DeFelsko UTGCX3, UTGCX1, UTGC1, UTGM1, UTGM3 User manual

Ultrasonic Thickness Gage

Instruction Manual

Advanced model

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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.

Quick Start

Press the button to power up the Gage. To conserve battery
life, the gage will automatically go to sleep after 5 minutes of
inactivity. While in Sleep Mode, the gage powers up significantly
faster— convenient when moving between parts or locations. The
gage will completely power off after 4 hours of inactivity.
Alternatively, select Power Off from the main menu. 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 (pg. 8).

4. Verify accuracy and adjust if necessary (pg. 7).

5. Measure the part (pg. 5).

Menu Operation

To access the Menu, power-up the gage, then press the center
navigation button . Either the keypad or touch screen can be
used to navigate the menu. If desired, touch screen functionality
can be disabled within the Setup menu (See Touch, pg. 12).

Select a menu option by touching it, or use the and but­tons to highlight the desired option and press to select it.

On menus longer than one page, the current page number is dis­played below the menu name. Navigate between pages using

when the first menu item is selected, or when the last
menu item is selected. If using touch, navigate between pages
by touching or , or by swiping up or down.

Press the button or swipe right to return to a previous screen.
Select Exit to close the Menu.

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Typical Display

When a Menu option is highlighted, the
icon indicates on-gage help is available.
Press or touch the icon to display the
help.

NOTE:

Update your gage to ensure that you

have the latest on-gage help information.

indicates that a sub-menu exists for the
Menu option. Select the option to display its
sub menu.

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

Currently
selected
material or
velocity of
material

Battery Icon

Measurement
Mode currently
set to multiple­echo

(UTG M /

UTG P probes only)

Current
Measurement

Unit of
Measurement

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Probes

When powered up the PosiTector automatically
determines what type of probe is attached and does a
self-check.

To disconnect a probe from a body, slide the plastic probe
connector horizontally (in the direction of the arrow) away
from the body. Reverse these steps to attach a new
probe. It is not necessary to power-down the Gage when
switching probes.

Additionally, the PosiTector gage body accepts a wide variety of
probe types including magnetic, eddy-current, and ultrasonic
coating thickness, surface profile, environmental, hardness, salt
contamination and ultrasonic wall thickness probes.

PosiTector UTG probes are available for a

variety of wall thickness applications:

• PosiTector UTG CA / UTG C – dual element, single-echo

probe ideal for measuring severely corroded/eroded materials.

PosiTector UTG CA models feature a built-in probe, while
PosiTector UTG C models feature a probe mounted on a 1 m

(3 ft) cable.

• PosiTector UTG CX - same specifications as UTG C above,

but includes a braided stainless steel cable jacket and
reinforced strain reliefs for protection in demanding
environments.

• PosiTector UTG CLF – dual element, single-echo probe

designed for measuring thick and/or attenuative materials such
as cast iron.

• PosiTector UTG M – single element, multiple-echo probe

features Thru-Paint capability designed to quickly and
accurately measure the metal thickness of a painted structure
without having to remove the coating.

• PosiTector UTG P – single element probe with automatic

single-echo or multiple-echo (Thru-Paint) mode depending on
material type and thickness. Ideal for high-resolution
measurements on thin plastics and metals.

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Ultrasonic Thickness Probes –

Theory of Operation

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 propagate through the
material is measured by the gage, represented as t1 and t2 below.

Single-echo PosiTector UTG probes (and PosiTector UTG M and
UTG P probes in single-echo mode) determine wall 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.

Probe

t

Probe

t

1

2

Coating

Steel

t

Figure 1

For uncoated materials t1relates directly to material thickness.
When a material is coated the propagation time is increased and
is shown above as t2.

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.

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2

Steel

t

>

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

Probe

Probe

t

1

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
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.

PosiTector UTG P Precision probes automatically switch
between multiple echo and single echo operation depending upon
the type and thickness of the material being measured.

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).

2t3

t

Coating

Figure 2

t

1

t

+ t2+ t3, dividing it by

1

2t3

Steel

t

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. Asingle drop of couplant is
sufficient when taking a spot measurement.

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2. Place the probe flat on the surface. Use moderate pressure to
press against the top of the probe with a thumb or index
finger when measuring with cabled probes.

When the probe senses echoed ultrasound, a coupled symbol

will appear and thickness values will be displayed. While the

probe is coupled, the PosiTector UTG continually updates the
display. The Gage will emit a “tick” sound every time the probe
takes a measurement. The Reading Tick option can be disabled
in the Setup menu (see pg. 11).

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 using the button 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.

NOTE:

and UTG P probes (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

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On smooth, uncoated metal surfaces PosiTector UTG M

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mode). Switching the Gage to single-echo SE Mode (see pg. 11)
will also help produce a steel-only thickness measurement

(PosiTector UTG M only).

