DeFelsko PosiTector PC User manual

Introduction ......................................................... 1
Kit Contents ........................................................ 1
Quick Start .......................................................... 2
Probes ................................................................. 3
Measurement Notes ............................................ 4
How to Measure .................................................. 5
Menu Operation .................................................. 7
Verification of Accuracy ....................................... 8
Zero ..................................................................... 8
Calibration and Adjustment ................................. 9
Adjustment Techniques ....................................... 9
Cal Settings Menu ............................................... 10
1 Point Adjust ................................................. 10
2 Point Adjust ................................................. 10
Setup Menu ......................................................... 12
Reset .............................................................. 12
Gage Info ....................................................... 13
Statistics .............................................................. 14
Memory Management ......................................... 15
Annotate ......................................................... 16
Display ........................................................... 17
Summaries ..................................................... 18
Screen Capture .............................................. 18
Accessing Stored Measurement Data ................ 18
PosiSoft Desktop Manager (PDM) ................. 19
PosiSoft.net .................................................... 19
PosiSoft 3.0 .................................................... 20
PosiSoft Mobile .............................................. 20
Table of Contents
Table of Contents

Connect Menu ..................................................... 21
Sync Now ....................................................... 21
Auto Sync ....................................................... 21
USB Drive ...................................................... 22
Bluetooth ........................................................ 24
Bluetooth Wireless Printer ............................. 24
WiFi ................................................................ 25
Powder Probes .............................................. 26
List ............................................................. 26
Change Order ............................................ 26
Add New .................................................... 26
Probe Off ................................................... 26
Connect ..................................................... 26
Updates .......................................................... 27
Probe RESET ..................................................... 27
Temperature ........................................................ 28
PosiTector Body Power Supply/Battery Indicator... 28
Change Probe Batteries ...................................... 28
Additional Accessories ........................................ 29
Technical Data .................................................... 31
Returning For Service ......................................... 32
Warranty .............................................................. 32

Introduction
Introduction
The PosiTector PC Powder Checker is a hand-held,
non-contact Coating Thickness Gage that uses an airborne high
frequency ultrasound to analyze coating powder applied to rigid
substrates to calculate and display a predicted cured thickness.
The Gage consists of an Advanced body and a Powder Checker
(PC) probe that communicate with each other via wireless
technology. They must stay within 10 meters (30 feet) of each
other while measuring. A rubber holster with belt loop allows the
PosiTector body to stay with the operator while measuring.
1
PosiTector PC Contents
- PosiTector body (Advanced)
- PosiTector probe (PC)
- PC Probe Connector Cover
- Probe zeroing fixture
- Replacement screen
- Protective lens shield
- Carabineer
- Wrist strap
- Protective rubber holster with belt clip
- 3 AAA alkaline batteries (gage body)
- 3 AA alkaline batteries (probe)
- Quick Guide instruction manual
- Instructional video
- Hard shell carrying case
- USB Cable
- PosiSoft.net account
- Two (2) year warranty on Body and Probe

2
To preserve battery life, the PosiTector body and
PC probe power down after approximately 5 minutes of no activity.
All settings are retained.
1. POWER-UP both units (probe first).
a) Power-up probe by pressing the button.
b) Power-up PosiTector body by pressing the center
navigation button.
A beep and the letters “PC” will display on the upper left corner
of the PosiTector LCD. This indicates both units are ready to
measure.
2. ZERO the probe (pg 8)
3. ADJUST to the specific powder if necessary (pg 10)
4. MEASURE the applied powder (pg 5)
Quick Start
Quick Start
NOTE:
Wrist Strap
We recommend attaching and wearing the
supplied wrist straps for both the PosiTector
body and PC probe. 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.
Typical Display
Predicted
Cured Thickness
Unit of Measurement
thou/mils
Battery Icon
2.1
PC
Probe
Connected

LCD Display
3
USB Port
Probe
Connector
Cover
PosiTector Body
The PosiTector body accepts a number of probe types including
magnetic, eddy current and ultrasonic coating thickness, surface
profile, environmental and ultrasonic wall thickness probes.
For the latest information on probe interchangeability,
see www.defelsko.com/probes
Probes
Probes

