DeFelsko PosiTest PC User manual

Instruction Manual v. 3.0
Powder Checker
Uncured Coating Thickness Gage
www.GlobalTestSupply.com
Find Quality Products Online at: [e-mail]

Introduction
The PosiTest PC Powder Checker is a hand-held, non-contact
coating thickness gage that uses high-frequency ultrasound to
predict the cured thickness of uncured powder coatings.
1
1. POWER-UP the PosiTest PC by pressing the button.
2. ZERO the gage using the supplied Zero Fixture (pg. 4).
3. EASURE the applied powder (pg. 4).
4. ADJUST to the specific powder if necessary (pg. 8).
Quick Start
PosiTest PC Contents
nPosiTest PC gage
nZero Fixture
nReplacement probe screen
n4 AAA alkaline batteries
nInstruction manual
nHard shell carrying case
nUSB Cable
nPosiSoft Desktop reporting software
nTwo (2) year warranty
To preserve battery life, the PosiTest PC will power
down after approximately 5 minutes of no activity. All settings are
retained.
NOTE:
The USB Port has several functions:
nGage updates (pg. 10)
nUSB Keyboard ode /
live stream readings (pg. 10)
nDownload stored readings to
PosiSoft Desktop (pg. 10)
nAllows the gage to be operated
without batteries when
connected to a suitable
USB power supply
Sensor/Screen
Display
Buttons
USB Port
www.GlobalTestSupply.com
Find Quality Products Online at: [e-mail]

Memory Mode: Turns emory ode ON.
The gage will store and maintain a running
average for up to 999 readings. Stored
measurements can be downloaded to PosiSoft
Desktop Software (pg. 10). When Memory Mode
is ON, the following menu options appear:
2
Press the and buttons simultaneously to
enter the gage menu. Navigate between menu
items using the or buttons. Use the to
select the highlighted menu item.
The following menu items are displayed:
Zero: Zeroes the instrument using the supplied Zero
Fixture (pg. 4)
1-Point Adjustment: Adjusts the gage to a known
thickness of powder (see Adjustment Techniques, pg. 8)
2-Point Adjustment: Adjusts the gage to two known
thicknesses of powder if the 1-Point Adjustment does not
improve accuracy (see , pg. 9)
Display Brightness: Adjusts the gage display
brightness using the and buttons.
RESET Memory Mode. All stored readings and the
running average will be cleared from gage memory.
Turns Memory Mode OFF
Memory Mode is unavailable when USB Keyboard
Mode is active
While in Memory Mode, press the button to discard
the last reading
NOTES:
Menu Navigation
www.GlobalTestSupply.com
Find Quality Products Online at: [e-mail]

3
Units: Toggles the display units between mils and
microns.
Sound: Turns the built-in speaker ON or OFF .
When set to OFF, a red speaker icon will appear in
the gage display.
Scan ode: In this mode, the gage will continuously
take readings, and only add a reading to memory when
the button is released. Ideal for quickly analyzing
large areas. (See Scan Mode, pg. 6)
USB Keyboard ode: When enabled and connected to
a computer, the PosiTest PC will be recognized as a
keyboard. Readings are sent to the computer as they
are taken, emulating keystrokes. (pg. 10)
emory ode is unavailable when in USB Keyboard ode.
NOTE:
Gage Reset: Restores the gage to default settings,
clears stored memory and calibration adjustments.
Power Off: Powers down the gage. Alternatively, the
gage will automatically power down after approximately
5 minutes of no activity. All settings are retained.
Exit enu: Exits the gage menu and returns to the main
measurement screen.
www.GlobalTestSupply.com
Find Quality Products Online at: [e-mail]

4
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 Gage Reset or whenever the
“Zero Probe” graphic is displayed.
1. Select Zero from the Gage menu.
2. Place the probe tip in the supplied Zero
Fixture.
3. Press the button and hold the Zero Fixture
on the probe until the hourglass icon
disappears and a green check mark is
displayed. If the zero fails, a red Xwill
display. Repeat the Zero process.
The Zero process can take up to 10 seconds
NOTE:
How to Measure
Power-up the PosiTest PC by pressing the button. With the
gage at least 10 cm (4 inches) away from the coated part, press
and hold the button. A target grid will appear on the display:
Target Grid
Distance Target Bar
Distance Paddle
Zero Fixture
Zeroing
www.GlobalTestSupply.com
Find Quality Products Online at: [e-mail]

5
While watching the gage display, move the probe tip closer to the
target, aligning the Distance Paddle with the Distance Target
Bar. The optimum distance for measurement is 2 cm (3/4 inch)
between the probe tip and the surface of the applied powder.
Ensure the PosiTest PC is held perpendicular to the surface.
The instrument will take a measurement when:
a. The Distance Paddle is near the Distance Target Bar. This
indicates that the instrument is the correct distance away
from the part.
b. The Distance Paddle is as wide as possible. This indicates
that the instrument is being held perpendicular to the surface.
For best results use emory ode (pg. 2) to generate averages.
The average of a series of measurements is often a more
meaningful prediction of cured thickness than a single reading.
If a thickness result does not appear after 5-6 seconds, release
the measurement button and try again.
Small and/or erratically swinging parts may present measurement
challenges. Steady the part whenever possible. If erroneous
readings continually result, change the measurement strategy by
rotating the gage, altering its alignment to the part, or by
2 cm (3/4 inch)
90°
Correct Incorrect
Correct Incorrect
www.GlobalTestSupply.com
Find Quality Products Online at: [e-mail]

6
0A good reading, but the predicted cured thickness is
less than the minimum range.
+++ A good reading, but the predicted cured thickness is
greater than the maximum range.
--- An indeterminate or invalid reading.
measuring a different location on the part. If a valid measurement
cannot be calculated, one of the following messages will be
displayed:
Single Reading ode (default)
The gage will automatically display the predicted cured thickness
after analyzing the powder. To take another reading, release the
button, then press and hold the again.
Scan ode
Press and hold the button. The gage continuously analyzes
the powder and displays the predicted cured thickness until the
button is released. The last valid measurement is added to
memory when the button is released if emory mode is on.
aintenance
The probe screen protecting the sensor of the PosiTest PC can
be unscrewed for cleaning. Accumulated powder should be
carefully removed from the screen by no more than 0.2 Pa (20 -
30 psi) of compressed air.
- Do not blow air directly into the sensor.
- Replacement screens are available for purchase.
www.GlobalTestSupply.com
Find Quality Products Online at: [e-mail]

7
Calibration and Adjustment
The PosiTest PC probe is factory calibrated and performs an
automatic self-check each time it calculates a measurement. For
most powder measurement applications, no further adjustment is
necessary. Simply Zero the gage (pg. 4) at the beginning of
each shift, then measure.
The PosiTest PC’s factory calibration accurately predicts cured
powder thickness for a wide range of powder coatings. However,
some powder formulations may require a Calibration Adjustment.
Begin by performing a Verification of Accuracy 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 (PosiTest PC and dry film thickness
instrument) then two adjustment techniques are available to
correct the variance (see Adjustment Techniques).
Verification of Accuracy
Before first use on a new powder and periodically thereafter, an
accuracy check should be performed. This ensures the gage
measures properly by comparing predicted thickness values with
actual cured thickness values.
1. Zero the probe (pg. 4).
2. Spray powder onto a flat, smooth metal sample.
3. easure the uncured powder with the PosiTest PC.
4. Cure the powder.
5. easure cured thickness with a magnetic or eddy current
coating thickness gage such as the PosiTest DFT or
PosiTector 6000.
6. Compare results.
A successful verification requires that the average of a series of
measurements by both instruments be within their combined
tolerances. If not, adjust the PosiTest PC using one of the
methods described in Adjustment Techniques (pg 8).
www.GlobalTestSupply.com
Find Quality Products Online at: [e-mail]

8
Adjustment Techniques
If the average of a series of measurements by both instruments
(PosiTest PC and dry film thickness instrument) is not within
combined tolerances, the PosiTest PC can be adjusted using
one of two methods:
1-Point Adjust – The first and most common choice.
2-Point Adjust – Used only if a 1 Pt Adjust does not
sufficiently improve accuracy.
1-Point Adjust
1. Spray approximately 75 microns (3 mils) of powder onto a
flat, smooth metal sample.
2. Select 1-Pt Adjust from the gage menu.
3. Take at least 3 uncured powder
measurements with the PosiTest PC. Press
the button to discard the last reading if
it should not be included in the average of the
measurements.
4. Select OK to confirm and store the average of the
measurements.
5. Cure the powder. The instrument will power off after 5
minutes of inactivity, but the uncured powder measurements
will be retained.
6. easure cured thickness with a magnetic or eddy current
dry-film thickness gage. Record the results.
7. Power-up the instrument, and select 1-Pt
Adjust from the gage menu and then
select the option.
8. Adjust the displayed reading lower or
higher to match the cured thickness value.
Select OK to store the adjustment.
9. Verify accuracy (pg. 7) to ensure the instrument is
measuring within tolerance.
This only appears if 1 pt adjustment
readings have been stored
NOTE:
www.GlobalTestSupply.com
Find Quality Products Online at: [e-mail]

9
2-Point Adjust
1. Spray powder onto two flat, smooth metal samples. Apply
approximately 40 microns (1.5 mils) on the first, and 75
microns (3 mils) on the second.
2. Select 2-Pt Adjust from the gage menu.
3. Take at least 3 uncured powder measurements on the first
(thin) powder sample with the PosiTest PC. Press the
button to discard the last reading if it should not be included
in the average of the measurements.
4. Select OK to confirm and store the average of the
measurements.
5. Take at least 3 uncured powder measurements on the
second (thick) powder sample with the PosiTest PC. Press
the button to discard the last reading if it should not be
included in the average of the measurements.
6. Select OK to confirm and store the average of the
measurements.
7. Cure the powder on both panels. The instrument will power
off after 5 minutes of inactivity, but the uncured powder
measurements will be retained.
8. easure cured thickness on both panels with a magnetic or
eddy current coating thickness gage. Record the results.
9. Select 2-Pt Adjust from the gage menu and then select
the option.
10. Adjust the displayed reading for the first (thin) sample lower
or higher to match the cured thickness
values. Select OK to store the adjusted
measurement value.
11. Adjust the displayed reading for the second
(thick) sample lower or higher to match
the cured thickness values. Select OK to
store the adjusted measurement value.
12. Verify accuracy (pg. 7) to ensure the
instrument is measuring within tolerance.
www.GlobalTestSupply.com
Find Quality Products Online at: [e-mail]

DO NOT unplug the Gage during the update operation.
10
PosiSoft Desktop
PosiSoft Desktop - Powerful desktop software (PC/ ac) for
downloading, viewing, printing and storing measurement data.
Includes a customizable, templated PDF Report Generator.
Gage Update
The PosiTest PC gage can be updated by the user.
To perform an update, the Gage must be connected with the USB
cable to an internet connected computer running PosiSoft Desktop.
If an update is available, a prompt will appear in PosiSoft for the
user to preform an update.
Ensure that stored measurements are downloaded to
PosiSoft Desktop before updating the gage.
NOTE:
USB Keyboard ode / Live Stream easurements
When enabled, the PosiTest PC will be recognized as a USB
keyboard device when connected to a computer. This mode is
compatible with any software that accepts keystrokes. Readings
are sent to the computer as they are taken, emulating keystrokes.
Can be used in both Single Reading ode and Scan ode.
emory ode is unavailable when in USB Keyboard ode.
www.GlobalTestSupply.com
Find Quality Products Online at: [e-mail]

11
Technical Data
easuring Range 20-100 microns
0.8-4.0 mils
Accuracy + 5 microns
+0.2 mil
Resolution 1 micron
0.1 mil
easurement Time 2-5 seconds
easurement Distance
to Powder 19 mm 0.75 inch
easurement Area 2 mm
0.08 inch
Temperature Range 0 to +50°C
+32° to +120°F
Gage Size 241 x 50 x 50 mm
9.5 x 2.0 x 2.0 in.
Gage Weight
(without batteries)
140 g
4.9 oz
Conforms to: AST D7378
This device complies with part 15 of the FCC Rules.
Operation is subject to the following two conditions: (1) This
device may not cause harmful interference, and (2) this
device must accept any interference received, including
interference that may cause undesired operation.
www.GlobalTestSupply.com
Find Quality Products Online at: [e-mail]

12
© 2018 DeFelsko Corporation USA All Rights Reserved
This manual is copyrighted with all rights reserved and may not be reproduced or transmitted,
in whole or part, by any means, without written permission from DeFelsko Corporation.
DeFelsko, PosiTest, PosiTector and PosiSoft are trademarks of DeFelsko Corporation
registered in the U.S. and in other countries. Other brand or product names are trademarks or
registered trademarks of their respective holders.
Every effort has been made to ensure that the information in this manual is accurate.
DeFelsko is not responsible for printing or clerical errors.
Returning for Service
Before returning the instrument for service…
1. Install new or newly recharged batteries in the proper
alignment as shown within battery compartment.
2. Examine the probe tip screen for dirt or damage.
Replacement screens are available for purchase.
3. Perform a Reset (pg. 3) and Zero (pg. 4).
I PORTANT:
If you must return the Gage for service, describe the problem fully
and include measurement results, if any. Be sure to also include
the probe, your company name, company contact, telephone
number and fax number or email address.
Limited Warranty, Sole Remedy
and Limited Liability
DeFelsko's sole warranty, remedy, and liability are the express
limited warranty, remedy, and limited liability that are set forth on
its website:
www.GlobalTestSupply.com
Find Quality Products Online at: [e-mail]