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Nuclear Gauge Calibration and

Verification System

OPERATING MANUAL

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 © 2018 InstroTek, Inc.
ValiDator Nuclear Gauge Moisture/Density Verification and
Calibration System
Manual Revision 6

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1. Table of Contents
****************************************

1. INTRODUCTION 2

2. ACCESSORIES AND APPLICATION 13

3. SOFTWARE INSTALLATION 15

4. SYSTEM OPERATION 17

5. THEORY OF OPERATION 36

6. INDEX 38

7. WARRANTY 40

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1. Introduction
We are happy and proud to share this Nuclear Moisture/Density Gauge
verification and calibration technology with you. ValiDator is the first and the
only traceable portable verification and calibration system in the industry.
InstroTek, Inc. would like to thank you for selecting the ValiDator as your field
verification and calibration device. The ValiDator Technology is covered by US
Patent numbers 5,923,726 and 6,050,725 including International patents.

We value your input and would like to hear from you with comments and
suggestions on how we can better serve you with this or other products.

This guide is designed as a reference for the operation of the Verification and
Calibration System. A thorough understanding of the operation and application
of Nuclear Moisture/Density gauges is necessary.

Please follow the nuclear gauge manufacturer recommendations with regard to

operation and safety concerns of these devices. All ValiDator operations should
be done from the end opposite the gauge source, stepping away three feet
while the source rod is in the measure position.

Why the ValiDator?

The American Society for Testing and Materials (ASTM) standards and American
Association of State Highway and Transportation Officials (AASHTO)
specifications require nuclear density gauges to be calibrated or verified every
12 months. In the absence of a field portable validation device, this commonly
would require returning a gauge to the manufacturer or other calibration
facilities. Strict shipping formalities, weeks without a gauge and expensive
calibration fees create a burden on gauge availability for field use.

Gauge owners have never had the option before of performing the verification
and re-calibration in the field. The ValiDator from InstroTek, Inc. is designed to
optimize the management of your gauge resources and help reduce
inconsistencies when multiple gauges are on-site. Multiple gauges calibrated
on the same device will reduce conflicts between results.

How to use the validator?

As easy as taking a field measurement, just place your CPN, Humboldt, InstroTek
or Troxler gauge on the ValiDator device and take a reading. Compare the
gauge wet density and moisture (M pcf) to the pass/fail range on the ValiDator
Calibration Sheet and your verification is complete. Even if the gauge
Verification fails, the optional Calibration Software would allow you to eliminate
the delays in calibration turn-around-time. Calibrate one or all depths in minutes.

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Supported Nuclear Gauges

It is important when you verify or calibrate your gauge that the correct chart
and values are selected. If there are gauges in your fleet that are not supported
on this list, you may establish guidelines for Verification of these gauges.
(Reference Verification Procedures for Gauges Not Supported page 20)

CPN

MC3 New, MC1 DR New: Gauges manufactured with two GM detectors.

Standard counts are generally between 30000 & 40000 counts.

MC3, MC1 DR: Gauges manufactured before approximately 1996 with one GM
detector. InstroTek currently does not support these gauges. Standard counts
are generally between 10000 & 20000. Please contact InstroTek for more
information on these gauge models or reference Verification Procedures for
Gauges Not Supported page 20.

MC1: InstroTek currently does not support verification of this gauge. Please
contact InstroTek for more information on this gauge model or reference
Verification Procedures for Gauges Not Supported page 20.

MC2: InstroTek currently does not support verification of this gauge. Please
contact InstroTek for more information on this gauge model or refer to manual
section Verification Procedures for Gauges Not Supported page 20.

MC3 and MC1 Elite:

These gauges are supported.

Humboldt
5001 B, 5001C, 5001P, 5001 EZ and 5001 SD are supported.

InstroTek
Model 3500 Xplorer and 3500 Xplorer 2 are supported.

Troxler
3401 & 3411: These gauges are only different in electronic functionality. Both
these gauges are supported by the ValiDator.

3430 & 3440: These gauges are only different in electronic functionality. Both
these gauges are supported by the ValiDator.

3411 New: (Very few gauges were produced, serial numbers greater than 17000)

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3450: Please contact InstroTek for instructions on how to calibrate these gauges.
These gauges, like 4640, operate with two independent measurement systems.
A special optional software application is required for these gauges.

