DeFelsko PosiTector SPG User manual

Table of Contents
Table of Contents
Introduction ........................................................ 2
Operation Overview ........................................... 3
Why is Measurement Important? ...................... 4
Probes ............................................................... 5
Menu Operation ................................................. 6
Calibration, Verification & Adjustment .......... 6
Cal Settings Menu ........................................ 8
Setup Menu .................................................. 9
Statistics ....................................................... 12
Memory Management .................................. 13
Connecting to a Computer............................ 17
Available Options............................................... 21
Temperature ...................................................... 22
Power Supply / Battery Indicator ....................... 22
Returning For Service ....................................... 23
Troubleshooting ................................................. 23
Technical Data ................................................... 24

2
Introduction
Introduction
The PosiTector Surface Profile Gage (SPG) is a hand-held
electronic instrument that measures the peak-to-valley height of
the surface profile of abrasive blast cleaned surfaces. It consists
of a body (Standard or Advanced) and probe.
PosiTector SPG Kit Contents
- PosiTector SPG Probe (pg. 5)
- Glass zero plate amd metal shim (pg. 8)
- Protective rubber holster with belt clip
- Protective Cap for Probe (pg. 2)
- Protective Lens Shield (pg. 2)
- Wrist strap (pg. 2)
- 3 Alkaline AAA batteries (pg. 22)
- Quick Guide Instructions
- Nylon carrying case with shoulder strap
- USB Cable (pg. 18)
- Certificate of Calibration traceable to NIST (pg. 4)
- Two (2) year warranty on Body and Probe
Protective Cap
PosiTector SPG 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.
Wrist Strap
We recommend attaching and wearing the
supplied wrist strap. 1
2
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.

3
Typical Screen
Current
Measurement
Battery Indicator
Unit of
Measurement
Factory Zero in
Use
1. Remove the protective plastic cap from probe.
2. Power-up Gage by pressing the center navigation button.
3. Place the included glass zero plate onto a stable, flat surface.
Take a measurement on the plate with the PosiTector SPG. If
the average of several readings is greater than ± 5 µm (0.2 mil),
zero the instrument (see pg. 8).
4. Place the probe FLAT on the surface to be measured such that
the tip of the probe reaches into the bottom of a profile valley.
HOLD STEADY. The Gage will BEEP twice and display the
measurement.
5. Lift the probe from the surface between measurements.
Operation Overview
Operation Overview
The PosiTector SPG powers-up when the center navigation
button is pressed. To preserve battery life, it powers-down after
approximately 5 minutes of no activity. All settings are retained.
R
Measurement
Type

4
Why is Measurement Important?
Steel is often abrasive blast cleaned or otherwise roughened prior
to painting. The peak-to-valley height of the resultant surface
profile is an important factor in the performance of applied
protective coatings.
Low profile may reduce coating bond strength (adhesion). Too high
and the peaks may receive insufficient coverage and possibly rust
prematurely. The costly application of more coating may be
required if the profile is too high.
For these reasons, surface profile should be measured prior to
coating application to ensure that it meets contract specifications.
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 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.

5
Probes
Probes
The PosiTector SPG consists of a body and a probe. See Info
(pg. 10) to find your body and probe type. More probe information
is available at www.defelsko.com/SPG. 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.
The supplied probe tip has a 60° angle to comply with
most test standards including ASTM D 4417 B. An
optional 30° angle tip with replacement tool is available for special
applications or to comply with Australian Standard AS 3894.5.
A replacement tool is included with the purchase of either the 60°
or 30° angle tips. Insert the two legs of the replacement tool into
the probe tip and turn counter clockwise to remove the tip. Insert
the new tip and tighten clockwise. Do not over tighten. Since the
factory zero setting may not always be precise after a probe tip
exchange, the gage should be checked on the included glass
plate and zeroed if necessary.

6
Memory
Statistics
Zero
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 SPG 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
Calibration, Verification & Adjustment
Calibration, Verification & Adjustment
The PosiTector SPG 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.

7
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 SPG is shipped with a Certificate of Calibration
showing traceability to a national standard. For organizations with
re-certification requirements, the PosiTector SPG 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 of Accuracy
Instrument accuracy is verified using the included metal shim and
glass zero plate.
Place the plate onto a stable, flat surface. Take several
measurements. If the average is greater than ±5 µm (0.2 mil), zero
the instrument (pg. 8).
Next, place the metal shim over the glass plate and measure
ensuring the probe needle touches the glass plate in the area
between the shim’s “legs”. The average of several measurements
should be within the combined tolerances of both the shim and the
gage (±10%). For example, measuring a 75 µm (3 mil) shim should
result in values between 67.5 µm (2.7 mils) and 82.5 µm (3.3 mils).
If not, see Returning for Service (pg. 23).
To guard against measuring with an improperly adjusted Gage,
verify the Gage at the beginning and the end of each work shift.
During the work shift, if the Gage is dropped or suspected of giving
erroneous readings, its accuracy should be re-verified.
In the event of physical damage, wear, high usage, or after an
established calibration interval, the gage should be returned to the
manufacturer for repair or calibration.

