DeFelsko PosiTector 6000 User manual

PosiTector 6000
®
INSTRUCTION MANUAL v. 7.1
Coating Thickness Gages

Table of Contents
Table of Contents
Introduction ....................................................... 3
Operation Overview .......................................... 4
Why is Measurement Important? ...................... 5
Probes ............................................................... 6
Menu Operation ................................................ 7
Calibration, Verification & Adjustment .......... 8
Cal Settings Menu ........................................ 9
Setup Menu .................................................. 13
Statistics ....................................................... 16
Memory Management ................................... 17
Connecting to a Computer ............................ 20
Available Options ............................................... 24
Temperature ....................................................... 27
Power Supply / Battery Indicator......................... 27
Returning For Service......................................... 28
Troubleshooting .................................................. 29
2

3
Introduction
Introduction
Principles of Operation
Fprobes use the magnetic principle to measure the thickness
of non-magnetic coatings on ferrous metals.
Nprobes use the eddy current principle to measure the
thickness of non-conductive coatings on non-ferrous metals.
FN probes combine the full abilities of both the "F" and "N"
probes.
PosiTector 6000 Kit Contents
- PosiTector 6000 Probe (pg. 6)
- Protective rubber holster with belt clip
- Protective Cap for Probe (some probes only)(pg. 3)
- Protective Lens Shield (pg. 3)
- Wrist Strap (pg. 3)
- 3 Alkaline AAA batteries (pg. 27)
- Quick Guide Instructions
- Nylon carrying case with shoulder strap
- USB Cable (pg. 20)
- Certificate of Calibration traceable to NIST (pg. 5)
- Two (2) year warranty on Body and Probe
The PosiTector 6000 hand-held, electronic instrument non-
destructively measures the thickness of coatings on metals,
quickly and accurately. It consists of a body (Standard or
Advanced) and probe (Built-in or Separate).
Plastic 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 instrument, can be left in place
to protect against paint overspray. Replacements can be
purchased.
Wrist Strap
We recommend attaching and wearing the
supplied wrist strap.
1
2
Protective Cap
Some PosiTector 6000 models are shipped with a protective plastic cap
over the probe. remove this cap prior to use. Replace it when the instrument
is not in use to protect the probe.

4
1. Remove protective plastic cap (if supplied) from probe.
2. Power-up Gage by pressing the center navigation button.
3. Place the probe FLAT on the surface to be measured. HOLD STEADY.
When a valid measurement is calculated, the Gage BEEPS twice and the
measurement is displayed.
4. Lift probe AT LEAST 2 INCHES (5cm) from the surface between
measurements - OR - leave probe on the surface in the same location for
continuous measurements.
Operation Overview
Operation Overview
The PosiTector 6000 powers-up when the center navigation button is
pressed. To preserve battery life, the Gage powers-down after approximate-
ly 5 minutes of no activity. All settings are retained.
If memory is ON while continuous measurements are being taken, only the
last value on the display (when the probe is lifted) is stored into memory.
Scan (pg.14) stores ALL measurements into memory.
Substrate
Current
Measurement
Battery Indicator
Unit of
Measurement
Microns
F
56
Typical Screen
Cal 1 Current Calibration
Setting
(Advanced Only)
Button Functions- Normal Operation
Adjust Down
Access the Menu
Adjust Up
Restore brightness
after dimming
(Advanced only)
Golden Rule
Golden Rule
Measure your uncoated part first! This quick zero-check determines if a
calibration adjustment is needed for your substrate. (see pg. 9)
Next, lay the included plastic shims onto a bare surface and measure them
individually to ensure the Gage measures a known thickness within
tolerance.
Factory Calibration
in Use

5
Certification
All 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 gage
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.Written
calibration procedures are available from DeFelsko Corporation at no
charge.
Why is Measurement Important?
Dry film thickness (DFT) is arguably the single most important measurement
made during the application and inspection of protective coatings. Coatings
are designed to perform their intended function when applied within a tight
DFT range as specified by the manufacturer. Correct thickness ensures
optimum product performance. Even the most basic specification will require
DFT to be measured.
Many physical and appearance properties of the finished coating are directly
affected by the film thickness including the color, gloss, surface profile,
adhesion, flexibility, impact resistance, and hardness of the coating. The fit
of pieces assembled after coating can be affected when film thickness isn’t
within tolerance.
Regular film thickness measurement helps control material costs, manage
application efficiency, maintain finish quality and ensure compliance with
contract specifications. Paint manufacturers recommend target ranges to
achieve optimum performance characteristics and clients expect these
parameters to be met.
Precisely measuring finish thickness has other benefits, too. Whether to
meet International Organization for Standardization (ISO), quality, or
customer requirements for process control, companies need to verify
coating quality to avoid wasting money reworking product.