4640: Not supported by the ValiDator I. The ValiDator II available from InstroTek
is specifically designed for verification and calibration of 4640B gauges and 3450
in the Thinlayer mode. Please contact InstroTek for information on how these
gauges can be verified and calibrated.

3430 and 3440 Plus Gauges: Please contact Instrotek for more information on
these gauge models, or reference Verification Procedures on page 18.

Seaman Nuclear
These gauges are not supported.

User Guide Information

ValiDator: Device used to verify and calibrate nuclear gauges.

Validation: Utilizing the ValiDator device to evaluate gauge calibration

accuracy at multiple depths, at an assigned density.

Verification: The process of using the Validation System to verify the calibration
accuracy of a nuclear density gauging device.

Calibration: The process of re-establishing the calibration parameters for a

nuclear density gauging device.

Calibration Parameters established by the calibration program and used by a

Constants: density gauge to calculate density and moisture.

ValiDator Factory established densities assigned to a specific Validator device

Density: for each measurement depth 0-12.

The ValiDator calibration reports are not exchangeable between different

ValiDator units.

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Safety
 Always operate in accordance with the nuclear
gauge manufacturer recommendations.
 Stand opposite the source rod when operating the
ValiDator Device.
 Move three feet (one meter) back when the
source rod is extended into the measurement
position.
 Use proper lifting techniques when loading and
unloading the ValiDator.
 Be aware of heavy machinery operating in the
area of testing.

Important: Follow the requirements of your nuclear materials license when

operating, maintaining and using nuclear gauges.

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Quick Start Instructions

The quick start instructions will benefit the new and the experienced operators
using the ValiDation System. The System Operation portion of this manual
contains detailed information about all aspects of the ValiDator system. The
Validation system is designed for use with various nuclear gauges manufactured
by CPN, Humboldt, InstroTek, and Troxler.

Important: Observe manufacturers recommendations regarding safety

precautions when operating density gauges. Stand opposite the source rod at
a distance of three feet or 1 meter when measurements are being taken. Follow
the requirements of your nuclear materials license.

Standard Counts for Daily or Rapid Verification: If you are evaluating your
gauges frequently for Quality Assurance, or will not be calibrating on-site, a daily
4 minute standard count may be used for the Standard counts on the
Evaluation Form for Verification. Take one 4-minute count at all other depths.
Standard count should be taken on a solid surface such as soil, asphalt or
concrete base. Do not take standard counts with the standard block on the
ValiDator, second floor, or the tailgate of a truck.

Standard Counts for Combination Verification and Calibration: If you will be

performing a scheduled Verification or Calibration and would like to optimize
the data collection process, perform an Extended Standard Count. (CPN: 20
minute count recording the Wet Count and H2O Count. Humboldt and Troxler:
Perform a Stat Test and record the average Density and Moisture count.) Record
the Standard Counts on the Evaluation form. Two 4-minute counts should be
averaged for Backscatter (BS) and Depth 12 measurements, due to the
relatively lower precision at these positions.

I. Verification Process

A. Align gauge on the ValiDator. For lowering the Source rod, slide the
gauge back until the rod is over the access hole. (See Gauge
Placement page 8)
B. Set count time for four (4) minutes. Note: All moisture verification is
done at the Backscatter position.
C. Backscatter measurements should be taken with the gauge aligned
with the surface stops; two four-min. counts should be averaged for
better precision.
D. Direct Transmission measurements require that the gauge
placement be adjusted to minimize the void between the source
rod and the inside of the ValiDator. After lowering the source rod
move it towards the control panel end of the gauge and to the left

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side alignment stops. Two 4 min. readings at depth 12 should be

averaged for better precision.
E. Complete a four (4) minute reading and record the gauge results
WD, M, DC and MC on the ValiDator Evaluation Form (page 10).
Make additional blank copies of this form for future use.
F. The Wet Density (WD) and Moisture (M) readings from the gauge
should fall between the range indicated on the gauge specific
ValiDator Calibration Data Table.
G. If the resulting densities indicate the gauge passes, consider the
verification process complete. The gauge is now verified for field
use.
H. If the gauge fails Validation, review precautions and repeat
Validation steps A-G.
I. A second failure would indicate that a calibration is needed.