8
Zeroing the Instrument
Zeroing the Instrument
Zero
The PosiTector SPG has only one adjustment point at zero. The
zero point can be set using one of two methods. Both methods are
found under the Zero menu option.
-The factory zero setting is restored during a RESET
(below)
-The factory zero setting may not always be precise,
particularly after a probe tip exchange. For best accuracy,
the gage should be zeroed on the included glass plate.
1.Select from the menu.
2.Press the (+) button to select the number of readings to be
used to obtain an average, typically 3.
3.Repeatedly measure the glass plate. After the last
measurement the gage will calculate a Zero which represents the
average of all the Zero readings taken.
Zero
Glass Plate Zero
Setting the instrument to zero on the glass plate is the preferred
zero adjustment method:
Factory Zero
If a glass plate or suitable smooth, hard surface is not available,
the factory zero setting can be restored:
1. Select from the menu.
2. Press the down button to select “Reset” and press the center
navigation button . The factory calibration icon will appear
on the LCD.
Zero
NOTE:

9
Setup
Setup Menu
Setup Menu
Reset
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.
- The zero adjustment is returned to the factory setting. Since
this may not always be a precise zero, the gage should be
checked on the glass plate (pg. 8)
- Menu settings are returned to the following:
Memory = OFF
Statistics Mode = OFF
Hi Lo Alarm = OFF
Bluetooth = 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:
NOTES: - Keep the gage away from metal during a Reset.
- Date and Time are not affected by either Reset.
Units = microns
Flip Display = Normal
Auto Sync = OFF
White on Black = OFF
USB Drive= ON
Language = English
Battery Type = Alkaline
Backlight = Normal
Bluetooth Streaming = OFF
- Bluetooth Pairing info is cleared.
- Menu settings are returned to the following:

10
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.
Flip Display
This option causes the display to read upside down. Ideal for use
overhead with the resultant display conveniently pointed toward
the operator.
White on Black
Inverts the LCD display to white on a black background to provide
better readability in some surroundings.
(Advanced models only)

11
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 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. 10).
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.
Converts the display from inch to metric or vice versa. Stored
measurements in memory are not converted.
Units
Battery Type
NOTE:
Converts displayed and printed words to the selected language.
Language
Switching units will turn off Statistics, HiLo Alarm, and
closes Memory.
NOTE:

12
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.
When selected, a icon and statistical summary will appear on
the display.
Remove the last measurement by pressing the (-) button. Press
(+) to clear statistics.
Clear
Statistics Menu
Statistics Menu
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
R
49.8
52 48
x
x
x↨
σ
↨
1.3
Maximum
measurement
n6
Measurement
Type
Battery Indicator

13
New Batch
Memory Management
Memory Management
Memory
The PosiTector SPG can record readings in memory for printing
to the optional Bluetooth wireless printer (pg. 20) , transfer to a
computer (pg. 19) or synchronizing with PosiTector.net (pg. 17).
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 dis-
play. 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.
Scroll through
display modes
(Advanced only)
Delete last reading
Access the Menu
Create a new batch
(Advanced only)
Restore brightness
after dimming
(Advanced only)

14
current batch
current sub-batch
statistics
(see pg. 12)
current reading
# of sub-batches in
current batch
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
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
can be accumulated for them. Batch 2 contains the statistics for
B2s1 and B2s2.
SmartBatch
The PosiTector SPG measures the depth of a single valley in
relation to the height of the surrounding peaks using a pointed,
cone-shaped probe.
A single depth measurement generally does not adequately
characterize the surface profile of an abrasive blast cleaned
surface. Repeated gage readings often differ due to surface
irregularities even at points close together. Therefore most
organizations and contract specifications require multiple
measurements be taken and analyzed to produce a final result that
better characterizes the surface.
The Smart Batch menu option sets-up the PosiTector SPG to
comply with the statistical approaches defined in various standards
and test methods published by organizations such as ASTM,
SSPC, ISO, IMO, US Navy, SANS and AS.
For instructions on how to use the Smart Batch™ feature, see
www.defelsko.com/smartbatch

15
Sends a statistical summary and individual measurements to the
optional Bluetooth wireless printer.
Print
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.
The following user selectable display options are available:
Display (appears only if a batch is currently open)
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.
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.
To cancel printing, press and hold the (-) and (+) buttons
simultaneously
NOTE:
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.
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.
NOTE:
Close
Stops the recording process, closes the current batch, and
removes batch information from the display.