6
The PosiTector 6000 consists of a body and a probe.
A wide selection of interchangeable probes are
available. Each retain their own unique calibration
information. All Gage bodies accept all probes.See info
(pg. 14) to find your body and probe type.
More probe information is available at
www.defelsko.com/p6000. To disconnect, a probe from a body,
power-down the instrument and pull 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. Coating thickness probes “sense”
when they are near metal and immediately attempt a measurement followed by another
every 2 seconds. They stop when removed from the vicinity of metal and power-down
after 5 minutes of no activity.
This continuous measurement feature is intended to allow careful probe placement on
small or odd-shaped surfaces. Ignore all readings taken before the probe is properly
placed.
Standard probes
These constant-pressure, stainless steel probes are hermetically
sealed to be totally waterproof - ideal for underwater use. Hold
them at the 2 knurled rings and push the outer spring-loaded sleeve
down.
FN Combination Probe
An FN probe combines the capabilities of both "F" and "N" probes.
Switching between the two is automatic. First, the probe attempts a
measurement using the magnetic principle. If the coating is non-
magnetic over steel, a reading is displayed with a letter "F". If not,
the probe automatically attempts a measurement using the eddy
current principle. If the coating is non-conductive over metal, a
reading is displayed with the letter "N" (see also N Lock pg. 11).
Do this...
Not this!
Probes
Probes

7
Memory
Statistics
Cal Settings
Setup
Connect
Help
Power Off
Exit
Sync Now
USB Drive
Auto Sync
Bluetooth
Updates
Exit
Menu Operation
Menu Operation
Instrument functions are menu controlled. To access the Menu,
power-up the instrument, then press the center navigation
button .
Below is a sample menu for a PosiTector 6000 Advanced Model:
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
Screen Capture
Press both (-)(+) buttons at any time 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 USB Drive pg. 22).

8
Calibration, Verification & Adjustment
Calibration, Verification & Adjustment
The PosiTector 6000 non-destructively measures the thickness
of coatings on metals. Three steps ensure best accuracy...
Calibration
Calibration is the controlled and documented process of
measuring traceable calibration standards and verifying that the
results are within the stated accuracy of the Gage. Calibrations
are typically performed by the Gage manufacturer or by a certified
calibration laboratory in a controlled environment using a
documented process.
The standards used in the calibration are such that the combined
uncertainties of the resultant measurement are less than the
stated accuracy of the Gage. Typically a 4:1 ratio between the
accuracy of the standard and the accuracy of the Gage is
sufficient.
The PosiTector 6000 is shipped with a Certificate of Calibration
showing traceability to a national standard. For organizations with
re-certification requirements, the PosiTector 6000 may be
returned at regular intervals for calibration. DeFelsko
recommends that our customers establish Gage 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.
Written Calibration Procedures are available online at no charge.
Verification
Verification is an accuracy check performed by the user using
known reference standards. A successful verification requires the
Gage to read within the combined accuracy of the Gage and the
reference standards.
A reference standard is a sample of a known thickness(es) against
which a user may verify the accuracy of the Gage. Reference
standards may be coated thickness standards, the included
plastic shims, or sample parts whose coating thickness has been
determined using other means.

9
1-point Calibration Adjustment
Also known as an offset or correction value, there are 4 ways to
perform this adjustment:
(i) Simple Zero Calibration Adjustment
Measure your uncoated part. If the Gage does not read "0" within the
tolerance of the probe being used, lift the probe from the surface and
adjust the display down (-) or up (+) until it reads "0". Measure and
adjust until the average of a series of readings on the uncoated surface
is within tolerance of "0" .
(ii) Average Zero Calibration Adjustment
To establish “0” on a rough or curved surface a preferred method
to (i) is to take several readings on the uncoated part and average
the result.
(a) Select from the Cal Settings menu.
(b) Press (+) to select the number of readings to be used to obtain
an average, typically 3 to 10 readings. The greater the variation
between readings, the more readings should be taken to obtain
an average.
(C) Repeatedly measure the uncoated part. The Gage will wait 2
seconds after placing the probe on the surface to allow the user
to correctly position the probe on the surface. After the last
measurement the Gage will calculate a Zero which represents
the average of all the Zero readings taken.
Zero
Cal Settings Menu
Cal Settings Menu
Cal Settings