Calibration, Verification and Adjustment

Three steps ensure best accuracy…

1. Calibration - typically performed by the manufacturer or a
qualified lab. All probes include a Certificate of Calibration.

2. Verification of Accuracy - as performed 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.

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.

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. 8.

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Cal Settings Menu

0

Zero

PosiTector UTG probes must be “zeroed” after a reset and

periodically during use. The Zero process compensates for probe
wear and temperature. To maintain the best accuracy, perform a
Zero when the ambient temperature changes.

PosiTector UTG C, UTG CA, UTG CX,
UTG CLF and UTG M probes:

1. Make sure the Gage is ON and the probe is wiped clean.

2. Apply a single drop of couplant onto the included zero block

(PosiTector UTG CA only) or built-in zero plate located on
the underside of the probe connector. DO NOT apply couplant
directly onto the probe face.

3. Open the Gage menu, navigate to Cal Settings, select
the Zero menu option, and follow the on-screen prompts.

4. When complete, the Gage will double-beep and display “----”.

PosiTector UTG P probe only:

1. Make sure the Gage is ON and the probe is wiped clean.

2. Hold the probe in the air away from all objects.

3. Open the Gage menu, navigate to Cal Settings, select
the Zero menu option, and follow the on-screen prompts.

4. When complete, the Gage will double-beep and display “----”.

Calibration Adjustment

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 symbol disappears whenever a
Calibration Adjustment is made to the Gage.

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C

The PosiTector UTG allows four simple adjustment choices. All
four methods are based on the simple premise of adjusting the
sound velocity.

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.

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.

Velocity

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

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 equal to, or slightly less than the thinnest part
to be measured.

Cal Lock

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

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Setup Menu

Units

Converts the display from millimeters to inch and vice versa.

Reset

Reset (menu reset) restores factory settings and returns the

Gage to a known condition. The following occurs:

- All batches, stored measurements, batch names and screen
captures are erased.

- All calibration adjustments are cleared and returned to the
Gage’s factory calibration settings.

- Menu settings are returned to the following:

Memory = OFF
Statistics = OFF
Hi Lo Alarm = OFF
Min Scan = OFF
Reading Tick = ON
Auto Dim = ON

Perform a more thorough Hard Reset as follows:

1. Power down the Gage and wait 5 seconds.

2. Simultaneously press and hold the 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 = Millimeter
Touch = ON
Flip Lock = OFF
Auto Sync .net = ON
Sound = Medium

A Scan = OFF
B Scan = OFF
Cal Lock = OFF
SE Mode = OFF
USB Stream = OFF
Display = None

Battery Type = Alkaline
Language = En glish
Backlight = Normal
Bluetooth Smar t = OFF
USB D rive = ON

SmartCouple = OFF
Bluetooth & Stream = OFF
WiFi & Access Point = OFF
USB Keyboard = OFF
BLE Keyboard = OFF

NOTE:

Date, Time and WiFi settings are not affected by either Reset.

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Min Scan

Normally, the PosiTector UTG continuously takes spot
measurements while in contact with a surface. When the probe is
lifted, the last reading will remain on the display. However, it is
sometimes necessary to examine a larger region to locate the
thinnest point. When Min Scan is selected, the PosiTector UTG
will take continuous readings and record min/max thicknesses
when the probe is lifted from the surface – ideal for quick
inspection over a large area.

A Scan

Displays a chart with the travel distance of
the ultrasonic pulse on the x axis and the
recieved pulse amplidude on the y axis .

PosiTector UTG M and PosiTector UTG
P probes provide two cursors (vertical

green lines) which allow the user to
measure the difference between echoes
shown in the graphic display.

B Scan

Displays a live chart of measured thicknesses,
representing a cross-sectional profile of the
test material.

SmartCouple

When selected, the probe, once coupled, will remain coupled
until the button is pressed. Eliminates unintentional decoupling.

SE Mode

Switches from multiple-echo to single-echo mode:

- To increase the measurement range

- To obtain thickness measurements in circumstances where
multiple-echo can not

Reading Tick

When selected (default), the Gage will emit a “tick” sound
every time the probe takes a measurement.

(Advanced models only)

(Advanced models only)

Coupled Smart Coupled

(PosiTector UTG M multiple-echo probe only)

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Sound

X

X

Adjusts the volume of built-in speaker (Off, Low, Medium, High).

Flip Lock

Disables the Auto Rotate feature by locking the display in its
current orientation.

Touch

Allows the touch screen functionality to be disabled. All gage
functions can also be controlled using the navigation buttons.

Set Clock

All measurements are date and time stamped (24-hour format)
when stored into memory. It is therefore important to set the
correct date and time. Use the and buttons to select a
value, and the and buttons to adjust it. The current date
and time setting can also be viewed at the top of the main menu.

