DeFelsko PosiTector UTG Full Manual

Full Guide v. 3.1

Ultrasonic Thickness Gage

Table of Contents

Introduction ......................................................... 1

Quick Start .......................................................... 1

Certification ......................................................... 3

Probes ................................................................. 4

How to Measure .................................................. 6

Surface Conditions .............................................. 7

Calibration, Verification and Adjustment ............. 8

Menu Operation .................................................. 9

Cal Settings Menu ............................................... 10

Zero ................................................................ 10

Thickness ....................................................... 11

Material .......................................................... 11

Velocity .......................................................... 11

2 Pt Adjust ..................................................... 12

Cal Lock ......................................................... 12

Cal Reset ....................................................... 12

Setup Menu ......................................................... 13

Reset .............................................................. 13

Min Scan ........................................................ 14

A Scan ............................................................ 14

B Scan ........................................................... 15

SE Mode ........................................................ 16

Smart Couple

.............................................. 17

Statistics Mode ............................................... 19

Memory Management .................................... 20

Annotate ......................................................... 23

Summaries ..................................................... 25

Screen Capture .............................................. 25

Assessing Stored Measurement Data ................ 26

PosiSoft Desktop Manager (PDM) ................. 26

PosiSoft.net .................................................... 27

PosiSoft 3.0 .................................................... 27

PosiSoft Mobile ........................................... 28

Connect Menu ..................................................... 29

Sync Now ....................................................... 29

Auto Sync ....................................................... 29

USB Drive ...................................................... 29

Bluetooth ........................................................ 31

Bluetooth Wireless Printer ............................. 32

Updates .......................................................... 35

Application Notes ................................................ 36

Measuring on pipes ....................................... 36

Measuring on rough surfaces ........................ 36

Measuring on hot surfaces ............................ 37

Measuring laminated materials ...................... 37

Troubleshooting - General................................... 38

Gage fails to power down............................... 38

Probe measures when lifted from surface...... 38

Gage is coupled but not measuring................ 38

Gage readings double expected thickness 38 Measurement jumps when probe is lifted 38

Troubleshooting - Multiple Echo (M) probes........ 39

Power Supply / Battery Indicator ........................ 42

Rechargeable Batteries ...................................... 42

Technical Data .................................................... 44

Probe Details & Specifications........................ 44

Operating Temperature Range....................... 44

Size / Weight.................................................. 44

Returning For Service ......................................... 45

Warranty .............................................................. 45

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).

The PosiTector UTG powers-up when the center navigation button is pressed. To preserve battery life, the instrument 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. 10)

4. Select the correct velocity of sound (see pg. 11)

5. Measure the part (see pg. 6)

Quick Start

PosiTector UTG Kit Contents

- PosiTector body (Standard or Advanced)

- PosiTector probe (UTG C or UTG M)

- 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

- Certificate of Calibration traceable to NIST

- PosiSoft.net account

- Two (2) year warranty on Body and Probe

Wrist Strap

We recommend attaching and wearing the supplied wrist strap.

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 instrument, can be left in place to protect against paint overspray or debris. Replacements can be purchased.

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.

USB Port

LCD Display

Zero Block

Probe Connector

PosiTector Body

UTG C probe

UTG M probe

5 MHz Dual Element

5 MHz Contact

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.

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.

Typical Display

Current Measurement

Currently selected material

Unit of Measurement

The Coupled Symbol appears when the probe is ultrasonically connected with a surface.

inch

Steel

Battery Icon

Measurement Mode currently set to multiple-echo

(UTG M probe only)

Factory Calibration settings in use.

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.

Probes

PosiTector UTG probes transmit an ultrasonic pulse into the

material to be measured. This pulse travels through the material towards the other side. When it encounters an interface such as air (back wall) or another material, the pulse is reflected back to the probe. The time required for the pulse to propogate through the material is measured by the Gage, represented as t1and t2 below.

PosiTector UTG C and UTG M (in single-echo mode) probes determine thickness by measuring t1(uncoated) or t2 (coated), dividing it by two and then multiplying by the velocity of sound for that material (steel). See Figure 1.

steel

coating

steel

Figure 1

Probe

For uncoated materials t1relates directly to material thickness. When a material is coated the propagation time is increased and

is shown above as t

Coatings such as paint have a slower velocity of sound than that of metal. Thus the single-echo technique will produce a thickness result greater than the actual combined coating+metal thickness.

Ultrasonic Thickness Probes - Theory of Operation

The PosiTector UTG M in multiple-echo mode determines thickness by measuring the time between at least three consecutive back wall echoes.

steel

Probe

Coating

Figure 2

Probe

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. In multiple-echo mode, the Gage determines thickness by measuring t

1+t2+t3

, dividing it

by six and then multiplying by the velocity of sound for that material. The resultant thickness calculation made by the instrument is therefore an accurate measurement of the steel thickness only, disregarding the coating thickness.

The velocity of sound is expressed in inches per microsecond or meters per second. It is different for all materials. For example, sound travels through steel faster (~0.233 in/µs) than it travels through plastic (~0.086 in/µs).

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. 35) to ensure probe compatibility with your Gage. For the latest information on probe interchangeability see www.defelsko.com/probes

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. When the probe senses echoed ultrasound, a coupled symbol

will appear on the display and thickness values will be displayed. While the probe is coupled, the PosiTector UTG continually updates the display.

3. When the probe is removed from the surface, the last measurement will remain on the display.

Occasionally, excess couplant will remain on the probe when the probe is lifted from the surface. This may cause the PosiTector UTG to display a final measurement value different from those observed when the probe was on the surface. Discard this value and repeat the measurement.

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.

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. Avoid this by using the Smart Couple

feature

(pg. 17)

On smooth, uncoated metal surfaces the Gage (in multiple-echo 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. Alternatively, laying a plastic shim on the surface with couplant applied to both sides to simulate a painted surface will help produce a steel-only thickness measurement (multiple-echo mode). Switching the Gage to single-echo SE mode (pg. 16) will also help produce a steel-only thickness measurement.

UTG M Probes:

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.Adjustment - to a known thickness or sound velocity for the

material to be measured

Calibration

Calibration is the controlled and documented process of measuring traceable calibration standards and verifying that the results are within the stated accuracy of the Gage. Calibrations are typically performed by the Gage manufacturer or by a certified calibration laboratory in a controlled environment using a documented process. The standards used in the calibration are such that the combined uncertainties of the resultant measurement are less than the stated accuracy of the Gage.

Written Calibration Procedures are available online at no charge http://www.defelsko.com/downloads.htm

Verification

Gage accuracy can and should be verified using known reference standards of the material to be tested.

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

To guard against measuring with an improperly adjusted Gage, verify the Gage at the beginning and the end of each work shift. During the work shift, if the Gage is dropped or suspected of giving erroneous readings, its accuracy should be re-verified.

Menu Operation

Instrument functions are menu controlled. To access the Menu, power-up the instrument, then press the center navigation button.

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

Memory

Statistics

Cal Settings

Setup

Connect

Help

Power Off

Exit

Sync Now

USB Drive

Auto SYNC

Bluetooth

Updates

Exit

Some buttons have a tick box to their right to indicate current status. An empty box indicates that feature is not active.

Current selection is displayed with darkened background

Down

Center

To navigate, use the Up and Down buttons to scroll and to SELECT.

Select Exit to exit from any menu.

Navigation Button

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.

The center button is purposely recessed to help eliminate unintentional powering-up of the instrument.

Cal Settings Menu

The PosiTector UTG is factory calibrated. In order for it to take accurate thickness measurements of a particular material it must be set to the correct sound velocity for that material. Be aware that material composition (and thus its sound velocity) can vary from stated tables and even between lots from a manufacturer. Adjustment to a sample of known thickness of the material to be measured ensures that the Gage is adjusted as close as possible to the sound velocity of that specific material. Samples should be flat, smooth and as thick as the maximum expected thickness of the piece to be tested.

The PosiTector UTG allows four simple adjustment choices. All four methods are based on the simple premise of adjusting the sound velocity. The first three adjustment methods make 1-point calibration adjustments to optimize the linearity of the PosiTector UTG over small ranges. The fourth method makes a 2-point calibration adjustment to allow for greater accuracy over a large range.

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. During zeroing, it does not matter what the current velocity setting is.

1. Make sure the instrument is on and the probe is wiped clean.

2. Apply a single drop of couplant onto the zero plate located on the underside of the probe connector. DO NOT apply couplant directly onto the probe face.

3. Select the Zero menu option and follow the on-screen prompts.

Calibration Adjustment

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. Apply a drop of couplant onto the reference standard.

2. Measure the reference standard.

3. Lift the probe. Select Thickness from the Cal Settings menu.

4. Adjust the display down (-) or up (+) to the reference thickness.

5. Press to the store the adjustment and exit.

Material

If a known thickness of the material is not available, but the material is known, this quick adjustment allows the user to load one of several preprogrammed material velocities.

1. Select Material from the Cal Settings menu.

2. Navigate to the desired material

3. Press to select and exit.

Velocity

If the sound velocity for the test material is known, the Gage can be adjusted to that specific sound velocity

Cal Lock

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. For best results, the thickness of the thicker reference standard should be equal to, or slightly greater than the thickest part to be measured. The thickness of the thinner reference standard should be as close as possible to the lower end of the expected measurement range.

1. Select 2 Pt Adjust from the Cal Settings menu.

2. Measure the thinner reference sample.

3. Lift the probe from the sample and adjust the display down (-)

or up (+) to the expected thickness.

4. When the expected thickness is reached, press

5. Measure the thicker reference sample.

6. Lift the probe from the reference sample and adjust down (-) or

up (+) to the expected thickness.

7. Press to store the adjustment and exit.

When checked, the icon appears and the current Cal settings are “locked” to prevent further user adjustments. Uncheck to make further adjustments.

Cal Reset

Clears all user calibration adjustments and returns the Material back to Steel. The factory calibration icon is displayed.

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.

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DeFelsko PosiTector UTG Full Manual

Specifications and Main Features

Frequently Asked Questions

User Manual