10
(iii) Simple Adjustment to a Known Thickness
It is sometimes desirable to adjust the Gage to a known thickness,
such as a shim, rather than adjusting it to zero.
Measure the object. If the expected reading is not obtained (within
tolerance), lift the probe from the surface and adjust the displayed
reading down (-) or up (+) to the expected thickness. Hold the
button down to increase the rate of adjustment.
(iv) Average Adjustment to a Known Thickness
On rough or curved surfaces a preferred method to (iii) is to take
several readings on the known thickness and average the result.
(a) Select from the Cal Settings menu.
(b) Press (+) to select the number of readings to be used to obtain
an average, typically 3 to 10 readings. The greater the variation
between readings, the more readings should be taken to obtain
an average.
(c) Repeatedly measure the known thickness reference. The
Gage will wait 2 seconds between readings to allow the user to
correctly position the probe on the surface. After the last
measurement the Gage will calculate and display the reading
which represents the average of all the measurements taken. If
the expected reading is not obtained (within tolerance) lift the
probe from the surface and adjust the reading down (-) or up (+)
to the expected thickness and press .
1 Pt Adjust

11
2-point Calibration Adjustment
Preferred method for very unusual substrate materials, shapes or
conditions. Provides greater accuracy within a limited, defined range.
1.Select from the Cal Settings menu.
2.Press (+) to select the number of readings to be used to obtain
an average on the thinner item, typically 3 to 10 readings. The
greater the variation between readings, the more readings
should be taken to obtain an average.
3.Repeatedly measure the thinner item. The Gage will wait for 2 seconds
on the surface to allow the user to correctly position the probe on the
surface. After the last measurement the Gage will calculate and display
a thickness value which represents the average of all the readings
taken using the factory calibration settings.
4.Lift the probe from the surface and adjust the displayed reading down (-) or
up (+) to the known thickness value of the thin item. Press to accept
this value.
5.Repeat steps 2 - 4 for the thicker item.
When selected, the icon will appear and all calibration settings are
“locked” to prevent further user adjustments. Uncheck to make further
adjustments.
2 Pt Adjust
Cal Lock ü
Select Non-Ferrous Lock (N Lock) when operating regularly on non-ferrous
substrates. The icon will appear and the probe will only use the eddy
current principle to shorten measurement time and extend battery life.
N Lock is useful when measuring coatings on plated steel. Normally the
probe measures both the coating + plating over the steel using the
magnetic principle. N Lock makes the Gage measure the coating over the
plating only.
Select N Lock to measure over slightly magnetic substrates; i.e. clear-coat
on gold over nickel-plated brass. Although the probe’s magnet is used for
the magnetic principle, it is also used in N Lock to magnetically saturate a
slightly magnetic substrate and allow the eddy current principle to operate
unhindered.
With N Lock engaged it is possible to obtain a reading when
measuring non-conductive coatings on steel. This is not recommended.
N Lock ü(FN ferrous/non-ferrous combination probes only)
C
N
CAUTION:

12
It is often convenient to store a particular calibration adjustment
before making another. Then, if you return to that part, the
corresponding calibration setting can be restored.
A “setting” is any calibration adjustment. The PosiTector 6000
always displays the current calibration setting (ex. Cal 3) in the
upper right corner of the display.
The setting called Cal 1 has unique features. It can be adjusted
but never deleted, and is always made active with factory settings
after a Reset (pg.13).
Creates a new calibration setting using the next available number
(Maximum of 10). By default, these new Cal settings are initially
created with the Gage’s factory settings. This is indicated with the
icon which appears at the bottom of the display. A warning
message will prevent the creation of a new Cal Memory if a batch
is open and has readings. Delete the batch first (pg.19).
Removes a setting completely from the list. That Cal number can
be reused later with the New command. A setting cannot be
deleted if readings have been stored into a batch using that
calibration setting. Delete all readings in that batch first (pg.19).
Although Cal 1 cannot be deleted, the Delete function will return
it to factory settings.
View stored Calibration Settings.
Loads an existing setting. Use the Up or Down buttons to scroll
until the desired setting appears, then press . A warning mes-
sage will prevent the opening of a stored Cal setting if a batch is
open and has readings. Create a new batch first or open a batch
containing no readings (pg.18).
View
Delete
Open
New
Cal Memory (Advanced models only)
Calibration Memory
Calibration Memory