Wireless Powder Checker probes:
The PosiTector PC wireless probe connects to all Advanced
PosiTector bodies. See Powder Probes (pg 26) for connection details.
Physically connected PosiTector probes:
To disconnect a probe from a PosiTector body, slide the
plastic probe connector horizontally (in the direction of the
arrow) away from the PosiTector body. Reverse these steps
to attach a new probe.
The PosiTector automatically determines what type of probe
is attached and does a self-check.
4
Maintenance
The screen at the measuring end of the PC probe can be unscrewed
for cleaning. Accumulated powder should be carefully removed from
the screen by no more than 0.2 MPa (20 - 30 psi) of compressed air.
Do not blow air directly into the probe. Replacement screens are
available.
During power-up a physically connected probe is recognized
when a PC probe is not available (powered-off).
To reconnect to a PC wireless probe (after power-up), select Connect,
within the Connect > Powder Probes menu. (pg 26)
The PosiTector body will automatically connect to an active wireless
PC probe during power-up. PC probe must be turned on.
NOTE:
If a thickness result does not appear after 5 seconds, release the
measurement button and try again. Wait 1 to 2 seconds between
readings.
Small, erratically swinging parts may present measurement challenges.
Steady the part whenever possible. If erroneous readings continually
result, change the measurement strategy by rotating the probe, altering
its alignment to the part, or by measuring a different location on the
part.
For best results use Statistics mode (pg 14) to generate averages.
The average of a series of measurements is often a more meaningful
prediction of cured thickness than a single reading.
Measurement Notes
Measurement Notes

5
Power-up both units. Bring the probe to within 5 cm
(2 inches) of the coating powder.
Press and hold the button. Bring the probe closer to the
powder. While watching the probe display, align the Distance
Paddle with the Distance Target Bar. (pg 5)
While the probe button is depressed, probe distance and angle
should be varied slightly keeping:
(a) the Distance Paddle close to the Distance Target Bar
(b) the Amplitude Indicator at maximum height (pg 5)
Release the button when you hear a double BEEP or see a
thickness measurement on either display.
How to Measure
How to Measure
Maximum
Amplitude Dot
Probe Display: ( button not pressed)
Amplitude Indicator
Results Indicator Distance Target Bar
Probe Batteries Status (pg 28)
Probe Connected Indicator
Predicted Cured Thickness Result
Distance Paddle
Predicted Cured
Thickness Result
Probe Display: ( button pressed)

6
Amplitude Indicator: Strength of the ultrasonic echo.
A high position indicates good probe orientation relative to
perpendicular. The bar will generally reach higher positions when
measuring thin powder and when the probe is at a 90-degree
angle to the powder surface.
Maximum Amplitude Dot: Marks the highest position the
Amplitude Indicator reached during the current measurement
attempt.
Predicted Cured Thickness Result: When a valid measurement
is calculated, the PosiTector body BEEPS twice and the predicted
cured measurement result is displayed on both the PC probe and
PosiTector body. Continuing to hold the probe button will result in
additional samples being collected.
There are 4 types of displayed measurement results:
43 Predicted thickness result.
0 The collected samples have resulted in a good reading,
but the resultant predicted cured thickness is less than the
minimum range.
++ The collected samples have resulted in a good reading,
but the resultant predicted cured thickness is greater than
the maximum range.
-- An indeterminate or invalid reading.
Wireless Indicator: The symbol indicates the PosiTector body
and wireless probe are communicating properly.
Results Indicator: When the probe is in the proper position and
good samples are being taken, a solid blue dot blinks on the probe
display, the PosiTector body displays a flashing green dot and
emits a high beep. When samples are inconclusive, an "X" blinks
on the probe display, the PosiTector body displays a flashing red
dot and emits a low beep.
Distance Paddle: Graphically represents the distance to the
target. It rises and falls to indicate distance from the probe tip to the
surface of the powder.
Distance Target Bar: The optimum distance for measurement is
18 mm (3/4 inch) between the tip of the probe and the surface of
the applied powder. During measurement, keep the Distance
Paddle close to the Distance Target Bar.

