Ultrasonic Coating Thickness Gage

Instruction Manual v. 3.1

Standard
and
Advanced
 Table of Contents
Introduction ......................................................... 4
Quick Start .......................................................... 4
Certification ......................................................... 5
Probes ................................................................. 7
How to Measure .................................................. 8
Calibration, Verification and Adjustment ............. 9
Menu Operation .................................................. 10
Cal Settings Menu ............................................... 11
Zero ................................................................ 11
Set Range ...................................................... 11
Thickness ....................................................... 12
Polyurea ......................................................... 12
Cal Lock ......................................................... 12
Cal Reset ....................................................... 12
Setup Menu ......................................................... 13
Reset .............................................................. 13
Gage Info ....................................................... 14
Graphics ......................................................... 14
Layers ............................................................ 16
Memory Management ......................................... 18
Standard Models Menu .................................. 18
Advanced Models Menu ................................ 19
Annotate ......................................................... 20
Display ........................................................... 21
Summaries ..................................................... 22
Screen Capture .............................................. 22
Accessing Stored Measurement Data ................ 23
PosiSoft Desktop Manager (PDM) ................. 23
PosiSoft.net .................................................... 24
PosiSoft Mobile .............................................. 25

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Connect Menu ..................................................... 26
Sync Now ....................................................... 26
Auto Sync ....................................................... 26
USB Drive ...................................................... 26
Bluetooth ........................................................ 28
Bluetooth Wireless Printer ............................. 29
WiFi ................................................................ 29
Updates .......................................................... 32
Application Notes ................................................ 33
Measuring on rough surfaces ........................ 33
Measuring on dense (hard) surfaces ............. 34
Measuring total thickness (multi-layers applications) ..... 34
Troubleshooting - General................................... 34
Gage does not turn on ................................... 34
Gage powers up but fails to stay on .............. 34
Gage readings are lower than expected ........ 34
Gage readings are higher than expected ...... 35
Gage does not yield accurate or consistent results ...... 35
Gage displays an error message ................... 35
Gage displays dashed line “----” .................... 35
and emits low-tone buzz ...................... 35
Power Supply / Battery Indicator ........................ 36
Rechargeable Batteries ...................................... 36
Additional Accessories ........................................ 36
Coating Thickness Standards ........................ 38
Technical Data .................................................... 39
Probe Details & Specifications........................ 39
Operating Temperature Range....................... 39
Size / Weight.................................................. 39
Returning For Service ......................................... 40
Warranty .............................................................. 40
3
 Introduction
The PosiTector 200 is a hand-held Coating Thickness Gage that
uses a non-destructive ultrasonic principle to measure coating
thickness on a wide variety of substrates. It consists of a body
(Standard or Advanced) and a probe (see Probes pg. 7).

PosiTector 200 Kit Contents

- PosiTector body (Standard or Advanced)
- PosiTector probe (200 B, C or D)
- Protective rubber cap for Probe
- Protective lens shield
- Wrist strap
- 3 AAA alkaline batteries
- Quick Guide instruction booklet
- Protective rubber holster
- Nylon carrying case with shoulder strap
- Belt clip for rubber holster and carrying case
- USB Cable
- 4 ounce (118 ml) bottle ultrasonic couplant
- Precision Plastic Shims
- 2500 microns (100 mils) Polystyrene Block (C & D Probe only)
- Certificate of Calibration traceable to NIST
- PosiSoft.net account
- Two (2) year warranty on Body and Probe
Quick Start
The PosiTector 200 powers-up when the center navigation button
is pressed. To preserve battery life, the Gage powers down
after approximately 5 minutes of no activity. All settings are
retained.
1. Remove the protective rubber cap from the probe.
2. Power-up Gage by pressing the center navigation button.
3. Zero the probe. (see pg. 11)
4. Adjust to a known thickness, if necessary. (see pg. 12)
5. Measure the part. (see pg. 8)

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Protective Cap
PosiTector 200 gages ship with a protective rubber cap over the
probe. Remove this cap prior to use. Replace it when the Gage is
not in use to protect the probe.

Wrist Strap
We recommend attaching and wearing the 2
supplied wrist strap.
1
Protective 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 Gage, can be left in place to
protect against paint overspray or debris. Replacements can be
purchased.

Couplant
Couplant is required to propagate ultrasound into the coating.
Water is a good couplant for smooth coatings. Use the supplied
glycol gel for rougher coatings. While it is unlikely that the
couplant will damage the finish or leave a stain on the surface, we
suggest testing the surface by using the couplant on a sample. If
testing indicates that staining has occurred, a small amount of
water can be used instead of couplant. Consult the Material Safety
Data Sheet available on our website and your coating supplier if
you suspect the couplant may damage the coating. Other liquids
such as liquid soap may also be used.

Certification
All PosiTector 200 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.

5
 PosiTector Body

USB Port
200 B probe

LCD
Display

200 C probe

Probe
Connector 200 D probe

Typical Display

Battery
Icon
2.1 thou/mils Unit of
Measurement
Current Factory Calibration
Measurement settings in use.

