PosiTector 6000INSTRUCTION MANUAL v. 6.2

for Basic (1) and Standard (2) models

Simple. Durable. Accurate.

Coating Thickness Gages

Separateprobe

Built-inprobe

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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 measurethe thickness of non-conductive coatings on non-ferrous metals.

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

Throughout this manual, the symbolindicates more information about the particular topicor feature is available on our website.

Go to: www.defelsko.com/manuals

NOTE:

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 ofcoatings on metals, quickly and accurately.

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Quick SQuick Sttartart1.Separate probe models - remove red protective

rubber cap 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 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 on the surface.

Golden RuleGolden RuleMeasure your uncoated part first! This quick zero-check determines if a calibration adjustment isneeded for your substrate. (See pg.5) Next, lay the included plastic shims onto the baresurface and measure them individually to ensure theGage can measure a known thickness withintolerance.

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Menu OperationMenu Operation

Calibration,Calibration, VVerificationerificationandand 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.

Current selection is dispayedwith darkened background

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.

Memory and Statistics onStandard (2) models only

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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.

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 furtheradjustment is necessary after a Reset (pg.11). 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.11). The symbol appears on the displaywhenever factory calibration settings are in use.

NOTE:

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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 currentcalibration adjustment to prevent further modification.(See “Cal Lock” on pg. 8)

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 theaverage 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.

NOTE:

NOTE:

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(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 a

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thicker 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.

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.

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Memory ModeMemory Mode

Standard (2) Gages only

The PosiTector 6000 can record 250measurements for on-screen statistical purposes, forprinting to an optional IR printer, or for downloadingto a personal computer using optional PosiSoftsoftware and USB cable.

-begins recording. Readings are simultaneouslydisplayed and stored. The icon appears andstatistics (Statistics pg.10) are displayed. Previouslyrecorded measurements are retained. Remove thelast reading from memory by pressing (-).

-stops the recording process and removes thestatistics from the display.

-removes all readings from memory.

-lists all stored readings on the display. It begins byshowing the last 10 measurement values. Scrollusing the (-) or (+) buttons. Hold for 1 second toscroll a page at a time. Press to exit.

-prints all stored measurements to the optional IRprinter. Press (-)(+) to cancel printing.

Downloading Measurements Stored in MemoryMeasurements stored in the Gage's memory (inbatches) can be downloaded to a computer usingoptional PosiSoft software and USB cable.Measurements are not erased from memory afterdownloading. PosiSoft® allows entry of notes and annotations,prints histograms and basic charts, manages data,

SSttatistical Functionsatistical Functions

-when Statistics is selected, a icon andstatistical 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 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 it

Mean(average)

StandardDeviation

No. of measurements Max and Min

measurement

StatisticsIcon

Lastreading

Standard (2) Gages only

and readings can be exported to a document orspreadsheet.

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-zeros all on-screen Statistics and HiLo tabulations.

is above the Hi limit. The LED will blink red ifreadings are outside limits. Press (+) to clear HiLoreadings.

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 for somereason. The following occurs: - all stored measurements are erased.- calibration adjustments are cleared and returned

to the Gage’s factory calibration settings. - This symbol appears on the display: It

disappears if a calibration adjustment is made bythe user.

- menu setting are returned to the following:Hi Res = OFF Memory = OFFCal Lock = OFF Statistics = OFFHi 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.

Setup MenuSetup Menu

NOTE:

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 um1 um over 1000 um

- 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.

NOTES:

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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.

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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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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.

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 notablydifferent temperature condition. When measuringsurfaces 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.

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

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TTroubleshootingroubleshootingSome common reports received by our ServiceDepartment along with possible causes are locatedon our website. Most conditions however can becleared with a Reset (pg.11).

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.

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 thebatteries become very weak the PowerWarning image will display and the Gage willautomatically power-down. To maintain user settingsand stored measurements, the batteries must bereplaced. USE ONLY “AAA” ALKALINE BATTERIES

This image appears if the memory of thegage has become corrupt. This can occur in

the event that the gage batteries were removedwhile the instrument was powered-on and the gagewas not able to self power-down. If this messageappears it will be followed by a full reset. All readingsin memory will be erased and gage settings will bereset to "out-of-the-box" settings.

To retain all user settings and storedmemory readings, only replace the batteries after theGage has automatically powered-down.-Nickel-cadmium and nickel-metal hydride recharge-able batteries will work but the Gage may appear tohave weak batteries.

NOTES:

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www.defelsko.com© DeFelsko Corporation USA 2009

All Rights Reserved

This manual is copyrighted with all rights reserved and may not be reproduced ortransmitted, in whole or part, by any means, without written permission fromDeFelsko Corporation.

DeFelsko, PosiTector and PosiSoft are trademarks of DeFelsko Corporation regis-tered in the U.S. and in other countries. Other brand or product names are trade-marks or registered trademarks of their respective holders.

Every effort has been made to ensure that the information in this manual is accu-rate. DeFelsko is not responsible for printing or clerical errors.

Limited WLimited Warrantyarranty, Sole Remedy, Sole Remedyand Limited Liabilityand Limited Liability

DeFelsko's sole warranty, remedy, and liability arethe express limited warranty, remedy, and limitedliability that are set forth on its website:

www.defelsko.com/terms

Returning for ServiceReturning for ServiceBefore returning the Gage for service…1.Install new Alkaline batteries in the proper

alignment 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.11).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 companyname, company contact, telephone number and faxnumber or email address.Website: www.defelsko.com/support