg. 5) to the surface of
the part.
4. Place the probe FLAT on the surface and
press down.
5. Lift the probe when you hear a double BEEP,
- OR - leave probe on the surface in the same location for
continuous measurements.
6. When completely finished, wipe the probe clean of couplant
then return the Gage to the protective pouch. There is no need
to disconnect the probe from the PosiTector during storage.
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Calibration, Verification and Adjustment
Calibration, Verification and Adjustment
Three steps ensure best accuracy…
1.Calibration - typically done by the manufacturer. All probes
include a Certificate of Calibration.
2.Verification of Accuracy - typically done by the user on known
reference standards such as plastic shims or coated thickness
standards.
3.Adjustment - to a known thickness
Calibration
Calibration is the high-level, controlled and documented process
of measuring traceable calibration standards over the full
operating range of the probe, and verifying that the results are
within the stated accuracy of the probe. Calibrations are
performed by the manufacturer, their authorized agent, or by an
accredited calibration laboratory in a controlled environment using
a documented process.
Verification
Verification is an accuracy check performed by the user on known
reference standards. A successful verification requires the Gage
to read within the combined accuracy of the probe and the
reference standards.
Adjustment
Adjustment, or Cal Adjustment, is the physical act of aligning the
probe’s thickness readings to match those of a known thickness
sample (removal of bias) in order to improve the accuracy of the
probe on a specific coating. See Thickness pg. 12.
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Menu Operation
Menu Operation
Gage functions are menu controlled. To access the Menu,
power-up the Gage, then press the center navigation button.
Below is a sample menu for a PosiTector 200 Advanced model:
Memory
Cal Settings
Setup
Connect
Help
Power Off
Exit
Some buttons have a tick box to their
right to indicate current status. An empty
box indicates that feature is not active.
Current selection is displayed
with darkened background
Up
Down
Center
To navigate, use the Up and Down buttons to
scroll and to SELECT.
Select Exit to exit from any menu.
ü
Navigation Button
Sync Now
USB Drive
Auto SYNC
Bluetooth
WiFi
Powder Probes
Updates
Exit
The center button is purposely recessed to help
eliminate unintentional powering-up of the Gage.
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Cal Settings Menu
Cal Settings Menu
Zero
PosiTector 200probes must be periodically zeroed using the
ZERO menu option to compensate for both extreme temperature
and probe wear effects. Before using, allow the probe to reach
ambient temperature.
If measurements will be made in extreme hot or cold temperatures,
it is recommended to ZERO the probe in the working environment.
If measurements will be made on rough substrates, it is
recommended to periodically ZERO the probe to compensate for
wear.
1. Make sure the Gage is on and the probe is wiped clean.
2. Hold probe in air, away from substrate.
3. Select the Zero menu option.
4. When complete, Gage will double beep and display “----”.
Set Range
The measuring range of each probe can be changed depending on
the specific application or the expected thickness range of the
coating system.
For most applications, the default range values do not have to be
adjusted. But some conditions, like surface roughness, may cause
the Gage to display very low or non-repeatable readings. In this
case, the low range may be increased to cause the Gage to only
display readings above the Lo value set by the user.
To adjust Set Range values...
1. Select or with the Up and Down buttons.
2. Use the (-)(+) buttons to decrease/increase the displayed value.
IMPORTANT:
The PosiTector 200 interprets the largest “echo” or “echoes”
within the selected range as the coating/coating or
coating/substrate echo. If the coating thickness is outside this
range, incorrect or dashed readings may occur.
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Here are some typical Range settings...
Expected paint thickness Lo Range Hi Range
500µm (20 mils) on concrete 130µm (5 mils) 1000µm (40 mils)
50µm (2 mils) on wood 25µm (1 mil) 250µm (10 mils)
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Cal Lock ü
When checked, the icon appears and the current calibration
settings are “locked” to prevent further user adjustments.
Cal Reset
Restores the Gage back to factory calibration and range settings.
The icon will appear on the display.
Thickness
Polyurea ü(PosiTector 200 D probes only)
When checked, the Gage loads a pre-programmed calibration
adjustment optimized for measurement of polyurea coatings.
“Polyurea” will appear on the upper right corner of the display.
D Probe Measuring Range: 2 - 200 mils (50 - 5000 um)
The PosiTector 200 measures most polymer coatings accurately
out-of-box with no adjustment required.
To determine if an adjustment is necessary, select a coating
sample of known thickness as close as possible in composition to
the intended application. For best results, the thickness of the
sample should be equal to or slightly greater than the maximum
expected thickness of the coating to be measured.