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 Probes
To disconnect a probe from a body, power-down the
Gage and slide 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.
PosiTector 200 probes are available for measuring a
wide variety of coating thickness applications.
B probe - 13 to 1000 microns (0.5 to 40 mils)
Ideal for polymer coatings on wood, plastic, composites, etc.
C probe - 50 to 3800 microns (2 to 150 mils)
Ideal for thicker coatings on concrete, fiberglass, etc.
D probe - 50 to 5000 microns (2 to 200 mils) - Polyurea
- 50 to 7600 microns (2 to 300 mils) - Other Coatings
Ideal for thick or soft (attenuative) coatings
NOTE: Range limits apply to polymer coatings only.
Additionally, the PosiTector accepts a number of probe types
including magnetic and eddy current coating thickness, surface
profile, environmental and ultrasonic wall thickness probes.
Perform the latest software Updates (pg. 32) to ensure probe
compatibility with your Gage. For the latest information on probe
interchangeability see www.defelsko.com/probes

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 Ultrasonic Thickness
Theory of Operation
The PosiTector 200 probe emits a high frequency sound pulse
that travels into the coating via a coupling gel and reflects from
ANY surface that is different in density. Coating thickness readings
are obtained by measuring the time taken for the ultrasonic signal
to propagate from the probe to the coating/substrate interface and
back. The travel time is divided by two and multiplied by the
velocity of sound in the coating to obtain the thickness of the
coating.

Couplant
Probe The PosiTector 200
interprets the largest
“echo” within the
selected range as the
Coating 1
coating/coating or
coating/substrate echo.
Coating 2

Substrate

How to Measure
1. Remove the protective rubber cap from probe.
2. Power-up Gage by pressing the center navigation
button.
3. Apply couplant (see pg. 5) to the surface of
the part.
4. Place the probe FLAT on the surface and
press down.
5. Lift the probe when you hear a double BEEP,
- OR - leave probe on the surface in the same location for
continuous measurements.
6. When completely finished, wipe the probe clean of couplant
then return the Gage to the protective pouch. There is no need
to disconnect the probe from the PosiTector during storage.

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 Calibration, Verification and Adjustment
Three steps ensure best accuracy…
1.Calibration - typically done by the manufacturer. All probes
include a Certificate of Calibration.
2.Verification of Accuracy - typically done by the user on known
reference standards such as plastic shims or coated thickness
standards.
3.Adjustment - to a known thickness

Calibration
Calibration is the high-level, controlled and documented process
of measuring traceable calibration standards over the full
operating range of the probe, and verifying that the results are
within the stated accuracy of the probe. Calibrations are
performed by the manufacturer, their authorized agent, or by an
accredited calibration laboratory in a controlled environment using
a documented process.

Verification
Verification is an accuracy check performed by the user on known
reference standards. A successful verification requires the Gage
to read within the combined accuracy of the probe and the
reference standards.

Adjustment
Adjustment, or Cal Adjustment, is the physical act of aligning the
probe’s thickness readings to match those of a known thickness
sample (removal of bias) in order to improve the accuracy of the
probe on a specific coating. See Thickness pg. 12.

9
 Menu Operation
Gage functions are menu controlled. To access the Menu,
power-up the Gage, then press the center navigation button.

Below is a sample menu for a PosiTector 200 Advanced model:

Memory Some buttons have a tick box to their

right to indicate current status. An empty
Cal Settings box indicates that feature is not active.

Setup Sync Now

Connect USB Drive
Help Auto SYNC ü
Power Off Bluetooth
Exit WiFi
Powder Probes
Current selection is displayed
with darkened background Updates
Exit
Navigation Button
Up To navigate, use the Up and Down buttons to
scroll and to SELECT.
Center

Down
Select Exit to exit from any menu.

NOTE: The center button is purposely recessed to help

eliminate unintentional powering-up of the Gage.

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 Cal Settings Menu
Zero
PosiTector 200 probes must be periodically zeroed using the
ZERO menu option to compensate for both extreme temperature
and probe wear effects. Before using, allow the probe to reach
ambient temperature.
If measurements will be made in extreme hot or cold temperatures,
it is recommended to ZERO the probe in the working environment.
If measurements will be made on rough substrates, it is
recommended to periodically ZERO the probe to compensate for
wear.
1. Make sure the Gage is on and the probe is wiped clean.
2. Hold probe in air, away from substrate.
3. Select the Zero menu option.
4. When complete, Gage will double beep and display “----”.

Set Range
The measuring range of each probe can be changed depending on
the specific application or the expected thickness range of the
coating system.
For most applications, the default range values do not have to be
adjusted. But some conditions, like surface roughness, may cause
the Gage to display very low or non-repeatable readings. In this
case, the low range may be increased to cause the Gage to only
display readings above the Lo value set by the user.
To adjust Set Range values...
1. Select or with the Up and Down buttons.
2. Use the (-)(+) buttons to decrease/increase the displayed value.

IMPORTANT:
The PosiTector 200 interprets the largest “echo” or “echoes”
within the selected range as the coating/coating or
coating/substrate echo. If the coating thickness is outside this
range, incorrect or dashed readings may occur.