16
When a batch is open, press Up to scroll through the
above display options.
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.13).
Each batch can contain a maximum of 10,000 readings
NOTES:

17
The PosiTector can be connected to a computer using the included
USB cable or Bluetooth wireless technology (pg. 20). The USB
connection has the following capabilities:
- Download readings via USB Mass Storage (pg. 19)
- Download readings and synchronize batch photos and notes via
PosiTector.net (pg. 17)
- Update the instrument firmware (pg. 21)
- Supply power to the instrument for extended use, or recharge
optional rechargeable batteries (pg. 22)
The USB port resides on the top of the instrument, behind a
rubber flap.
Connecting to a Computer
Connecting to a Computer
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
thickness 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.

18
Measurement data can be shared with authorized users via a
secure login from any computer and most web enabled devices
including smart phones.
PosiTector Desktop Manager (PDM) is a small Windows based
application which allows automatic two-way communication
(synchronization) between the Gage and PosiTector.net (internet
connection required). When installed, PDM runs as a start-up
application and resides in the Windows notification area (system
tray) of a PC. PDM is available as a free download within your
PosiTector.net account.
Register your Gage on PosiTector.net to take full advantage of your
gage’s capabilities. See www.PosiTector.net
Outputting Stored Readings
Outputting Stored Readings
Stored readings can be accessed using one of the following:
USB mass storage - connect your PosiTector to a PC/Mac using
the suppled USB cable to access and print stored readings and
graphs. No software or internet connection required.
PosiTector.net - a free web-based application offering secure
centralized storage of thickness readings. Access your readings
from any web connected device. (See www.PosiTector.net and
Sync Now pg. 19)
Bluetooth Printer (sold separately) Stream readings as they are
taken or print batch readings and statistics. See (pg. 20) for pairing
information.
Legacy PosiSoft Support - Existing PosiSoft users can continue
using the familiar legacy PosiSoft software to download readings.
Upgrade your PosiSoft version at: www.DeFelsko.com/PosiSoft

19
Immediately initiates synchronization with PosiTector.net when
connected (USB or Bluetooth) to an internet connected PC running
PosiTector Desktop Manager. (pg. 18)
Multiple gages can be synchronized simultaneously when
connected using multiple connections (for example two gages
connected via USB and one gage connected via Bluetooth).
Sync Now
Connect
Connect Menu
Connect Menu
Auto SYNC ü
Allows the instrument to automatically synchronize with
PosiTector.net when initially connected (USB or Bluetooth) to an
internet connected PC running PosiTector Desktop Manager. (pg.
18)
Additional measurements added to memory while connected are
synchronized only when the USB cable is disconnected, then
reconnected or when Connect>Sync Now is selected.
Synchronizing (Sync) is the process whereby PosiTector stored
measurement data uploads to PosiTector.net (from both Standard
and Advanced models) while images and batch notes are down-
loaded to the instrument (Advanced model only). This transfer
occurs when the instrument is connected via USB or Bluetooth
Wireless Technology to a web-enabled PC running the PosiTector
Desktop Manager (pg. 18). It can be triggered either manually
(USB or Bluetooth) or automatically (USB only).
USB Drive ü
Universal Serial Bus (USB) is a specification to establish
communication between devices and a host controller (usually a
personal computer). USB has effectively replaced a variety of
interfaces such as serial and parallel ports.
The PosiTector uses a USB mass storage device class which
provides a simple interface to retrieve data in a manner similar to
USB flash drives, cameras or digital audio players.

20
PosiTector Advanced models have Bluetooth functionality to:
On: Turns Bluetooth functionality On. When selected, the icon
will appear on the display. To deactivate Bluetooth, select Off.
Pairing: The instrument and receiving device must be paired
before stored or streamed readings can be transmitted. For pair-
ing instructions, see www.defelsko.com/printer
Info: Lists information about your current Bluetooth connection,
including the currently paired device and MAC address.
Stream: When checked, the instrument will stream readings to
the paired Bluetooth Device as they are taken. Readings can be
streamed as they are taken to the optional Bluetooth printer or
third-party computer software.
Bluetooth (Advanced models only)
- Communicate with the PosiTector Desktop Manager (PDM)
in lieu of a USB cable.
- Stream individual readings to a computer or Bluetooth
wireless printer as they are taken.
- Print to the optional battery powered Bluetooth wireless
printer.
When checked, any computer can view and synchronize readings
stored in memory by navigating a virtual drive labeled “PosiTector”
using the included USB cable.
A formatted HTML report is viewed by selecting the "index.html"
file found in the root directory. Optionally, text ".txt" files located in
each batch folder provide access to measurement values. Stored
readings and graphs can be viewed or copied using universal
PC/Mac web browsers or file explorers.
When your PosiTector is first connected to your Windows PC via
a USB cable, an enumeration process is started that installs device
drivers without re-booting your computer. You may see several
pop-up windows in the taskbar at the bottom right of your screen.
Wait for the entire process to be completed before proceeding.
When connected (see photo pg. 17), power is supplied
through the USB cable. The batteries are not used and the body
will not automatically power down. If rechargeable (NiMH)
batteries are installed, the instrument will trickle charge the
batteries.
NOTE: