Ultrasonic Thickness Gage Full Guide v. 3.
Table of Contents Introduction ......................................................... Quick Start .......................................................... Certification ......................................................... Probes ................................................................. How to Measure .................................................. Surface Conditions .............................................. Calibration, Verification and Adjustment ............. Menu Operation .....
Assessing Stored Measurement Data ................ PosiSoft Desktop Manager (PDM) ................. PosiSoft.net .................................................... PosiSoft 3.0 .................................................... PosiSoft Mobile ........................................... Connect Menu ..................................................... Sync Now ....................................................... Auto Sync ....................................................... USB Drive ............
Introduction The PosiTector UTG is a hand-held Ultrasonic Thickness Gage that uses the non-destructive ultrasonic pulse-echo principle to measure the wall thickness of a wide variety of materials. It consists of a body (Standard or Advanced) and probe (UTG C or UTG M, see pg. 4).
Protective Cap PosiTector UTG gages ship with a protective plastic cap over the probe. Remove this cap prior to use. Replace it when the instrument is not in use to protect the probe. Wrist Strap 2 We recommend attaching and wearing the 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.
Typical Display Currently selected material The Coupled Symbol appears when the probe is ultrasonically connected with a surface. Measurement Mode currently set to multiple-echo Steel (UTG M probe only) Battery Icon inch Current Measurement Unit of Measurement Factory Calibration settings in use. Certification All PosiTector UTG probes include a Certificate of Calibration. For organizations with re-certification requirements, instruments may be returned at regular intervals for calibration.
Probes To disconnect a probe from a body, power-down the instrument 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. Ultrasonic Thickness Probes - Theory of Operation PosiTector UTG probes transmit an ultrasonic pulse into the material to be measured.
t2 t3 Probe t1 t1 t2 t3 Coating Probe The PosiTector UTG M in multiple-echo mode determines thickness by measuring the time between at least three consecutive back wall echoes. steel Figure 2 In the figure above, multiple-echo mode measures only the time between echoes. Regardless of whether the steel is coated or not, all times between echoes are the same.
How to Measure 1. Remove rubber cap from probe. Couplant (glycol gel - included) must be applied to the surface to be tested to eliminate air gaps between the wear face and the surface. A single drop of couplant is sufficient when taking a spot measurement. 2. Place the probe flat on the surface. Use moderate pressure to press against the top of the probe with the thumb or index finger.
Surface Conditions Ultrasonic measurements are affected by the condition, roughness and contour of the surface to be tested. Measurement results may vary on coarse surfaces. Where possible, it is recommended to seat the transducer on a smooth flat surface that is parallel to the opposite side of the material. On rough surfaces, the use of a generous amount of couplant minimizes the surface effects and serves to protect the transducer from wear, particularly when dragging the probe across a surface.
Calibration, Verification and Adjustment Three steps ensure best accuracy… 1.Calibration - typically done by the manufacturer or a qualified lab. All probes include a Certificate of Calibration 2.Verification of Accuracy - as done by the user on known reference standards such as calibration step blocks. 3.
In the event of physical damage, wear, high usage, or after an established calibration interval, the Gage should be returned to the manufacturer for repair or calibration. Adjustment Adjustment, or Calibration Adjustment is the act of aligning the Gage's thickness readings to match that of a known reference sample. See Calibration Adjustment pg. 10. Menu Operation Instrument functions are menu controlled. To access the Menu, power-up the instrument, then press the center navigation button.
Cal Settings Menu Zero PosiTector UTG probes can be "zeroed" to compensate for temperature and wear. This action is not required when operating in multiple echo mode (UTG M probes only) except when the instrument is new and after a Reset (pg. 13). However, it ensures best accuracy when operating in SE (single-echo) mode. Therefore, it is a good idea to "zero" the probe before each work shift and when the temperature of the part changes.
Thickness The most common method of adjustment is to measure a sample of known thickness. Select a reference standard of material as close as possible in composition to the intended application. For best results, the thickness of the reference standard should be equal to or slightly greater than the thickness of the part to be measured. 1. 2. 3. 4. 5. Apply a drop of couplant onto the reference standard. Measure the reference standard. Lift the probe. Select Thickness from the Cal Settings menu.
1. Select Velocity from the Cal Settings menu. 2. Adjust the display down (-) or up (+) to the desired velocity. Holding the (-) or (+) buttons increases the rate of change. 3. Press when the desired velocity is reached. 2 Pt Adjust A 2-Point adjustment allows for greater accuracy while simultaneously adjusting probe zero. Select two reference standards as close as possible in composition to the intended application.
Setup Menu Reset Reset (soft reset) restores factory settings and returns the instrument to a known condition. The following occurs: - All batches, stored measurements, images, and batch names are erased. - All calibration adjustments are cleared and returned to the Gage’s factory calibration settings.
Min Scan ü Normally, the PosiTector UTG C takes a single spot measurement at a rate of 6 readings per second while in contact with a surface. When the probe is lifted, the minimum reading thickness will remain on the display. It is sometimes necessary to examine a larger region to locate the thinnest point. When Min Scan is selected, the PosiTector UTG C will measure at a rate of 20 readings per second and display min/max values.
Adjust Display Gain - Adjusts the A-Scan amplitude/sensitivity. Use the (-)(+) buttons to decrease/increase gain. Adjust Display Lo/Hi Range - Adjusts the minimum and maximum displayed range for the A-Scan. Use the (-)(+) buttons to decrease/increase gain. Note: This does not change the instruments measuring range. Move Cursor - The Cursor allows for further analysis of the A-Scan. Use the (-)(+) buttons to move the cursor along the A-Scan.
B-Scan Menu Use the Up (move left) and Down (move right) buttons to navigate. Adjust Display Lo/Hi Range - Adjusts the minimum and maximum displayed range for the B-Scan. Use the (-)(+) buttons to decrease/increase gain. Note: This does not alter the instruments measuring range. Clear Display - Press to clear the B-Scan display and start over. Save Screen Capture - Press to capture and save an image copy of the current display.
SmartCouple ü Coupled Smart Coupled When selected, the probe, once coupled, will remain coupled until the (+) button is pressed. Eliminates unintentional decoupling. During scanning operations, the probe can be become physically decoupled, that is physically separated from the material, either due to the rough and/or scaly surface of the material or due to user operation.
Flip Display This option causes the display to rotate 180°. Ideal for right-sideup 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.
Language Converts displayed and printed words to the selected language. Statistics Mode ü x Statistics A statistical summary will appear on the display. Remove the last measurement by pressing the (-) button. Press (+) to clear statistics. Standard Mean (average) Deviation # of measurements Maximum measurement Minimum measurement Last reading Statistics Icon HiLo Alarm x mm ü Allows the Gage to visibly and audibly alert the user when measurements exceed user-specified limits.
Memory Management The PosiTector UTG can record readings in memory for printing, transferring to a computer or synchronizing with PosiSoft.net. Readings are date and time stamped as they are taken. Button functions with Memory ON: Scroll through display modes (Advanced only) Create a new batch (Advanced only) Delete last reading Restore brightness after dimming (Advanced only) Access the Menu Standard models store up to 250 readings in one batch. The Memory Menu includes the following options...
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.
New Sub-Batch (appears only if a batch is currently open) Creates a new sub-batch within the currently opened batch. Shortcut: When a sub-batch is open, create a new sub-batch by pressing (+). In the following example, B7s2 is a sub-batch of Batch 7. Sub-batching allows the user to group related batches so that statistics can be accumulated for them. Batch 7 contains the statistics for B7s1 and B7s2.
Delete Removes a batch or sub-batch completely from memory. The name is deleted and all measurements are erased. Sub-batches can be deleted individually. To delete all related sub-batches, simply delete the top-level batch. 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.
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 Stack Chart A-Scan B-Scan 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. 27) and PosiSoft Mobile (pg.
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.
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. 29). 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: 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.
PosiSoft Mobile: Is a Gage-based software application featured in all PosiTector Advanced instruments (serial numbers 730,000+).
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).
When checked, any computer can view datasets 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 datasets and graphs can be viewed or copied using universal PC/Mac web browsers or file explorers.
Retrieving stored screen captures The last 10 screen captures (pg. 25) stored in memory can be ccessed 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.
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.
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.
Accessing your PosiTector PosiSoft Mobile (pg. 28) 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.
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.
Application Notes Measuring on pipes (UTG C probes) When measuring the thickness of pipe walls, the proper placement of the transducer is important. On pipe diameters larger than 10cm (4 inches), it is recommended to place the probe parallel to the long axis of the pipe. For smaller diameter pipes, it is recommended that two measurements be taken, one with the probe perpendicular, and another with the probe parallel to the long axis of the pipe.
Measuring on hot surfaces Measurements taken at higher temperatures (above 100° C / 212° F) require special consideration. Both material sound velocity and probe zero will change with temperature. For maximum accuracy at high temperatures, adjustment should be performed using a material of known thickness heated to the temperature where measurements are to be performed. The probe should remain on the surface only as long as it takes to get a measurement.
Troubleshooting Some common reports received by our Service Department along with possible causes. Most conditions however can be cleared with a Reset (pg. 13). UTG C and UTG M probes Gage fails to power down Ensure the probe is clean and free of couplant. The Gage will not turn off if coupled symbol is displayed on LCD. Probe continues to measure after lifted from surface Wipe away any excess couplant on probe tip. Gage is coupled, but not measuring See Surface Conditions, pg. 7.
UTG M multiple echo (ME) probes only Gage displays -.-- (dashed lines) when measuring on an smooth uncoated surface in multiple echo mode See UTG M probes note on pg. 5 Gage is coupled, but not measuring On smooth, uncoated metal surfaces the Gage (in multiple echo (ME) mode) may occasionally be unable to give a measurement result even when the "coupled" symbol appears. Use additional couplant and lighter pressure on the probe when measuring. Switching the Gage to SE mode (pg.
wheels may be necessary using care not to gouge the surface. Or 4. There may be a coating on both sides of the metal. Switch to SE mode for best results. ME (multiple echo) and SE (single echo) results are not the same When measuring a COATED piece of metal, ME and SE modes will likely produce different thickness values as expected. The ME value will be thinner since it represents the thickness of only the metal (ignores the coating).
Flaws, voids or pits A void or flaw inside a metal object is better detected in SE mode where the Gage will measure the distance from the surface down to the flaw. Scan-mode will help locate the flaw. In ME mode the Gage may not “see” the flaw and will display a thicker, total thickness value. Measuring the depth of a rod ME mode may produce accurate results in situations where SE mode may not be able to measure at all.
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. 18). The battery indicator displays a full bar with fresh alkaline or fully charged batteries installed. As the batteries weaken, the bar will be reduced.
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 (pg. 23). USB Cable A USB Cable is provided with every PosiTector.
Technical Data Operating Range: Gage: 0 to 50° C (+32° to +120° F) Probe: -20° to 55° C (-4° to +131° F) continuous Material Surface Temp: -40° to +150° C (-40° to +300° F) Size: 146 x 61 x 28 mm (5.75” x 2.4” x 1.1”) Weight: 140 g (4.9 oz.) without batteries Conforms to: ASTM E797 This device complies with part 15 of the FCC Rules.
Returning for Service Before returning the instrument for service… 1.Install new or newly recharged batteries in the proper alignment as shown within battery compartment. 2.Examine the probe tip for dirt or damage. 3.Perform a Hard Reset (pg. 13) and a Zero (pg. 10). 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.