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Here are some typical Range settings...
Expected paint thickness Lo Range Hi Range
500µm (20 mils) on concrete 130µm (5 mils) 1000µm (40 mils)
50µm (2 mils) on wood 25µm (1 mil) 250µm (10 mils)
Thickness
The PosiTector 200 measures most polymer coatings accurately
out-of-box with no adjustment required.

To determine if an adjustment is necessary, select a coating

sample of known thickness as close as possible in composition to
the intended application. For best results, the thickness of the
sample should be equal to or slightly greater than the maximum
expected thickness of the coating to be measured.

Measure the coated sample. If the average of a series of

measurements on the sample is not close to the known
thickness...
1. Select the Thickness menu option.
2. Use (-) or (+) to decrease/increase the displayed measurement
thickness value to match the known thickness of the sample.
3. For Advanced models with multiple layers selected, use the
Down navigation button to select the next layer and adjust as
necessary.
4. To save adjustments, use Down navigation button to highlight
OK and press the center navigation button.
Polyurea ü (PosiTector 200 D probes only)

When checked, the Gage loads a pre-programmed calibration

adjustment optimized for measurement of polyurea coatings.
“Polyurea” will appear on the upper right corner of the display.
NOTE: D Probe Measuring Range: 2 - 200 mils (50 - 5000 um)
Cal Lock ü
When checked, the icon appears and the current calibration
settings are “locked” to prevent further user adjustments.
Cal Reset
Restores the Gage back to factory calibration and range settings.
The icon will appear on the display.
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 Setup Menu
Reset
Reset (soft reset) restores factory settings and returns the Gage
to a known condition. The following occurs:
- All batches, stored measurements, images, batch names and
screen captures are erased.
- All calibration and range adjustments are cleared and returned
to the Gage’s factory settings.
- The icon will appear on the display.
- Menu settings are returned to the following:
Memory = OFF Bluetooth = OFF Layers = 1
Graphics = ON Display = None Layer Name = Layer 1
Cal Lock = OFF Layer Color = blue

Perform a more thorough Hard Reset by powering down the

Gage, waiting several seconds, then simultaneously holding both
the center and (+) buttons until the Reset symbol
appears. This returns the Gage to a known, “out-of-the-box”
condition. It performs the same function as a menu Reset with the
addition of:
- Bluetooth Pairing info is cleared.
- Menu settings are returned to the following:
Units = microns Battery Type = Alkaline
Flip Display = Normal Backlight = Normal
White on Black = OFF USB Drive= ON
Language = English Auto Sync = OFF
Polyurea = OFF
NOTE: Date, Time and WiFi settings are not affected by either
Reset.

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 Gage Info
Displays the model number & serial number, probe type & serial
number, PosiSoft.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

Gage to your PosiSoft.net account.

Graphics ü (Advanced models only)

When selected, the Gage displays a

graphical representation of the
ultrasonic pulse as it travels through the
coating system.

As the probe is depressed and the

ultrasonic pulse travels through the
coating system, the pulse encounters
changes in density at the interfaces
between coating layers and between the
coating and the substrate.

These interfaces are depicted by a "peak". The greater the change

in density, the higher the peak. The more gradual the change in
density, the greater the width of the peak. For example, two coating
layers made of essentially the same material and "blended" would
result in a low, wide peak. Two materials of very different density
and a well-defined interface would result in a high, narrow peak.

The PosiTector 200 chooses the highest peak (single layer) or

peaks (multi-layer) within the Set Range. For example, if the
number of layers is set to 3, the three highest peaks would be
identified with small red triangles. The peak values are also
displayed numerically as thickness measurements.

NOTE: The Graphics display can also be accessed using the

Set Range menu option.

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Use the navigation Up (move left) and Down (move right) buttons
to highlight icons on the graphic display.

Zoom - Visually magnifies the waveform of the displayed

peaks for more visibility. Pressing the (+) or (-) button repeatedly
will increase/decrease the zoom.

Set Range - Press the (-) or (+) buttons to adjust the

Gage’s Lo or Hi measuring range (See pg. 11).

Cursor - The Cursor allows for further analysis of displayed

waveform. Use the (-)(+) buttons to move the green cursor line left
or right over the waveform. The thickness value is displayed at the
top right of the cursor line. This feature is particularly
useful in multi-layer applications where there are more than
3 distinct layers.

Screen Capture - Press to capture and save an image

copy of the current display. The last 10 screen captures are stored
in memory and can be accessed when connected to a computer
(See examples pg. 22 and PosiSoft USB Drive pg. 23).
Shortcut: Press and hold the (-)(+) buttons simultaneously to
capture any screen.

Menu - Press to access the Gage’s main menu.

Exit - Press to close the Graphics display. Press the Up

button to return to the Graphics display.

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 Layers (Advanced models only)

Advanced models of the PosiTector 200 are capable of

numerically displaying up to three individual layer thicknesses in a
multi-layer system.
Example:
Two Layer Application
Couplant
Probe

Layer 1
Layer 2
Substrate

From the Layers menu option... Total

thickness
Select up to three individual layer thickness values:

Edit:
- Edit Layer Names (up to 7 characters)
- Edit Layer Color (blue, green or red) - See Display, pg. 21.

NOTES:
• Before setting up the Gage for multi-layer measurement, it is
recommended that you first take measurements in single
layer mode and interpret the results using the Graphics option
(See pg. 14).
• When a batch is Open, press the Up button to view the Batch
Chart.

16
 Flip Display
This option causes the display to rotate 180°. Ideal for right-side-
up viewing when the sensors are pointed away from the user.

White on Black (Advanced models only)

Inverts the LCD display to white on a black background to provide
better readability in some surroundings.

Backlight (Advanced models only)

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.

Set Clock
All measurements are date and 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 Gage’s date and time can also be viewed in Gage Info
(pg. 14).

Battery Type
Selects the type of batteries used in the Gage from a choice of
“Alkaline”, “Lithium” or “NiMH” (Nickel-metal hydride
rechargeable). If NiMH is selected, the Gage will trickle charge the
batteries while connected via USB to a PC or optional AC charger
(Gage must be powered ON). 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 eneloop (NiMH) rechargeable batteries
(pg. 36).
Units
Converts the display from inch to metric or vice versa. Stored
measurements in memory are not converted.
Switching units will turn off Statistics view and closes Memory.
Language
Converts displayed and printed words to the selected language.

17
 Memory Management
The PosiTector 200 has internal memory storage for recording
measurement data. Stored measurements can be reviewed
on-screen or accessed via computers, tablets and smart phones.
Measurements are date and time-stamped.

Button functions with Memory ON:

Scroll through display Create a new batch
modes (Advanced only) (Advanced only)

Delete last reading Restore brightness

after dimming
Access the Menu
(Advanced only)

Standard models store up to 250 readings in one batch.

The Memory Menu includes the following options...

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 display.
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.

Standard Model display with Memory ON shows measurement

statistics:
Mean
(average) # of readings
in memory
Standard Deviation

Maximum Minimum
measurement measurement

Last
reading

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Advanced models store 100,000 readings in up to 1,000
batches. The Memory Menu includes the following options...

New Batch
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. Each reading is also data/time stamped.

Shortcut: When a batch is open, press (+) to create a new batch

current batch # readings in current batch

Mean (average) Standard Deviation

Maximum Minimum
measurement measurement

Last reading

NOTES:
• Remove the last reading from the current open batch by
pressing (-).
• Calibration adjustments cannot be made if readings are
stored in memory.
• If memory is ON, continuous measurements can be taken but
results will not be stored in memory.
Open
Selects a previously created batch name to open and make
current. If it contains measurements, onscreen statistics will
immediately reflect values calculated from this batch.
Close
Stops the recording process, closes the current batch, and
removes batch information from the display.

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 Delete
Removes a batch completely from memory. The name is deleted
and all measurements are erased.

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.

Annotate
Create meaningful batch names and
enter notes directly on the Gage using a
familiar onscreen QWERTY
keyboard.

Use the Gage’s navigation and (-)(+)

buttons to enter annotations.

Annotations can be synchronized with

PosiSoft.net and are included in all
PosiSoft reports (see Accessing
Stored Measurement Data, pg. 23).

NOTE: Annotations can also be

created using PosiSoft.net (pg. 24) or PosiSoft Mobile (pg. 25).

Print
Sends a statistical summary and individual measurements to the
optional Bluetooth wireless printer (see pg. 29).
NOTE: To cancel printing, press and hold the (-) and (+) buttons
simultaneously.

20
 Display (appears only if a batch is currently open)
The following user selectable display options are available:
Chart: A real-time chart of batch readings
x-y Chart for Stack Chart for
Single Layer Application Multi-Layer Application

Image: Batch image

Notes: Instructions, descriptions or notes (see Annotate, pg.20)

None: Default screen shows statistics

When a batch is open, press Up to scroll through the above
Shortcut: display options.
NOTE: PosiSoft.net (pg. 24) and PosiSoft Mobile (pg. 25) are used to
insert an Image and Notes into a batch.

21
NOTES: Remove the last reading from the current open batch by
pressing (-).

Calibration adjustments cannot be made if any measurements

were taken with that Cal setting and stored into a batch.

Each batch can contain a maximum of 10,000 readings.

Summaries (Advanced models only)

Displays a summary of all stored

batches including the name, probe
type, number of readings and type.

In the following example, Batch 3

(B3) indicates an “F” 6000 coating
thickness probe was used to record a
total of “6” readings in “PA2” mode.

Screen Capture
Press both (-)(+) buttons at any time to capture and save an
image copy of the current display. The last 10 screen captures
are stored in memory and can be accessed when connected to
a computer (see PosiSoft USB Drive pg. 23).
Sample Screen Captures

22
 Accessing Stored Measurement Data
PosiSoft solutions for viewing, analyzing and reporting data:
PosiSoft USB Drive - connect the
PosiTector to a PC/Mac using the
supplied USB cable to access and print
stored readings, graphs, photos, notes
and screen captures. No software or
internet connection required. USB Drive
must be selected (See pg. 26).
PosiSoft.net - a free web-based application offering secure
centralized storage of PosiTector readings. Access your data from
any web connected device. Go to: www.PosiSoft.net
PosiSoft 3.0 - Desktop Software for downloading, viewing and
printing your measurement data.
PosiSoft Mobile (Advanced models only) - access readings, graphs,
capture photos and update annotations through WiFi enabled
devices, such as tablets, smart phones and computers.