7
The center button is purposely recessed to help eliminate
unintentional power-up.
When no probe is attached, a limited menu will be displayed.
Connect probe for full menu.
Menu Operation
Menu Operation
Gage functions are menu controlled. To access the Menu,
power-up the PC Probe and PosiTector body, then press the
center navigation button.
Below is a sample menu for a PosiTector PC:
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
Updates
Powder Probes
Exit
NOTES:

8
Factory Calibration Symbol
Factory Calibration Symbol
This symbol indicates the instrument is measuring with factory
calibration settings. It appears whenever a Reset (pg 12) is
performed or whenever a new calibration setting (pg 11) is created.
It disappears whenever a calibration adjustment is made (pg 10) or
when a user calibration is loaded from cal memory
(pg 11). A probe Zero (pg 8) does not change the status of the
symbol.
Place the measuring end of the PC probe into the
Powder Probe Fixture.
Select Zero from the Gage menu.
The Zero process can take up to 30 seconds.
Zero
Zero
Verification of Accuracy
Verification of Accuracy
Before first use on a new powder and periodically thereafter, the
user should perform an accuracy check. This ensures the gage
measures properly by comparing predicted thickness values with
actual cured thickness values.
Zero the probe (pg 8).1.
Spray powder onto a flat, smooth metal sample.2.
Measure the uncured powder with the PosiTector PC.3.
Cure the powder.4.
Measure cured thickness with a magnetic or eddy current5.
coating thickness gage such as the PosiTector 6000.
Compare results.6.
A successful verification requires that the average of a series of
measurements by both instruments be within their combined
tolerances. If not, adjust the PosiTector PC using one of the
methods described on page 9.
For best accuracy, perform a Zero at the beginning of every shift
to compensate for temperature and humidity changes. It is also
required after a Reset (pg 12).
NOTE:

9
Calibration and Adjustment
Calibration and Adjustment
The PosiTector PC probe is factory calibrated and performs an
automatic self-check each time it calculates a measurement. For many
powder measurement applications no further adjustment is necessary.
Simply Zero at the beginning of each shift, then measure.
Sometimes gage measurement calculations can be influenced by the
composition of the coating powder. A calibration adjustment improves
accuracy in these circumstances.
Adjustment, or Calibration Adjustment, is the act of aligning the
gage's predictions to match those of a known cured sample.
Begin by performing a Verification of Accuracy (pg 8) to determine
if there is a need for an adjustment. If the average of several
thickness results is outside the combined tolerances of the two
measuring instruments (PosiTector PC and dry film thickness
instrument) then two adjustment techniques are available to
correct the variance (see Adjustment Techniques, pg 9).
User adjustments are stored in the current Cal setting. It may be
desirable to open a new Cal setting first (see Cal Memory, pg 11).
Adjustment Techniques
Adjustment Techniques
To ensure the gage is working properly, the user should
periodically perform an accuracy check by comparing predicted
thickness values with actual cured thickness values (pg 8).
If the average of a series of measurements by both instruments
(PosiTector PC and dry film thickness instrument) is not within
combined tolerances, the PosiTector PC can be adjusted using
one of two methods...
1 Pt Adjust - The first and most common choice.1.
2 Pt Adjust - If a 1 Pt Adjust does not improve accuracy.2.
See Cal Settings menu, pg 10 for more details.

10
2 Pt Adjust
Cal Settings Menu
Cal Settings Menu
Spray approximately 75 microns (3 mils) of powder onto a flat,1.
smooth metal sample.
Select 1 Pt Adjust then select Measure.2.
Take at least 3 uncured powder measurements with the3.
PosiTector PC. Results will be stored in the gage.
Select OK.4.
Cure the powder.5.
Gage may be powered off. It will retain the cal
measurements during a power cycle.
Measure cured thickness with a magnetic or eddy current6.
coating thickness gage. Record the results.
Select 1 Pt Adjust then select Adjust.7.
Adjust the displayed reading average lower (-) or higher (+)8.
to match the cured thickness value. Select OK.
1 Pt Adjust
Spray powder onto 2 flat, smooth metal samples. Place1.
approximately 40 microns (1.5 mils) on one and 75 microns
(3 mils) on the other.
Select 2 Pt Adjust then select Measure.2.
Take at least 3 uncured powder measurements on the thin3.
powder panel with the PosiTector PC. Results will be stored
in the gage. Select OK.
Take at least 3 uncured powder measurements on the thick4.
powder panel with the PosiTector PC. Results will be stored
in the gage. Select OK.
Cure the powder on both panels.5.
Gage may be powered off. It will retain the cal
measurements during a power cycle.
Measure cured thickness on both panels with a magnetic or6.
eddy current coating thickness gage. Record the results.
Select 2 Pt Adjust then select Adjust.7.
Adjust the displayed 1st point reading average lower (-) or8.
higher (+) to match the cured thickness values. Select OK.
Adjust the displayed 2nd point reading average lower (-) or9.
higher (+) to match the cured thickness values. Select OK.
NOTE:
NOTE:

11
Removes a cal 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 16).
Although Cal 1 cannot be deleted, the Delete function will
return it to factory settings.
View stored Calibration Settings.
Cal Memory
When measuring a specific part with a specific powder, it is often
convenient to be able to store any unique calibration adjustments
made for that application. Then, if you return to that part, the
corresponding Cal setting can be conveniently and quickly
restored.
A “cal setting” is any calibration adjustment. The PosiTector PC
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 12).
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 16).
Loads an existing cal setting. Use the Up or Down buttons to
scroll until the desired setting appears, then press . A
warning message 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 15).
View
Delete
Open
New

12
NOTES: - A probe Zero (pg 8) must be performed after a Reset.
- Date, Time and stored WiFi settings are not affected by
either Reset.
Units = microns
Flip Display = Normal
Auto Sync = OFF
Backlight = Normal
USB Drive= ON
It performs the same function as a menu Reset with the addition
of:
- All calibration adjustments and Cal Memory are cleared and
returned to the Gage’s factory calibration settings.
- Bluetooth Pairing info is cleared.
- Menu settings are returned to the following:
Reset
Reset (soft reset) restores factory settings and returns the Gage
to a known condition. The following occurs:
- All batches, stored measurements, images, and batch names
are erased.
- Menu settings are returned to the following:
Bluetooth = OFF
WiFi = OFF
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.
Setup Menu
Setup Menu
Cal Lock = OFF
Display = None
Memory = OFF
Statistics = OFF
White on Black = OFF
Language = English
Battery Type = Alkaline
When selected, the icon will appear and all calibration settings
are “locked” to prevent further user adjustments. Uncheck to make
further adjustments.
Cal Lock ü
Clears the calibration adjustments for the open Cal setting.
The factory calibration icon will appear on the display.
Cal Reset

13
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
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 13).
Set Clock
White on Black
Inverts the LCD display to white on a black background to provide
better readability in some surroundings.
Flip Display
This option causes the display to read upside down allowing for
alternate positioning techniques.
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.
Converts displayed and printed words to the selected language.
Language
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.

14
Battery Type
Selects the type of batteries used in the PosiTector body from a
choice of “Alkaline”, “Lithium” or “NiMH” (Nickel-metal hydride
rechargeable). If NiMH is selected, the PosiTector 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.
NOTE:
(PosiTector body only)
When selected, a icon and statistical summary will appear on
the display.
Remove the last measurement by pressing the (-) button.
Press (+) to clear statistics.
Statistics Mode
Statistics Mode
Mean
(average)
Standard
Deviation
# of
measurements
Minimum
measurement
Statistics
Icon
Last
reading
Statistics ü
50
microns
n6
49.8
52 48
x
x
x↨
σ
↨
1.3
Maximum
measurement
Clear
Clears all on-screen Statistics.

15
Scroll through
display modes
Delete last reading
Access the Menu
Create a new batch
Restore brightness
after dimming
Memory stores 100,000 readings in up to 1,000 batches.
“New Batch” closes any currently opened batch and creates a new
batch name using the lowest available number. The icon
appears. New batch names are date stamped when created.
Memory Management
Memory Management
The PosiTector PC 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.
current batch
Last reading
# readings in current batch
Remove the last reading from the current open batch by•pressing (-).
If memory is ON, continuous measurements can be taken•and 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 batches are date stamped when they
are created. Each reading is also data/time stamped.
Shortcut: When a batch is open, press (+) to create a new batch
Maximum
measurement
Standard Deviation
Minimum
measurement
Mean (average)

16
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.
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 18).
Annotations can also be
created using PosiSoft.net (pg 19) or
PosiSoft Mobile (pg 20).
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.
NOTE:
Sends a statistical summary and individual measurements to the
optional Bluetooth wireless printer (see pg 24).
Print
To cancel printing, press and hold the (-) and (+) buttons
simultaneously.
NOTE:

Notes: Instructions,
descriptions
or notes
(see Annotate, pg 16)
17
The following user selectable display options are available:
Display
(appears only if a batch is currently open)
Chart:A real-time chart
of batch readings
x-y Chart for
Single Layer Application
When a batch is open, press Up to scroll through the
above display options.
Shortcut:
None: Default screen
shows statistics
Image: Batch image
PosiSoft.net (pg 19) and PosiSoft Mobile (pg 20) are used to•
insert an Image and Notes into a batch.
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.
Each batch can contain a maximum of 10,000 readings.•
NOTES: