PosiTector 6000INSTRUCTION MANUAL v. 6.0/M

for Memory (3) models

Coating Thickness Gages

Separateprobe

Built-inprobe

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: 516-295-4300 • FAX: 516-295-4399

IntroductionIntroduction

Power-up / Power-downPower-up / Power-downThe PosiTector 6000 powers-up when any button ispressed. To preserve battery life, the Gage powers-down after approximately 3 minutes of no activity. Allsettings are retained.

Principles of OperationF probes use the magnetic principle to measure

the thickness of non-magnetic coatings on ferrousmetals.

N probes use the eddy current principle to meas-ure the thickness of non-conductive coatings onnon-ferrous metals.

FN probes combine the full abilities of both the "F"and "N" probes.

CertificationAll probes or gages are shipped with a Certificate ofCalibration. For organizations with re-certificationrequirements, gages may be returned at regularintervals for calibration. DeFelsko recommends thatcustomers establish gage calibration intervals basedupon their own experience and work environment.Based on our product knowledge, data andcustomer feedback, a one year calibration intervalfrom either the date of calibration, date of purchase,or date of receipt is a typical starting point.

The PosiTector 6000 hand-held, electronic Gagenon-destructively measures the thickness of coat-ings on metals, quickly and accurately.

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Quick SQuick Sttartart1.Separate probe models - remove black protective

rubber cap from probe if supplied. Built-in probemodels - remove Gage from protective rubberholster.

2.Turn Gage on with any button.3.Place the probe FLAT on the surface to be

measured. HOLD STEADY. When a validmeasurement is calculated, the Gage BEEPStwice, the bi-color LED blinks green, and themeasurement is displayed.

4.Lift probe AT LEAST 2 INCHES (5cm) from thesurface between measurements - OR - leave probeon the surface in the same location for continuousmeasurements every 2 seconds. Do not drag theprobe sideways across the surface.

Golden RuleGolden RuleMeasure 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 theGage measures a known thickness within tolerance.

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Menu OperationMenu Operation

Current selection isdisplayed with darkenedbackground

Some buttons have a tick boxto their right to indicate currentstatus. An empty box indicatesthat feature is not active.

Gage functions are menu controlled. To access theMenu, turn the Gage on, then press the button.

To navigate, press (-) to scroll DOWN, (+) to scrollUP and to SELECT. Press both (-)(+) buttons atany time to exit any menu or select Exit from theMenu.

When there are more menu options than can fitonto one screen, a scroll bar will appear. Thedark area indicates what portion of the totalmenu you are currently viewing.

List boxes have a down arrow on the right-hand side.Use the (-) and (+) buttons until your desired choiceappears, then press to select this choice andmove focus onto the next item.

“Focus” is currently at thisunselected (empty) square box

“Radio” buttons.Only one can be

selected at a time.

“List“ box

a “tick” indicates this squarebox has been selected

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Calibration,Calibration, VVerificationerificationand and AdjustmentAdjustment

Three steps ensure best accuracy…

1. Calibration - typically done by the manufactureror a qualified lab

2. Verification of Accuracy - as done by the user3. Adjustment - to a known thickness

CalibrationCalibration is the controlled and documentedprocess of measuring traceable calibrationstandards and verifying that the results are within thestated accuracy of the Gage. Calibrations aretypically performed by the Gage manufacturer or bya certified calibration laboratory in a controlledenvironment using a documented process.

VerificationVerification is an accuracy check performed by theuser using known reference standards. A successfulverification requires the Gage to read within thecombined accuracy of the Gage and the referencestandards.

AdjustmentAdjustment, or Calibration Adjustment is the act ofaligning the Gage's thickness readings to match thatof a known sample in order to improve theeffectiveness of the Gage on a specific surface or ina specific portion of its measurement range. 1-pointor 2-point calibration adjustments are possible andthese are stored in calibration settings (pg. 9).

the symbol disappears whenever acalibration adjustment is made to the gage.

The PosiTector 6000 is factory calibrated andperforms an automatic self-check each time it takesa measurement. For many applications no further

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adjustment is necessary after a Reset (pg.15). Justcheck ZERO on the uncoated substrate, thenmeasure.But sometimes Gage readings can be influenced bychanges in substrate shape, composition, surfaceroughness or by measuring in a different location onthe part. That is why Calibration Adjustments aremade possible.1- or 2-point Calibration Adjustments may beperformed if readings are not falling within theexpected range of thickness for the application beingmeasured. Where a calibration adjustment method has notbeen specified, use a 1-point method first. If meas-uring the included shims reveals inaccuracies, usethe 2-point method. Factory Calibration settingscan be restored at any time by performing a Reset(pg.15), creating a NEW calibration setting (pg. 9), orby DELETING the adjustments made to the Cal 1calibration setting (pg.10). The symbol appearson the display whenever factory calibration settingsare in use.

