ELECTROMATIC PosiTector 6000 User manual

PosiTector 6000
INSTRUCTION MANUAL v. 6.0/M
for Memory (3) models
Coating Thickness Gages
Separate
probe
Built-in
probe
ELECTROMATIC
E Q U I P M E N T C O., I N C.
600 Oakland Ave., Cedarhurst, NY 11516–U.S.A.
TEL: [phone] •FAX: [phone]

Introduction
Introduction
Power-up / Power-down
Power-up / Power-down
The PosiTector 6000 powers-up when any button is
pressed. To preserve battery life, the Gage powers-
down after approximately 3 minutes of no activity. All
settings are retained.
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 meas-
ure the thickness of non-conductive coatings on
non-ferrous metals.
FN probes combine the full abilities of both the "F"
and "N" probes.
Certification
All probes or gages are shipped with a Certificate of
Calibration. For organizations with re-certification
requirements, gages 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.
The PosiTector 6000 hand-held, electronic Gage
non-destructively measures the thickness of coat-
ings on metals, quickly and accurately.
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3
Quick S
Quick St tart art
1.Separate probe models - remove black protective
rubber cap from probe if supplied. Built-in probe
models - remove Gage from protective rubber
holster.
2.Turn Gage on with any button.
3.Place the probe FLAT on the surface to be
measured. HOLD STEADY. When a valid
measurement is calculated, the Gage BEEPS
twice, the bi-color LED blinks green, 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 every 2 seconds. Do not drag the
probe sideways across the surface.
Golden Rule
Golden Rule
Measure your uncoated part first! This quick zero-
check determines if a calibration adjustment is need-
ed for your substrate. (See pg.5)
Next, lay the included plastic shims onto a bare sur-
face and measure them individually to ensure the
Gage measures a known thickness within tolerance.

4
Menu Operation
Menu Operation
Current selection is
displayed with darkened
background
Some buttons have a tick box
to their right to indicate current
status. An empty box indicates
that feature is not active.
Gage functions are menu controlled. To access the
Menu, turn the Gage on, then press the button.
To navigate, press (-) to scroll DOWN, (+) to scroll
UP and to SELECT. Press both (-)(+) buttons at
any time to exit any menu or select Exit from the
Menu.
When there are more menu options than can fit
onto one screen, a scroll bar will appear. The
dark area indicates what portion of the total
menu you are currently viewing.
List boxes have a down arrow on the right-hand side.
Use the (-) and (+) buttons until your desired choice
appears, then press to select this choice and
move focus onto the next item.
“Focus” is currently at this
unselected (empty) square box
“Radio” buttons.
Only one can be
selected at a time.
“List“ box
a “tick” indicates this square
box has been selected

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Calibration,
Calibration, V Verification erification
and
and Adjustment Adjustment
Three steps ensure best accuracy…
1. Calibration - typically done by the manufacturer
or a qualified lab
2. Verification of Accuracy - as done by the user
3. Adjustment - to a known thickness
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.
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.
Adjustment
Adjustment, or Calibration Adjustment is the act of
aligning the Gage's thickness readings to match that
of a known sample in order to improve the
effectiveness of the Gage on a specific surface or in
a specific portion of its measurement range. 1-point
or 2-point calibration adjustments are possible and
these are stored in calibration settings (pg. 9).
the symbol disappears whenever a
calibration adjustment is made to the gage.
The PosiTector 6000 is factory calibrated and
performs an automatic self-check each time it takes
a measurement. For many applications no further
NOTE:

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adjustment is necessary after a Reset (pg.15). Just
check ZERO on the uncoated substrate, then
measure.
But sometimes Gage readings can be influenced by
changes in substrate shape, composition, surface
roughness or by measuring in a different location on
the part. That is why Calibration Adjustments are
made possible.
1- or 2-point Calibration Adjustments may be
performed if readings are not falling within the
expected range of thickness for the application being
measured.
Where a calibration adjustment method has not
been specified, use a 1-point method first. If meas-
uring the included shims reveals inaccuracies, use
the 2-point method. Factory Calibration settings
can be restored at any time by performing a Reset
(pg.15), creating a NEW calibration setting (pg. 9), or
by DELETING the adjustments made to the Cal 1
calibration setting (pg.10). The symbol appears
on the display whenever factory calibration settings
are in use.
With “FN” Gages, calibration adjustments are
made only to the “F” or “N” mode (stored independently
under a particular Cal), whichever was measured last.
Once adjusted, you may “lock” the current cal-
ibration adjustment to prevent further modification. (See
“Cal Lock” on pg. 9)
1-point Calibration Adjustment
Also known as an offset or correction value, there
are 4 ways to perform this adjustment:
(1) 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
NOTE:
NOTE:

7
average of a series of readings on the uncoated surface
is "0" .
(2) Average Zero Calibration Adjustment
To establish “0” on a rough or curved surface a
preferred method is to take several readings on the
uncoated part and average the result.
1.Select the Zero menu option.
2.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.
3.Repeatedly measure the uncoated part. 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 "0" which represents the average of all
the Zero readings taken.
(3) 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.
(4) Average Adjustment to a Known Thickness
On rough or curved surfaces a preferred method is
to take several readings on the known thickness and
average the result.
1.Select 1 Pt Adjust from the Cal Settings menu.
2.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.
3.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 .
2-point Calibration Adjustment
-Preferred for very unusual substrate materials,
shapes or conditions. Provides greater accuracy
within a limited, defined range.
This method requires taking two readings at known
thickness values: a thin value (often zero) and a
thicker value. These values should be on either side
of the thickness range to be measured.
1.Select 2 Pt Adjust 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.
8

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 the
current calibration settings are “locked” to prevent
further user adjustments.
User Mode Calibration
There are applications where 1- or 2-point
calibrations will not work satisfactorily such as when
measuring magnetic coatings, or conductive
coatings over non-metals. For these applications the
included PosiSoft software can download special Cal
settings.
Calibration Memory
Calibration Memory
It is often convenient to retain 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 currentcalibra-
tionsetting(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 (see pg.15).
-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
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-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 (see Memory
Management pg. 11). Although Cal 1 cannot be
deleted, the Delete function will return it to factory
settings.
-sends a list of all Calibration Settings to either the IR
printer using the Gage’s built-in IR port, or to a PC’s
default printer using the included USB cable.
10
-loads an existing setting. Use the (-)(+) buttons to
scroll the List box 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. (see pg.12)
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. (see pg.12)

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Memory Management
Memory Management
The PosiTector 6000 can record 10,000
measurements in up to 1000 groups (batches). Ideal
for on-screen statistical purposes, printing to an
optional IR printer or PC’s default printer, or for
downloading to a personal computer using the
included PosiSoft software and USB cable.
Readings are time-stamped as they are taken.
-closes any currently opened batch and creates a
new batch name using the next higher number. For
example, if only Batch 1 and Batch 3 exist, then Batch
4would be created and made the current batch. The
icon appears and basic statistics are displayed.
Each measurement will now be simultaneously
shown on the display 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.
When a batch is open, create a new batch
by pressing (+)
-creates a new sub-batch. In this 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.
(Appears only if a batch is currently open)
current batch
current sub-batch
and # readings statistics
(see pg. 14)
Shortcut:
current reading
# of sub-batches in
current batch
When a sub-batch is open, create a new
sub-batch by pressing (+)
Shortcut:

-the PA2 feature helps the user determine if film
thickness over a large area conforms to user
specified min/max levels.
-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 (see pg.9).
-stops the recording process, closes the current
batch or sub-batch, and removes the statistics from
the display.
-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.
-lists all readings onto the display from the current or
most recently used batch or sub-batch. It begins by
showing the last 10 measurement values. Scroll
using the (-) or (+) buttons. Hold for 1 second to
scroll a page at a time.
To change or delete a value, scroll to that value
(align the “+” symbol beside it) then either take
another measurement to change it, or press to
delete it or exit. Statistics are updated.
To exit press (-)(+) buttons simultaneously.
Shortcut:
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Downloading Measurements Stored in Memory
Measurements stored in the Gage's memory (in
batches) can be downloaded to a computer using
the supplied USB cable and the supplied PosiSoft
software. Measurements are not erased from
memory after downloading.
PosiSoft® ver.2.11 or higher is supplied on a CD for
downloading readings to a computer. It runs on
Windows-based PC computers using Microsoft
Windows® 2000 SP3 or higher with a USB port. It
allows entry of notes and annotations, prints
histograms and basic charts, manages data, and
readings can be exported to a document or
spreadsheet.
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-outputs a statistical summary to the optional IR
printer using the built-in IR port, or to a PC’s default
printer using the included USB cable. Individual
measurements with their time stamp are printed if
the Readings box is ticked. A histogram is printed if
the Graph box is ticked. HiLo calculations are printed
using current HiLo settings if HiLo Alarm is turned on
(see pg.14).
- Calibration adjustments cannot be made if any
measurements were taken with that setting and
stored into a batch.
- Remove the last reading from the current open
batch by pressing (-).
NOTES:

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S
St tatistical Functions atistical Functions
-when Statistics is selected, a icon and statistical
summary will appear on the display.
Remove the last measurement by pressing the (-)
button. Press (+) to clear statistics.
-This mode allows the Gage to visibly and audibly
alert the user when measurements exceed user-
specified limits.
When HiLo Alarm is first 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 this setting.
The icon will appear on the display.
Measurements will now be compared to your defined
limits. The Gage beeps and blinks green twice if
results are within those limits. A single low tone will
display if it is below the Lo limit, and a HIGH tone if it
is above the Hi limit. The LED will blink red if readings
are outside limits. Press (+) to clear HiLo readings.
Mean
(average)
Standard
Deviation
# of
measurements Max and Min
measurement
Statistics
Icon
Last
reading
-zeros all on-screen Statistics and HiLo tabulations.

This option causes the display to read upside down.
Ideal for use on a worktable (separate probe models)
and overhead (built-In probe models) with the
resultant display conveniently pointed toward the
operator.
Reset restores factory settings and returns
the Gage to a known, out-of-the-box
condition. It is handy when settings have been
changed, if the Gage behaves unusually, or if a
calibration adjustment is not possible. The following
occurs:
- all batches are closed and stored measurements
are erased.
- all Cal settings are cleared and returned to the
Gage’s factory calibration settings (Cal 1).
- this symbol appears on the display: It
disappears if a calibration adjustment is made by
the user.
- menu settings are returned to the following:
Hi Res = OFF Cal Lock = OFF
Statistics = OFF Hi Lo Alarm = OFF
N Lock = OFF (FN models only)
A more thorough Reset can be performed when the
Gage is powered down by holding the (+) button
until the Reset symbol appears. This is handy
when the Gage fails to power-up or operate properly.
It performs the same function as a menu Reset with
addition of Units = microns, Flip Display = Normal and
Language = English.
-Keep the Gage away from metal during a Reset.
-Date and Time are not affected by any Reset.
Setup Menu
Setup Menu
NOTES:
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When Hi Res is selected, the displayed gage resolu-
tion becomes as follows:
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
0.01 mm 1.00 - 99.99 mm
- Gage accuracy is not affected by the Hi Res Mode.
This menu button converts the display and all stored
readings from inch to metric or vice versa.
All batches are date-stamped when created, and all
measurements are time-stamped (24 hour format)
when stored into these batches. It is therefore impor-
tant to keep both the date and time current using this
menu button. Alternatively, the date and time can be
automatically updated when the gage is connected
to PosiSoft using the Gage Utilities -> Set Clock func-
tion in PosiSoft.
NOTES:

Sep
Separate Probes arate Probes
Separate Probe Gages consist of
a gage body and a probe. A wide
selection of interchangeable
probes are available. Each retain
their own unique calibration infor-
mation. All Gage bodies accept all
probes.To disconnect, power-down the Gage and
pull the plastic probe connector horizontally (in the
direction of the arrow) away from the Gage body.
When powered-up the PosiTector 6000
automatically determines what type of
probe is attached and does a self-check.
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 3 minutes
of no activity.
The continuous measurement feature is only
intended to allow careful probe placement on small
or odd-shaped surfaces. Simply ignore all readings
taken before the probe is properly placed. Do not
drag the probe sideways.
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. The probe first
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
Do this...
Not this!
17

T
Temperature emperature
Operating range: +32° to +120°F (0 to +50°C)
The PosiTector 6000 compensates automatically
for temperature. Allow a few minutes for the probe to
reach ambient temperature before measuring.
Discard the first measurement taken in a notably dif-
ferent temperature condition. When measuring sur-
faces much hotter or colder than ambient, lift the
probe at least 6 inches (15cm) and allow 1 second
off the surface between measurements.
TIP: Ferrous substrates with extreme temperatures
between -150°F and +450°F (-100°C and +230°C)
can be measured with the PosiPen B. It is ideally
suited for measuring on small, hot or hard-to-reach
surfaces.
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".
Non-Ferrous Lock
(Option appears on FN Combination models only)
Select N Lock when operating regularly on non-
ferrous substrates. The probe will only use the eddy
current principle when measuring. This shortens
measurement time and extends battery life.
N Lock is also useful in instances such as measuring
coatings on plated steel.
A
Available Options vailable Options
A variety of accessories are available to help you get
the most from your PosiTector 6000 coating
thickness gage.
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Returning for Service
Returning for Service
Before returning the Gage for service…
1.Install new Alkaline batteries in the proper align-
ment as shown within battery compartment.
2.Examine the probe tip for dirt or damage. The
probe should move up and down freely.
3.Perform a Gage Reset (pg. 15).
4.Place a plastic shim onto bare metal (steel or non-
steel, depending upon whether you have an "F" or
"N" Gage) and attempt a measurement.
If you must return the Gage for service, describe the
problem fully and include measurement results, if
any. Be sure to also include the Gage, your compa-
ny name, company contact, telephone number and
fax number or email address.
T
Troubleshooting roubleshooting
Some common reports received by our Service
Department along with possible causes are located
on our website. Most conditions however can be
cleared with a Reset (pg. 15).
Nickel-cadmium and nickel-metal hydride recharge-
able batteries will work but the Gage may appear to
have weak batteries.
To retain all user settings and stored memory read-
ings, only replace the batteries after the Gage has
automatically powered-down.
Changing The Batteries
Changing The Batteries
The battery icon displays four bars with fresh
alkaline batteries installed. As the batteries weaken,
the number of bars will be reduced. When the battery
Icon is down to one bar , the Gage can still be
used, but the batteries should be changed at the ear-
liest opportunity. USE ONLY “AAA” ALKALINE BATTERIES

W
Warranty arranty
DeFelsko fully warrants its products against defects
in workmanship or materials under normal use for a
period of two years from date of purchase. In the
event that an instrument is believed to be defective,
return the product with proof of purchase to your
dealer. If upon DeFelsko’s inspection of the
instrument, it is determined in our sole discretion that
the returned instrument is defective as to
workmanship or material, the instrument will be
repaired or replaced at DeFelsko’s sole option.
In no event shall DeFelsko be liable for any indirect,
special, incidental or consequential damages.
The warranty is voided if the Instrument has been
opened.
Data subject to change without notice.
T
Technical Dat echnical Data a
Gage body dimensions:
5.75" x 2.5" x 1.2" (146 x 64 x 31 mm)
Battery Life: 50 hours continuous / 36,000 readings.
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ELECTROMATIC
E Q U I P M E N T C O., I N C.
600 Oakland Ave., Cedarhurst, NY 11516–U.S.A.
TEL: [phone] •FAX: [phone]