Measure the coated sample. If the average of a series of
measurements on the sample is not close to the known
thickness...
1. Select the Thickness menu option.
2. Use (-) or (+) to decrease/increase the displayed measurement
thickness value to match the known thickness of the sample.
3. For Advanced models with multiple layers selected, use the
Down navigation button to select the next layer and adjust as
necessary.
4. To save adjustments, use Down navigation button to highlight
OK and press the center navigation button.
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Reset
Reset (soft reset) restores factory settings and returns the Gage
to a known condition. The following occurs:
- All batches, stored measurements, images, batch names and
screen captures are erased.
- All calibration and range adjustments are cleared and returned
to the Gage’s factory settings.
- The icon will appear on the display.
- Menu settings are returned to the following:
Perform a more thorough Hard Reset by powering down the
Gage, waiting several seconds, then simultaneously holding both
the center and (+) buttons until the Reset symbol
appears. This returns the Gage to a known, “out-of-the-box”
condition. It performs the same function as a menu Reset with the
addition of:
- Bluetooth Pairing info is cleared.
- Menu settings are returned to the following:
Setup Menu
Setup Menu
Units = microns
Flip Display = Normal
White on Black = OFF
Language = English
Battery Type = Alkaline
Backlight = Normal
USB Drive= ON
Auto Sync = OFF
Polyurea = OFF
Memory = OFF
Graphics = ON
Cal Lock = OFF
Bluetooth = OFF
Display = None
Layers = 1
Layer Name = Layer 1
Layer Color = blue
Date, Time and WiFi settings are not affected by either
Reset.
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Graphics ü(Advanced models only)
Gage Info
Displays the model number & serial number, probe type & serial
number, PosiSoft.net registration key, the amount of remaining
memory for storage of readings, date and time and software
packages.
For security purposes, the registration key is required to add the
Gage to your PosiSoft.net account.
When selected, the Gage displays a
graphical representation of the
ultrasonic pulse as it travels through the
coating system.
As the probe is depressed and the
ultrasonic pulse travels through the
coating system, the pulse encounters
changes in density at the interfaces
between coating layers and between the
coating and the substrate.
These interfaces are depicted by a "peak". The greater the change
in density, the higher the peak. The more gradual the change in
density, the greater the width of the peak. For example, two coating
layers made of essentially the same material and "blended" would
result in a low, wide peak. Two materials of very different density
and a well-defined interface would result in a high, narrow peak.
The PosiTector 200 chooses the highest peak (single layer) or
peaks (multi-layer) within the Set Range. For example, if the
number of layers is set to 3, the three highest peaks would be
identified with small red triangles. The peak values are also
displayed numerically as thickness measurements.
The Graphics display can also be accessed using the
Set Range menu option.
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Cursor - The Cursor allows for further analysis of displayed
waveform. Use the (-)(+) buttons to move the green cursor line left
or right over the waveform. The thickness value is displayed at the
top right of the cursor line. This feature is particularly
useful in multi-layer applications where there are more than
3 distinct layers.
Screen Capture - Press to capture and save an image
copy of the current display. The last 10 screen captures are stored
in memory and can be accessed when connected to a computer
(See examples pg. 22 and PosiSoft USB Drive pg. 23).
Press and hold the (-)(+) buttons simultaneously to
capture any screen.
Menu - Press to access the Gage’s main menu.
Exit - Press to close the Graphics display. Press the Up
button to return to the Graphics display.
Use the navigation Up (move left) and Down (move right) buttons
to highlight icons on the graphic display.
Zoom - Visually magnifies the waveform of the displayed
peaks for more visibility. Pressing the (+) or (-) button repeatedly
will increase/decrease the zoom.
Set Range - Press the (-) or (+) buttons to adjust the
Gage’s Lo or Hi measuring range (See pg. 11).
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Advanced models of the PosiTector 200 are capable of
numerically displaying up to three individual layer thicknesses in a
multi-layer system.
From the Layers menu option...
Select up to three individual layer thickness values:
Edit:
- Edit Layer Names (up to 7 characters)
- Edit Layer Color (blue, green or red) - See Display, pg. 21.
Before setting up the Gage for multi-layer measurement, it is•
recommended that you first take measurements in single
layer mode and interpret the results using the Graphics option
(See pg. 14).
When a batch is Open, press the Up button to view the Batch•
Chart.