With “FN” Gages, calibration adjustments aremade only to the “F” or “N” mode (stored independentlyunder 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 AdjustmentAlso known as an offset or correction value, thereare 4 ways to perform this adjustment:(1) Simple Zero Calibration AdjustmentMeasure your uncoated part. If the Gage does not read"0" within the tolerance of the probe being used, lift theprobe from the surface and adjust the display down (-)or up (+) until it reads "0". Measure and adjust until the

NOTE:

NOTE:

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average of a series of readings on the uncoated surfaceis "0" . (2) Average Zero Calibration AdjustmentTo establish “0” on a rough or curved surface apreferred method is to take several readings on theuncoated 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 10readings. The greater the variation betweenreadings, the more readings should be taken toobtain an average.

3.Repeatedly measure the uncoated part. The Gagewill wait 2 seconds between readings to allow theuser to correctly position the probe on the surface.After the last measurement the Gage will calculateand display "0" which represents the average of allthe Zero readings taken.

(3) Simple Adjustment to a Known ThicknessIt is sometimes desirable to adjust the Gage to aknown thickness, such as a shim, rather thanadjusting it to zero.Measure the object. If the expected reading is notobtained (within tolerance), lift the probe from thesurface and adjust the displayed reading down (-) orup (+) to the expected thickness. Hold the buttondown to increase the rate of adjustment.(4) Average Adjustment to a Known ThicknessOn rough or curved surfaces a preferred method isto take several readings on the known thickness andaverage 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 10readings. The greater the variation betweenreadings, the more readings should be taken toobtain an average.

3.Repeatedly measure the known thicknessreference. The Gage will wait 2 seconds betweenreadings to allow the user to correctly position theprobe on the surface. After the last measurementthe Gage will calculate and display the readingwhich represents the average of all themeasurements taken. If the expected reading isnot obtained (within tolerance) lift the probe fromthe 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 accuracywithin a limited, defined range.

This method requires taking two readings at knownthickness values: a thin value (often zero) and athicker value. These values should be on either sideof 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 beused to obtain an average on the thinner item,typically 3 to 10 readings. The greater the variationbetween readings, the more readings should betaken to obtain an average.

3.Repeatedly measure the thinner item. The Gagewill wait for 2 seconds on the surface to allow theuser to correctly position the probe on the surface.After the last measurement the Gage will calculateand display a thickness value which represents theaverage of all the readings taken using the factorycalibration settings.

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4.Lift the probe from the surface and adjust thedisplayed reading down (-) or up (+) to the knownthickness value of the thin item. Press to acceptthis value.

5.Repeat steps 2 - 4 for the thicker item.

When selected, the icon will appear and thecurrent calibration settings are “locked” to preventfurther user adjustments.User Mode CalibrationThere are applications where 1- or 2-pointcalibrations will not work satisfactorily such as whenmeasuring magnetic coatings, or conductivecoatings over non-metals. For these applications theincluded PosiSoft software can download special Calsettings.

Calibration MemoryCalibration Memory

It is often convenient to retain a particularcalibration adjustment before making another. Then,if you return to that part, the correspondingcalibration setting can be restored.

A “setting” is any calibration adjustment. ThePosiTector 6000 always displays the currentcalibra-tionsetting(ex. Cal 3) in the upper right corner of thedisplay.

The setting called Cal 1 has unique features. It can beadjusted but never deleted, and is always madeactive with factory settings after a Reset (see pg.15).

-creates a new calibration setting using the nextavailable number (Maximum of 10). By default, thesenew Cal settings are initially created with the Gage’sfactory settings. This is indicated with the icon

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-removes a setting completely from the list. That Calnumber can be reused later with the New command.A setting cannot be deleted if readings have beenstored into a batch using that calibration setting.Delete all readings in that batch first (see MemoryManagement pg. 11). Although Cal 1 cannot bedeleted, the Delete function will return it to factorysettings.

-sends a list of all Calibration Settings to either the IRprinter using the Gage’s built-in IR port, or to a PC’sdefault printer using the included USB cable.