PosiSoft Desktop Manager (PDM):

A small Windows based application which allows automatic two-
way communication (synchronization) between the Gage and
PosiSoft.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 PosiSoft.net account or at
www.defelsko.com/downloads
Register your Gage on PosiSoft.net to take full advantage of your
Gage’s capabilities. See www.PosiSoft.net
NOTE: PDM is not required for WiFi enabled gages (pg. 29).

23
PosiSoft.net:
To enhance the operation of your Gage, all PosiTector users have
access to the features provided by PosiSoft.net. It is a web-based
application offering secure centralized management of readings.
After (1) a user account has been created, (2) a Gage has been
registered, and (3) the PosiSoft Desktop Manager is downloaded
and installed onto a Windows PC (not required for WiFi connected
gages), synchronization of measurement data can be performed
either manually or automatically whenever the PosiTector is
connected to a web enabled PC (USB cable or Bluetooth wireless
technology) or WiFi network (Advanded gages only). Gage
measurements stored in memory are uploaded; images and batch
notes are synchronized.
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.
Measurement data can be shared with authorized users via a
secure login from any computer and most web enabled devices
including smart phones.
NOTE: A PosiSoft.net account is not required to Update (pg. 32)
your PosiTector. Simply download and install PosiSoft Desktop
Manager at www.defelsko.com/downloads

PosiSoft 3.0:
Desktop Software that can be installed onto your Windows PC and
allows the user to download, view, print and analyze their
measurement data.
Reports and graphs with annotations and corporate logo can be
generated. Data can be exported to XML or CSV (comma
delimited) text files.
NOTE: PosiSoft Software is available for use with DeFelsko’s
complete line of electronic instruments and is available for download
at www.defelsko.com/posisoft

24
PosiSoft Mobile:
Is a Gage-based software application featured in all PosiTector
Advanced instruments (serial numbers 730,000+).
PosiSoft Mobile allows users to:
• browse stored measurement data including
notes, images, statistics and charts
• update batch names/notes using your
mobile device's keyboard
• insert images directly into Gage batches
using your mobile device's camera or
image library
• remotely view the live display of a working
PosiTector & more
PosiSoft Mobile can be
accessed from any WiFi
enabled device using a
standard web browser.
Ideal for use with devices such as Windows
Phone/Mobile, Blackberry (RIM), Android,
Apple iOS and more.
In addition to browser based access,
PosiSoft Mobile Managers are available for
Apple iOS and Android users.

See www.defelsko.com/wifi/wifi_mobile

25
 Connect Menu
Synchronizing (Sync) is the process whereby PosiTector stored
measurement data uploads to PosiSoft.net (from both Standard
and Advanced models) while images and batch notes are
downloaded to the Gage (Advanced model only). This transfer
occurs when the Gage is connected via USB, Bluetooth or directly
through your WiFi router/hotspot via WiFi. It can be triggered either
manually (USB, Bluetooth or WiFi) or automatically (USB only).

Sync Now
When selected, the Gage immediately synchronizes stored
measurement data via USB, Bluetooth or WiFi to PosiSoft.net
(PosiSoft Desktop Manager (pg. 19) and an internet connection
are required when using USB or Bluetooth.)
Multiple gages can be synchronized simultaneously when
connected using multiple connections (for example two gages
connected via USB and one gage connected via WiFi or
Bluetooth).

Auto SYNC ü
Allows the Gage to automatically synchronize stored
measurements with PosiSoft.net when initially connected to the
internet via a PC running PosiSoft Desktop Manager (pg. 19) or a
local WiFi network.
Additional measurements added to memory while connected are
synchronized only when the USB cable is disconnected, then
reconnected or when the Sync Now option is selected.

USB Drive ü
Universal Serial Bus (USB) is a specification for 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.

26
When checked, any computer can view 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" or
“START_HERE.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.
NOTE: When connected, 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 Gage will trickle charge the batteries.

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Retrieving stored screen captures
The last 10 screen captures (pg. 22) stored in memory can be
accessed by navigating to the “screen_capture” directory within
the “PosiTector” virtual drive.

Bluetooth (Advanced models only)

PosiTector Advanced models have Bluetooth functionality to:

- Communicate with the PosiSoft 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.
On: Turns Bluetooth functionality On. When selected, the icon
will appear on the display. To deactivate Bluetooth, select Off.
Pairing: The Gage and receiving device must be paired before
stored or streamed readings can be transmitted. For pairing
instructions, see www.defelsko.com/bluetooth
Info: Lists information about your current Bluetooth connection,
including the currently paired device and MAC address.
Stream: When checked, the Gage will stream readings to the
paired Bluetooth Device as they are taken. Readings can be
streamed as they are taken to the optional Bluetooth wireless
printer (pg. 29) or third-party computer software.
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Bluetooth Wireless Printer
PosiTector Advanced models can output to
the optional battery powered Bluetooth
wireless printer one of two ways:
• Stream individual readings as they are taken.
• Print stored batch readings and summaries.
Begin by entering the Connect > Bluetooth menu. Turn Bluetooth
ON and “Pair” the PosiTector to the printer.
See: www.defelsko.com/bluetooth
Streaming: In the Connect > Bluetooth menu, select the Stream
tick box. All readings will now be simultaneously displayed on the
LCD and sent to the printer.
Printing: In the Memory menu, select Print.

WiFi (Advanced models only)

Allows wireless communication with devices such as tablets,

smart phones and computers connected to your local wireless
network or portable mobile hot spot. See www.defelsko.com/WiFi

On/Off ü : Turns WiFi functionality On. When selected, the

icon will appear on the display. To deactivate WiFi, select Off.

Access Point ü : Connect your smart device/computer to a

PosiTector Advanced body wirelessly without the need for a
separate network. Wirelessly import readings into PosiSoft 3.0
Desktop Software or access PosiSoft Mobile in the field or
whenever a WiFi network is not available or out-of-range.

To enable, select Access Point from the Connect > WiFi menu.
The Access Point icon will display in the upper left of the
PosiTector display.

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 Securing your Access Point
To ensure the PosiTector is only accessible to authorized devices,
it is important that you enter a passphrase (password) for the
Access Point. The default Passphrase is password.

In the Connect > WiFi > Setup menu, select AP Passphrase.

Press button to display on-screen keyboard. Enter a
Passphrase for the Access Point. The Passphrase will be required
for all devices connecting to the PosiTector’s Access Point.

The PosiTector is now visible to all WiFi enabled devices. Simply

connect your devices WiFi to the new PosiTector Access point. All
PosiTectors are uniquely identified by their respective gage body
serial numbers.

AP Channel
Default Channel: 6
For most users the default channel will not have to be altered.
If you are experiencing poor connection or are unable to connect,
try another channel.

In the Connect > WiFi > Setup menu, select AP Channel.

Press the UP center navigation button to highlight the channel.
Use the (-) or (+) buttons to change the channel. Press the DOWN
navigation button and select OK. Press the button.

Import readings into PosiSoft 3.0 Desktop Software (pg. 24)

From the PosiSoft 3.0 menu, select Import > From Gage. All
connected gages will display their unique serial number.
Measurement data will be displayed upon completion of the
import.

The time it takes for import will depend on the number of Batches
and measurements present within the gage. Imports generally
take no longer than a few seconds.

Batches are not erased from the gages memory during import.
They remain on the gage until they have been deleted by the user.
For more information regarding PosiSoft 3.0:
http://www.defelsko.com/posisoft/posisoft_software.htm
30
 Accessing your PosiTector PosiSoft Mobile (pg. 25)
For use on Apple iOS and Android devices:
PosiSoft Mobile Manager apps exist for Apple iOS and Android users.
Simply download the App from the Apple App Store or Google Play.

Once your smart device/computer has been connected to the

PosiTector Access Point, open the PosiSoft Mobile Manager app.
Select your PosiTector from the list to open PosiSoft Mobile.

For use with all WiFi enabled devices:

Any WiFi enable device connected to the PosiTector Access Point can
view the instrument’s built-in PosiSoft Mobile web interface. Using your
device’s web browser, enter the IP address of your PosiTector to
access the features of PosiSoft Mobile.

In the Connect > WiFi menu, select Information to view the

IP address associated with your PosiTector.

Enter the displayed IP address into your devices web browser exactly
as it appears. Example: 192.168.0.1:8080

For more information regarding PosiSoft Mobile:

http://www.defelsko.com/posisoft/posisoft_mobile.htm

Networks: The Gage will allow the user to add a new network and will
automatically check for available local networks. Available networks
detected by the Gage are listed on the screen along with any networks
that the Gage has previously been connected to that are not currently
within connection range.

Information: Gage displays information about the local WiFi network

connection including...
• SSID: the network’s name
• State: displays if the Gage is connected to the network or not
• IP Address: the network’s IP Address. Users can enter this
number into a web-browser of any WiFi enabled device that is
connected to the same network in order to view the Gage’s
synced batches through PosiSoft Mobile (See pg. 20).
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Setup: Allows user to setup a WiFi connection
• IP Settings: enter the IP information as follows...
IP Type (DHCP or Static), IP Address, Gateway, Netmask,
DNS1, DNS2.
• Server Enable: enables a connection between the network
and the Gage.
• Gage Name: enter a name for the Gage
(up to 14 Characters).
• WiFi Reset: erases all WiFi settings.

Updates
Determines if a software update is available for your Gage. If an
update is available, a prompt will appear allowing the user to
choose to perform the update at this time or not.

To perform an update the Gage must be connected to an internet

connected PC with PosiSoft Desktop Manager (pg. 23), or WiFi
network (pg. 29).
NOTE: Ensure that stored measurements are backed up to a PC
or PosiSoft.net. The Gage may perform a Hard Reset (pg. 13)
after completion of the update and ALL readings in memory would
be erased.
Updates - Sample Screen

Currently installing 2/3

update 2 of 3 total
Progress bar

! DO NOT unplug the Gage during the update operation.

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 Application Notes
The PosiTector 200 uses an ultrasonic principle to measure
coating thickness of most coatings on most substrates. An
ultrasonic signal is a very high frequency sound wave. Like the
echoes you hear when you shout in a large hall or canyon the
PosiTector 200 listens for echoes from acoustic boundaries
within your application.
The PosiTector 200 probe emits a high frequency sound pulse
that travels into the coating via a coupling gel and reflects from
ANY surface that is different in density. Coating thickness
readings are obtained by measuring the time taken for the
ultrasonic signal to propagate from the probe to the
coating/substrate interface and back. The travel time is divided by
two and multiplied by the velocity of sound in the coating to obtain
the thickness of the coating. The strength of the reflected signal
from the coating/substrate interface determines the ability of the
Gage to measure the thickness of the coating. Since most
applications are not homogeneous the Gage will "hear" many
echoes when placed on a coating/substrate. The Gage "hears"
ALL reflections within the measurement limits of the Gage and
assumes the largest “echo” is the coating/substrate echo (single
coating applications only). Adjustable measurement Ranges have
been provided for the user to force the Gage to ignore echoes
from unwanted boundaries within the sample. Several examples
below help to illustrate the use of the Set Range (pg. 11) feature
for specific applications.

Measurement of coatings with rough surfaces.

When rough coatings are measured, the Gage typically identifies
the thickness from the top of the coating peaks down to the
substrate (#1). Couplant fills the voids between the probe and the
coating (#2) creating an additional interface. If echoes from the
couplant/coating interface (#2) are stronger than the
coating/substrate interface (#1), an adjustment (increase) of
Lo Value may be required for the Gage to display the weaker (#1)
echo.

33
 Probe Couplant

Coating #1 #2

Substrate

Measurement of dense (hard) coatings.

A significant echo occurs at the probe/coating interface. The
relative strength of this echo compared to the coating/substrate
echo requires that Lo Value be increased.

Measurement of total thickness in multi-layer coating

applications.
Multiple coating/coating/substrate interfaces may generate
several echoes. The user may need to adjust the Gage’s
Set Range (pg. 11) to ignore echoes from coating/coating
interfaces.

Troubleshooting
Some common reports received by our Service Department along
with possible causes. Most conditions however can be cleared
with a Reset (pg. 13).
Gage does not turn on
Make sure the + and - battery terminals are positioned properly
and that fresh batteries are being used.

Gage powers up but fails to stay on

Replace batteries with fresh batteries. If problem persists return
Gage for service.

Gage readings are much lower than expected

Gage may be measuring surface roughness. Raise the value of
Lo Range (See pg. 11).

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Gage readings are much higher than expected
Gage may be measuring both the coating and substrate. Lower
the value of Hi Range (See pg. 11).

Gage does not yield accurate or consistent results

See the Set Range (pg. 11) and Thickness Adjustment (pg. 12)
sections to ensure the Gage has been optimized for your
application. Check the Gage on traceable standards.

Gage displays an error message while ZERO FAILED

attempting probe ZERO
Make sure to hold the probe in the air and OK
ensure the probe is free of couplant and
the probe tip area is clean. If problem persists, note the error
message and contact our technical support department.

Gage displays dashed line “----” and emits low-tone buzz

while attempting to obtain measurement
This occurs when the Gage is unable to obtain a measurement
result. Ensure sufficient couplant (gel) has been applied to the
surface of the coating and repeat measurement.

When the Gage is set up for multiple layers, “----” will be displayed
for each layer the Gage is unable to obtain a measurement result
for. The most common reasons for this is that the individual layers
are too acoustically similar or are too thin for the Gage to
distinguish between them. Reduce the number of layers the Gage
is set up for and repeat measurement.

35
 Power Supply / Battery Indicator
Power Source: 3 AAA alkaline, Lithium or optional Nickel-metal
hydride (NiMH) rechargeable batteries. For best battery indicator
results, ensure the appropriate Battery Type is selected in the
Setup > Battery Type menu (pg. 17).
The battery indicator displays a full bar with fresh alkaline
or fully charged batteries installed. As the batteries weaken, the
bar will be reduced. When the battery symbol is low
the Gage can still be used, but the batteries should be changed or
recharged at the earliest opportunity. The Gage will turn off
automatically when batteries are very low, preceded by a Low
Battery Warning on the display.
! To retain all user settings and stored memory readings, only
replace the batteries after the Gage has powered-down.
Battery performance decreases at low temperatures.

Additional Accessories
Rechargeable Battery Pack - 4 AAA eneloop batteries
The PosiTector can operate on rechargeable batteries and
DeFelsko recommends the use of eneloop (NiMH) rechargeables.
eneloop batteries combine the advantages of regular rechargeable
batteries and disposable (Alkaline) batteries. They discharge very
slowly and can be stored for long periods without having self
discharge concerns. Eneloop batteries come pre-charged and
ready to use immediately. See: www.eneloop.info

AC Power Cable Kit

An optional AC Power Cable Kit is available for continuous
operation or battery charging through the PosiTector’s built-in
USB port (as shown on page 22). This kit supplies several
alternate power solutions for your battery-operated PosiTector.
They allow the gage to operate continuously without the need for
batteries.

36
Use the USB cable alone to connect a PosiTector to your PC's
built-in USB port that acts as a continuous power source. Or
connect the cable to the included power adaptor which plugs into
any AC wall electrical outlet, 110 or 220V.
A selection of electrical plugs is included which are capable of
dealing with most country’s outlets.The USB cable provided can
also be used for Accessing Stored Measurement Data
(See pg. 23).

USB Cable
A USB Cable is provided with every PosiTector. Replacement
USB cables are available.

Couplant
One 4 oz. bottle of Ultrasonic Gel (couplant) is provided with every
PosiTector 200 probe. Additional 4 oz. bottles are available and
sold in a cases of 12.

Bluetooth Printer
This lightweight wireless printer receives data from all PosiTector
gages via Bluetooth wireless technology. It is battery-operated and
prints readings and statistical summaries.

Nylon Case
Convenient soft shell nylon case for carrying a PosiTector. Case
has compartments for Certificates of Calibration, instruction
manuals and other accessories.

Protective Lens Shield

One lens shield is included with every PosiTector instrument.
Additional package of five (5) thin plastic lens shields are available
and ideal for protecting the PosiTector display from paint and
overspray.

37
Coating Thickness Standards
Certified Thickness Standards are used to verify the accuracy and
operation of coating thickness gages and are an important
component in fulfilling both ISO/QS-9000 and in-house quality
control requirements. Contracts often specify that coating
thickness measurements be taken by gages whose measurement
accuracy is traceable to a National Metrology Institute such as
NIST or PTB.
Standards are typically purchased as an accessory to coating
thickness gages. Many customers find it more practical to verify
the accuracy of their own gages in-house, rather than utilize
DeFelsko’s calibration services. This is particularly true when
many gages are in use and/or when accuracy verification is
performed often.
There are 4 types of coating thickness standards available:
Certified Coated Metal Plates are the best solution for verifying
the calibration, accuracy and operation of most magnetic, eddy
current or ultrasonic coating thickness gages. They fulfill both ISO
and in-house quality control requirements. At ±0.43µm (±0.017 mil)
Certified Coated Metal Plates are the most accurate solution.
Certified Polystyrene Blocks are for use with C and D probes.
Certified Plastic Shims (foils) provide an economical alternative
to coated metal plates. They have a reduced accuracy of ±2 µm
(±0.08 mil). A coating thickness Gage measures shim thickness
when this shim is placed over a rigid, flat surface.
Non-Certified Plastic Shims (foils) provide a quick operational
check of the Gage and they allow the user to perform practice
measurements when placed over a rigid, flat surface. A set of 5
shims is included with every PosiTector 200 probe.

38
 Technical Data
PosiTector
B/Std B/Adv C/Std C/Adv D/Std D/Adv
200 Model
Measures total
thickness X X X X X X

Measures X X X
Individual Layers

Graphic Display X X X

Thick, soft coatings like

Typical Polymer coatings Coatings on polyurea, asphaltic
Applications on wood, plastic, concrete, neoprene, very thick
etc. fiberglass, etc. polymers, etc.
13 – 1000 microns 50 – 3800 microns 50 – 7600 microns
Range*
0.5 – 40 mils 2 – 150 mils 2 – 300 mils
+/- (2 microns + 3% of reading) +/-(20um + 3% of reading)
Accuracy
+/- (0.1 mils + 3% of reading) +/- (1 mil + 3% of reading)
Minimum 13 50 500
Individual Layer - microns - microns - microns
Thickness** 0.5 mils 2 mils 20 mils
Thickness
DeFelsko STDA3 DeFelsko STDP6 DeFelsko STDP1
Standard
* Range limits apply to polymer coatings only.
** For multiple layer applications only. Dependent on material being measured.
Gage Size: 200 B and C probes 200 D probe
135 x 61 x 28 mm Probe Details

(5.25” x 2.4” x 1.1”)

Weight:
140 g (4.9 oz.)
without batteries

Temperature Range:
0 to 40°C
(+32° to +104°F)
Conforms to: ASTM D6132 and ISO 2808
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.
39
 Returning for Service
Before returning the Gage for service…
1.Install new or newly recharged batteries in the proper alignment
as shown within battery compartment.
2.Examine the probe tip for dirt or damage.
3.Perform a Hard Reset (pg. 13) and a Zero (pg. 11).
4.Place a plastic shim onto a hard surface (i.e. glass) and attempt
a measurement. (pg. 8)

IMPORTANT:
If you must return the Gage for service, please fill out and include
the Service Form located at www.defelsko.com/support with the
Gage. 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.defelsko.com/terms

www.defelsko.com
© DeFelsko Corporation USA 2014
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 and PosiTector 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.

40