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NOTES:
Substrate
Layer 2
Tot al
thickness
Layers (Advanced models only)
Layer 1
Couplant
Probe
Example:
Two Layer Application
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Converts displayed and printed words to the selected language.
Language
Selects the type of batteries used in the Gage from a choice of
“Alkaline”, “Lithium” or “NiMH” (Nickel-metal hydride
rechargeable). If NiMH is selected, the Gage will trickle charge the
batteries while connected via USB to a PC or optional AC charger
(Gage must be powered ON). The battery state indicator icon is
calibrated for the selected battery type. No damage will occur if the
wrong battery type is selected.
DeFelsko recommends eneloop (NiMH) rechargeable batteries
(pg. 36).
Battery Type
Selects display brightness (Sun, Normal or Night). All settings will
dim slightly after a period of no activity to conserve battery life.
Press the Down button to brighten the display.
Backlight (Advanced models only)
All measurements are date and time stamped (24 hour format)
when stored into memory. It is therefore important to keep both
the date and time current using this menu option. Use the Up and
Down buttons to scroll, and the (-) and (+) buttons to adjust a
value. The Gage’s date and time can also be viewed in Gage Info
(pg. 14).
Set Clock
Converts the display from inch to metric or vice versa. Stored
measurements in memory are not converted.
Units
Switching units will turn off Statistics view and closes Memory.
White on Black
Inverts the LCD display to white on a black background to provide
better readability in some surroundings.
(Advanced models only)
Flip Display
This option causes the display to rotate 180°. Ideal for right-side-
up viewing when the sensors are pointed away from the user.
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Memory Management
Memory Management
Standard models store up to 250 readings in one batch.
The Memory Menu includes the following options...
On:turns memory on and begins recording
Off: stops recording (stored readings remain in memory)
Clear:removes all readings from memory
View: lists group statistics and all stored readings on the display.
It will begin by showing statistics based on all readings in
memory. Use the Up and Down buttons to scroll through all
readings. Press to exit.
Button functions with Memory ON:
Scroll through display
modes (Advanced only)
Delete last reading
Access the Menu
Create a new batch
(Advanced only)
Restore brightness
after dimming
(Advanced only)
The PosiTector 200 has internal memory storage for recording
measurement data. Stored measurements can be reviewed
on-screen or accessed via computers, tablets and smart phones.
Measurements are date and time-stamped.
Mean
(average)
Standard Deviation
# of readings
in memory
Minimum
measurement
Last
reading
Maximum
measurement
Standard Model display with Memory ON shows measurement
statistics:
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current batch
Last reading
# readings in current batch
Open
Selects a previously created batch name to open and make
current. If it contains measurements, onscreen statistics will
immediately reflect values calculated from this batch.
Close
Stops the recording process, closes the current batch, and
removes batch information from the display.
Remove the last reading from the current open batch by•pressing (-).
Calibration adjustments cannot be made if readings are•stored in memory.
If memory is ON, continuous measurements can be taken but•results will not be stored in memory.
NOTES:
New Batch
Closes any currently opened batch and creates a new batch name
using the lowest available number. For example, if only Batch 1
and Batch 3 exist, then Batch 2 would be created and made the
current batch. The icon appears and basic statistics are
displayed. Each measurement will be displayed and stored into
this new batch. On screen statistics are immediately updated with
each measurement. New batch names are date stamped at the
time they are created. Each reading is also data/time stamped.
Shortcut: When a batch is open, press (+) to create a new batch
Advanced models store 100,000 readings in up to 1,000
batches. The Memory Menu includes the following options...
Maximum
measurement
Standard Deviation
Minimum
measurement
Mean (average)
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Sends a statistical summary and individual measurements to the
optional Bluetooth wireless printer (see pg. 29).
Print
To cancel printing, press and hold the (-) and (+) buttons
simultaneously.
NOTE:
Annotate
Create meaningful batch names and
enter notes directly on the Gage using a
familiar onscreen QWERTY
keyboard.
Use the Gage’s navigation and (-)(+)
buttons to enter annotations.
Annotations can be synchronized with
PosiSoft.net and are included in all
PosiSoft reports (see Accessing
Stored Measurement Data, pg. 23).
Annotations can also be
created using PosiSoft.net (pg. 24) or PosiSoft Mobile (pg. 25).
Delete
Removes a batch completely from memory. The name is deleted
and all measurements are erased.
View
Scroll using the Up or Down buttons through information,
statistical summary, and a list of each reading in the currently
opened batch.
Press to exit.
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