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-loads an existing setting. Use the (-)(+) buttons toscroll the List box until the desired setting appears,then press . A warning message will prevent theopening of a stored Cal setting if a batch is open andhas readings. Create a new batch first or open abatch containing no readings. (see pg.12)

which appears at the bottom of the display. Awarning message will prevent the creation of a newCal Memory if a batch is open and has readings.Delete the batch first. (see pg.12)

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Memory ManagementMemory Management

The PosiTector 6000 can record 10,000measurements in up to 1000 groups (batches). Idealfor on-screen statistical purposes, printing to anoptional IR printer or PC’s default printer, or fordownloading to a personal computer using theincluded PosiSoft software and USB cable.Readings are time-stamped as they are taken.

-closes any currently opened batch and creates anew batch name using the next higher number. Forexample, if only Batch 1 and Batch 3 exist, then Batch4 would be created and made the current batch. The

icon appears and basic statistics are displayed.Each measurement will now be simultaneouslyshown on the display and stored into this new batch.On screen statistics are immediately updated witheach measurement. New batch names are datestamped at the time they are created.

When a batch is open, create a new batchby pressing (+)

-creates a new sub-batch. In this example, B2s2 is asub-batch of Batch 2. Sub-batching allows the user togroup related batches so that statistics can beaccumulated for them. Batch 2 contains the statisticsfor B2s1 and B2s2.

(Appears only if a batch is currently open)

current batch

current sub-batchand # readings statistics

(see pg. 14)

Shortcut:

current reading

# of sub-batches incurrent batch

When a sub-batch is open, create a newsub-batch by pressing (+)Shortcut:

-the PA2 feature helps the user determine if filmthickness over a large area conforms to userspecified min/max levels.

-selects a previously created batch or sub-batchname to open and make current. If it containsmeasurements, on-screen statistics will immediatelyreflect values calculated from this batch. Thecalibration setting (i.e. Cal 2) associated with thisbatch is also opened (see pg.9).

-stops the recording process, closes the currentbatch or sub-batch, and removes the statistics fromthe display.

-removes a batch or sub-batch completely frommemory. The name is deleted and all measurementsare erased. Sub-batches can be deleted individually.To delete all related sub-batches, simply delete thetop-level batch.

-lists all readings onto the display from the current ormost recently used batch or sub-batch. It begins byshowing the last 10 measurement values. Scrollusing the (-) or (+) buttons. Hold for 1 second toscroll a page at a time.

To change or delete a value, scroll to that value(align the “+” symbol beside it) then either takeanother measurement to change it, or press todelete it or exit. Statistics are updated.

To exit press (-)(+) buttons simultaneously.Shortcut:

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Downloading Measurements Stored in MemoryMeasurements stored in the Gage's memory (inbatches) can be downloaded to a computer usingthe supplied USB cable and the supplied PosiSoftsoftware. Measurements are not erased frommemory after downloading.

PosiSoft® ver.2.11 or higher is supplied on a CD fordownloading readings to a computer. It runs onWindows-based PC computers using MicrosoftWindows® 2000 SP3 or higher with a USB port. Itallows entry of notes and annotations, printshistograms and basic charts, manages data, andreadings can be exported to a document orspreadsheet.

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-outputs a statistical summary to the optional IRprinter using the built-in IR port, or to a PC’s defaultprinter using the included USB cable. Individualmeasurements with their time stamp are printed ifthe Readings box is ticked. A histogram is printed ifthe Graph box is ticked. HiLo calculations are printedusing current HiLo settings if HiLo Alarm is turned on(see pg.14).

- Calibration adjustments cannot be made if anymeasurements were taken with that setting andstored into a batch.

- Remove the last reading from the current openbatch by pressing (-).

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SSttatistical Functionsatistical Functions

-when Statistics is selected, a icon and statisticalsummary 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 audiblyalert the user when measurements exceed user-specified limits.

When HiLo Alarm is first selected, the current Losetting is displayed. Adjust down (-) or up (+).Alternatively, measure a coating with a thicknessclose to the required value and make finaladjustments with the buttons. Select NEXT to acceptthis 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 definedlimits. The Gage beeps and blinks green twice ifresults are within those limits. A single low tone willdisplay if it is below the Lo limit, and a HIGH tone if itis above the Hi limit. The LED will blink red if readingsare outside limits. Press (+) to clear HiLo readings.

Mean(average)

StandardDeviation

# of measurements Max and Min

measurement

StatisticsIcon

Lastreading

-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 theresultant display conveniently pointed toward theoperator.