Setup
Setup Menu
Setup Menu
Reset
13
NOTES:
Memory = OFF
High Res = OFF
Statistics Mode = OFF
Hi Lo Alarm = OFF
Scan Mode = OFF
Cal Lock = OFF
Bluetooth = OFF
Display = None
N Lock = OFF
Perform a more thorough Hard Reset by powering down the
instrument, waiting several seconds, then simultaneously holding
both the center and (+) buttons until the Reset symbol
appears. This returns the instrument to a known “out-of-the-box”
condition. It performs the same function as a menu Reset with
addition of:
- Bluetooth Pairing info is cleared
- Menu Settings are returned to the following:
- Keep the Gage away from metal during a Reset.
- Date and Time are not affected by a Reset.
Units = microns
Flip Display = Normal
Auto Sync = OFF
White on Black = OFF
Fast Mode = OFF
Language = English
Battery Type = Alkaline
Backlight = Normal
Bluetooth Streaming = OFF
USB Drive = ON
Reset (soft reset) restores factory settings and returns the
instrument to a known condition. The following occurs:
- All batches, stored measurements, images, and batch names
are erased.
- All calibration adjustments and Cal Memory are cleared and
returned to the gage’s factory calibration settings.
- Menu settings are returned to the following:

14
Info
Displays the model number & serial number, probe type & serial
number, PosiTector.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
instrument to your free PosiTector.net account.
Increases the displayed Gage resolution as follows:
Hi Res ü
Resolution Range
0.01 mil 0.00 - 99.00 mils
0.1 mil 100.0 - 999.9 mils
0.1 um 0.0 - 999.9 um
1.0 um over 1000 um
Gage accuracy is not affected.
NOTE:
Increases measurement speed for most probes. Useful for quick
inspection or when measuring large areas with thick coatings
where proper probe positioning is not critical. Swift up/down probe
movement is required. Reduced accuracy may be noted.
In ordinary operation, the PosiTector 6000 takes thickness measurements
every 2 seconds when placed onto a surface. Normally, the user raises the
probe after it has taken a single measurement and relocates it to a second
location.
Scan mode modifies this behavior in two ways. First, measurements are
taken much faster. Second, all measurements are recorded when memory
is on. As the probe slides along the surface in scan mode, the PosiTector
6000 takes single measurements in quick succession. This may reduce the
life of the probe. Recommended for smooth surfaces only.
Scan ü
Fast ü
(Advanced models only)
This option causes the display to read upside down. Ideal for use on a
worktable (separate cable probes) and overhead (removable built-in
probes) with the resultant display conveniently pointed toward the operator.
Flip Display

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)
15
Converts the display from inch to metric or vice versa. Stored
measurements in memory are not converted.
All batches are date-stamped when created, and all readings are
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 instrument’s data and
time can also be viewed in Info (pg. 14).
Units
Set Clock
Selects the type of batteries used in the instrument from a choice
of “Alkaline”, “Lithium” or “NiMH” (Nickel-metal hydride
rechargeable). If NiMH is selected, the instrument will trickle
charge the batteries while connected via USB to a PC or optional
AC charger. 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 the use of eneloop (NiMH)
rechargeable batteries.
Battery Type
Switching units will turn off Statistics, HiLo Alarm, and
closes Memory.
NOTE:
White on Black
Inverses the LCD display to white on a black background to
provide better readability in some surroundings.
(Advanced models only)
NOTE:
Language
Converts displayed and printed words to the selected language.

16
Clear
Statistics Menu
Statistics Menu
When selected, a icon and statistical summary will appear on
the display.
Remove the last measurement by pressing the (-) button. Press
(+) to clear statistics.
Allows the Gage to visibly and audibly alert the user when
measurements exceed user-specified limits.
When HiLo Alarm is selected, the current Lo setting is displayed.
Adjust down (-) or up (+). Alternatively, measure a coating with a
thickness close to the required value and make final adjustments
with the buttons. Select NEXT to accept this value. The current Hi
setting is now displayed. Follow the same procedure to adjust the
Hi setting.
The icon will appear on the display.
Measurements will be compared to your defined HiLo limits. The
Gage beeps if results are within those limits. A single low tone will
sound if the reading is below the Lo limit, and a high tone if it is
above the Hi limit. Press (+) to clear HiLo readings.
Mean
(average)
Standard
Deviation
# of
measurements
Minimum
measurement
Statistics
Icon
Last
reading
Statistics ü
HiLo Alarm ü
Clears all on-screen Statistics and HiLo tabulations.
50
microns
n6
49.8
52 48
x
x
x↨
σ
↨
1.3
Maximum
measurement