Battery Type

Selects the type of batteries used in the Gage from a choice of
“Alkaline”, “Lithium” or “NiMH” (nickel-metal hydride rechargeable).
The battery state indicator symbol is calibrated for the selected
battery type. No damage will occur if the battery type used in the
Gage does not match the selected battery type.

Statistics Mode

Statistics

A statistical summary will appear on the display. Remove the last
measurement by pressing the button. Press to clearstatistics.

–

Average

–

Maximum Value

–

Standard Deviation

–

Minimum Value

HiLo Alarm

Allows the Gage to visibly and audibly alert the user when
measurements exceed user-specified limits.

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Memory Management

The PosiTector UTG has internal memory storage for recording
measurement data. Stored measurements can be reviewed on­screen or accessed via computers, tablets and smart phones. All
stored measurements are date and time-stamped.The symbol
appears when the Gage is set to store measurement data.

Standard models
Advanced models

batches. “New Batch” closes any currently opened batch and
creates a new batch name using the lowest available number.
New batch names are date-stamped when they are created.

store up to 1,000 readings in one batch.

store 250,000 readings in up to1,000

Scroll through display
modes (Advanced only)

Delete last reading

Access the Menu

Screen Capture

Press both and buttons simultaneously to save an image of
the current display. The last 100 screen captures are stored in
memory and can be accessed when connected to a computer
(see PosiSoft USB Drive below).

Create a new batch
(Advanced only)

Restore brightness
after dimming

Accessing Stored Measurement Data

DeFelsko offers the following free solutions for viewing, analyzing
and reporting data:

PosiSoft USB Drive - Connect the Gage to a PC/Mac using the
supplied USB-C cable. View and print readings and graphs using
universal PC/Mac web browsers or file explorers. No software or
internet connection required.

PosiSoft Desktop - Powerful desktop software (PC/Mac) for
downloading, viewing, printing and storing measurement data.
Includes a customizable, templated PDF Report Generator. No
internet connection required.

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WiFi

USB

When USB Drive is enabled , the PosiTector uses a USB
mass storage device class which provides users with a simple
interface to retrieve stored data in a manner similar to USB flash
drives and digital cameras. USB Drive is also required to import
stored measurements into PosiSoft Desktop software (pg. 13).

(Advanced models only)

NOTE:

USB-C cable. The batteries are not used and the body will not
automatically power down.

When enabled and connected to a computer, the PosiTector will

be recognized as a Keyboard. Readings are sent to the computer

as they are taken, emulating keystrokes, followed by a carriage
return.

While connected, power is supplied through the included

Keyboard

(Advanced models only)

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(Advanced models only)

Stream individual readings to a USB connected computer via a
serial protocol. Ideal for use with serial compatible SPC data
collection software.

NOTE:

Sync .net Now

The above WiFi and USB menus contain a Sync .net Now option.
When selected, the Gage immediately synchronizes stored
measurement data via its respective communication method
(internet connection required).

Alternatively, select Auto Sync .net from within the USB connect
menu to automatically synchronize upon connection to a PC.
Additional measurements added to memory while connected are
synchronized only when the USB cable is disconnected and
reconnected, or when the Sync .net Now option is selected. WiFi
connected gages automatically attempt synchronization upon
power up.

NOTE:

synchronize measurements with PosiSoft.net.

PosiSoft Desktop is required when using USB to

Bluetooth

Allows communication with a smart device running the
PosiTector App (pg. 14) via auto-pairing Bluetooth Smart (BLE)
wireless technology.

(Advanced models only)

(Advanced models only)

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Sync Batches

Select batches to flag them for synchronization to the PosiTector
App. Sync Batches is useful when connecting a new device to a
gage with pre-existing batches, since only batches created while
Bluetooth Smart is enabled are automatically selected.

Selected batches are synchronized when the next reading is
taken in a batch flagged for synchronization, or when the Sync
Batches option is selected at the bottom of the list of selected
batches.

NOTE:

from batches selected in the Sync Batches menu are held in a
queue until communication with the PosiTector App is re­established.

Transfers selected batches to the PosiTector App. Send Batches
is useful when switching between devices, as only readings and
batches that have yet to be synchronized with any smart device
are synchronized automatically.

The Send Batches option is visible in the menu when the Gage
is connected to a smart device running the PosiTector App.

If Bluetooth Smart is disabled or disconnected, data

Send Batches

BLE Keyboard

When enabled and connected to a computer, the PosiTector will
be recognized as a wireless Keyboard. Readings are sent to the
computer as they are taken, emulating keystrokes, followed by a
carriage return.

WARNING:

update. (see pg. 10)

(Advanced models only)

The Gage will perform a Hard Reset after an

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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. 10) and a Zero (pg. 8).

4. If issue is not resolved, Update (pg. 16) your PosiTector

gage body and re-attempt measurements.

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