Reset restores factory settings and returnsthe Gage to a known, out-of-the-boxcondition. It is handy when settings have beenchanged, if the Gage behaves unusually, or if acalibration adjustment is not possible. The followingoccurs: - 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 bythe 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 theGage is powered down by holding the (+) buttonuntil the Reset symbol appears. This is handywhen the Gage fails to power-up or operate properly.It performs the same function as a menu Reset withaddition of Units = microns, Flip Display = Normal andLanguage = English.

-Keep the Gage away from metal during a Reset.-Date and Time are not affected by any Reset.

Setup MenuSetup Menu

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When Hi Res is selected, the displayed gage resolu-tion becomes as follows:

Resolution Range0.01 mil 0.00 - 99.00 mils0.1 mil 100.0 - 999.9 mils

0.1 um 0.0 - 999.9 um0.01 mm 1.00 - 99.99 mm

- Gage accuracy is not affected by the Hi Res Mode.

This menu button converts the display and all storedreadings from inch to metric or vice versa.

All batches are date-stamped when created, and allmeasurements 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 thismenu button. Alternatively, the date and time can beautomatically updated when the gage is connectedto PosiSoft using the Gage Utilities -> Set Clock func-tion in PosiSoft.

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SepSeparate Probesarate ProbesSeparate Probe Gages consist ofa gage body and a probe. A wideselection of interchangeableprobes are available. Each retaintheir own unique calibration infor-mation. All Gage bodies accept all

probes. To disconnect, power-down the Gage andpull the plastic probe connector horizontally (in thedirection of the arrow) away from the Gage body. When powered-up the PosiTector 6000automatically determines what type ofprobe is attached and does a self-check.Probes “sense” when they are near metaland immediately attempt a measurementfollowed by another every 2 seconds.They stop when removed from the vicinityof metal and power-down after 3 minutesof no activity.The continuous measurement feature is onlyintended to allow careful probe placement on smallor odd-shaped surfaces. Simply ignore all readingstaken before the probe is properly placed. Do notdrag the probe sideways.

Standard probesThese constant-pressure, stainlesssteel probes are hermetically sealedto be totally waterproof - ideal forunderwater use. Hold them at the 2knurled rings and push the outerspring-loaded sleeve down. FN Combination ProbeAn FN probe combines thecapabilities of both "F" and "N" probes. Switchingbetween the two is automatic. The probe firstattempts a measurement using the magneticprinciple. If the coating is non-magnetic over steel, areading is displayed with a letter "F". If not, the probe

Do this...

Not this!

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TTemperatureemperatureOperating range: +32° to +120°F (0 to +50°C)The PosiTector 6000 compensates automaticallyfor temperature. Allow a few minutes for the probe toreach 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 theprobe at least 6 inches (15cm) and allow 1 secondoff 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 ideallysuited for measuring on small, hot or hard-to-reachsurfaces.

automatically attempts a measurement using theeddy current principle. If the coating is non-conductive over metal, a reading is displayed withthe 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 eddycurrent principle when measuring. This shortensmeasurement time and extends battery life.N Lock is also useful in instances such as measuringcoatings on plated steel.

AAvailable Optionsvailable OptionsA variety of accessories are available to help you getthe most from your PosiTector 6000 coatingthickness gage.

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Returning for ServiceReturning for ServiceBefore 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 theproblem fully and include measurement results, ifany. Be sure to also include the Gage, your compa-ny name, company contact, telephone number andfax number or email address.

TTroubleshootingroubleshootingSome common reports received by our ServiceDepartment along with possible causes are locatedon our website. Most conditions however can becleared with a Reset (pg. 15).

Nickel-cadmium and nickel-metal hydride recharge-able batteries will work but the Gage may appear tohave weak batteries. To retain all user settings and stored memory read-ings, only replace the batteries after the Gage hasautomatically powered-down.

Changing The BatteriesChanging The BatteriesThe battery icon displays four bars with freshalkaline batteries installed. As the batteries weaken,the number of bars will be reduced. When the batteryIcon is down to one bar , the Gage can still beused, but the batteries should be changed at the ear-liest opportunity. USE ONLY “AAA” ALKALINE BATTERIES

WWarrantyarrantyDeFelsko fully warrants its products against defectsin workmanship or materials under normal use for aperiod of two years from date of purchase. In theevent that an instrument is believed to be defective,return the product with proof of purchase to yourdealer. If upon DeFelsko’s inspection of theinstrument, it is determined in our sole discretion thatthe returned instrument is defective as toworkmanship or material, the instrument will berepaired 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 beenopened.Data subject to change without notice.

TTechnical Datechnical DataaGage 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: 516-295-4300 • FAX: 516-295-4399