17
New Batch
Memory Management
Memory Management
Memory
The PosiTector 6000 can record readings in memory for printing to the
optional Bluetooth wireless printer (pg. 21), transfer to a computer (pg. 21)
or synchronizing with PosiTector.net. (pg. 21). Readings are time-stamped
as they are stored.
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.
Shortcut:
Standard models store up to 250 readings in one batch. The following
appears within the Memory menu:
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.
Advanced models store 100,000 readings in up to 1,000 batches (groups).
The following appears within the Memory menu:
When a batch is open, press (+) to create a new batch
New Sub-Batch (appears only if a batch is currently open)
Creates a new sub-batch within the currently opened batch.
When a sub-batch is open, create a new sub-batch by
pressing (+)
Shortcut:
In the following example, B2s2 is a sub-batch of Batch 2. Sub-
batching allows the user to group related batches so that statistics
Scroll through dis-
play modes
(Advanced only)
Delete last reading
Access the Menu
Create a new batch
(Advanced only)
Restore brightness
after dimming
(Advanced only)

Delete
Removes a batch or sub-batch completely from memory. The
name is deleted and all measurements are erased. Sub-batches
can be deleted individually. To delete all related sub-batches,
simply delete the top-level batch.
18
Determines if a coating system complies with the IMO
performance standard for protective coatings.
See www.defelsko.com/9010
New PA2
New 90/10
Helps determine if film thickness over a large area conforms to
user specified min/max levels. See www.defelsko.com/pa2
Open
Selects a previously created batch or sub-batch name to open and
make current. If it contains measurements, on-screen statistics will
immediately reflect values calculated from this batch. The
calibration setting (i.e. Cal 2) associated with this batch is also
opened (pg. 12).
A solid triangle is displayed to the right of the batch
name when sub-batches are present. Press to view sub-
batches. This also applies to the Delete, View and Print options.
current batch
current sub-batch
statistics
(see pg. 16)
current reading
# of sub-batches in
current batch
NOTE:
can be accumulated for them. Batch 2 contains the statistics for
B2s1 and B2s2.
microns
B2
71.3 1.5
s=3
s3 n5
72.4
74 72
x
↨
σ
↨
x
72
0.9
σ
# readings in current
sub-batch
Close
Stops the recording process, closes the current batch or sub-
batch, and removes the statistics from the display.

19
Sends a statistical summary and individual measurements to the
optional Bluetooth wireless printer.
Print
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.
When a batch is open, press Up to scroll through the
above display options.
To cancel printing, press and hold the (-) and (+) buttons
simultaneously.
NOTE:
Display (appears only if a batch is currently open)
The following user selectable display options are available:
Chart: A real-time x-y chart of batch or sub-batch readings.
Image: An image uploaded (synchronized) from PosiTector.net
Notes:Instructions or notes uploaded from PosiTector.net
None: Default screen showing statistics information when a
batch is open
Shortcut:
Remove the last reading from the current open batch by
pressing (-).
Calibration adjustments cannot be made if any measurements were taken
with that setting and stored into a batch.
If memory is ON while continuous measurements are being taken, only the
last value on the display (when the probe is lifted) is stored into memory.
Scan Mode stores ALL measurements into memory (pg. 14).
Each batch can contain a maximum of 10,000 readings.
NOTES:
Annotate
Use the Gages navigation and (-)(+) buttons to enter meaningful
batch names and enter notes directly on the instrument using a
familiar onscreen QWERTY keyboard. Annotations can be syn-
chronized with PosiTector.net and are included in USB Mass
Storage reports.

20
Connecting to a Computer
Connecting to a Computer
The PosiTector can be connected to a computer using the included
USB cable or Bluetooth wireless technology (pg. 23). The USB
connection has the following capabilities:
- Download datasets via USB Mass Storage (pg. 21)
- Download readings and synchronize batch photos and notes via
PosiTector.net (pg. 20)
- Update the instrument firmware (pg. 24)
- Supply power to the instrument for extended use, or recharge
optional rechargeable batteries (pg. 27)
The USB port resides on the top of the instrument, behind a
rubber flap.
PosiTector.net
To enhance the operation of their Gage, all PosiTector users have
access to the features provided by PosiTector.net. It is a free web-
based application offering secure centralized management of
readings.
After (1) a user account has been created, (2) a gage has been
registered, and (3) the PosiTector Desktop Manager is
downloaded and installed onto a Windows PC, synchronization of
measurement data can be performed either manually or
automatically whenever the PosiTector is connected to a web
enabled PC by either USB cable or Bluetooth wireless technology.
Gage measurements stored in memory are uploaded; images and
batch notes are downloaded.
Uploaded data can be manipulated using a standard internet web
browser from any location in the world - job site or head office.
Reports and graphs with annotations and corporate logo can be
generated. Data can be exported to XML or CSV (comma
delimited) text files.