II. Calibration Process

Note: Gauge Calibration is a sophisticated process and should only be

attempted by advanced and trained users. Please refer to the Calibration
Section of the Manual for calibrating gauges.

Precautions before You Begin

Nuclear gauge: Note: Do not take a Standard Count on the ValiDator.

 Clean Base
 Record the Current passing standard count in the field location where
Validation is to be performed.
 Count time set to four (4) minute counts
 Stable Gauge Electronics (Run the manufacturer recommended diagnostics
if field results are questionable.)
 No other gauges should be within 30ft (10 meters) of the testing area.
 When taking measurements stand opposite the source side of the unit a
distance of three feet (1 meter) away.
 Gauge positioned correctly on the ValiDator. (Refer to Gauge Placement
page 8)
 Gauges meet the requirements for supported gauges. (Refer to User Guide
page 4)

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ValiDator Device:

 Top surface free of debris

 Placed on solid level surface, three feet from any vertical structure.
 Tailgates, Carpeted floors, upper floors of buildings, trailers, and uneven
surfaces are not acceptable.

Equipment

Items required for Verification and Calibration include: ValiDator Device,

ValiDator Density Data (In shipping case), ValiDator Evaluation Form (page 10 of
user guide), stable nuclear gauge, and current gauge calibration data (for
calibration option).

Gauge Placement

Nuclear gauges differ between manufacturers. It is important to align each

gauge using the positioning stops on the top and left of the ValiDator.

Backscatter & Moisture Readings

All Backscatter (Depth 0) and Moisture readings should be taken with the gauge
flush with the stop at the top and on the left as shown below.

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Direct Transmission (Depths 2-12) Readings

Direct Transmission (Depths 2-12) readings require the gauge to be positioned

such that the void between the source rod and the inside of the ValiDator block
is minimized. Slide the gauge back until you can drop the source rod in the hole
on top of the ValiDator. Once the source rod drops in the hole, make sure to
keep the gauge flush with the left stop and slide the gauge back away from the
top stop until it can’t be moved any further.

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ValiDator Evaluation Form

ValiDator S/N ___________________________ Verification/Calibration

Date: ____________
Gauge S/N ___________________________
Operator: ____________
Gauge Model ___________________________
Daily Standard
Counts DS________________________ MS________________________
Calibration
Standard Counts DS________________________ MS________________________
Establish these counts using the average counts from the results of a Stat Test, 20-
minute count or (5) 4 min. Counts. This data is used for the Calibration process.
Count Time 15 sec 1min 4 (Recommended) 16 20 Circle one
Gauge at Backscatter
Stop
Depth Pass WD Fail DC Pass M Fail MC
BS P ____________ F ____________ P ____________ F ____________
BS P ____________ F ____________ P ____________ F ____________
BS Avg. P ____________ F ____________ P ____________ F ____________
2 P ____________ F ____________
3 P ____________ F ____________
4 P ____________ F ____________
5 P ____________ F ____________
6 P ____________ F ____________
7 P ____________ F ____________
8 P ____________ F ____________
9 P ____________ F ____________
10 P ____________ F ____________
11 P ____________ F ____________
12 P ____________ F ____________
12 P ____________ F ____________
12 Avg. P ____________ F ____________

Notes/Re-counts:

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Example of Gauge Calibration Report

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Example Gauge Calibration Report Key

1) Make (CPN, Humboldt, InstroTek or Troxler)

2) Model

3) Serial Number

4) Calibration Standard Counts

5) Calibration Date

6) Factory Density Constants (A, B, C Parameters)

7) Calibration Block Densities lb. /ft3 or kg/m3

8) Calibration Block Counts

9) Factory Moisture Constants

(E & F or A & B for CPN gauges)

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2. ValiDator Accessories and Application

Before using the ValiDator, it is recommended that the user read this manual
and understand the operation of this system.

List of Equipment & Accessories

User Guide
ValiDator (Calibration Box)
ValiDator Density Data (Laminated Sheets)
Quick Start Instructions
NIST Certificate

List of Optional Accessories

Optional VeriFier Software (USB Flash Drive)

3430 and 3440 Constant Download Cable
InstroTek 3500 Gauge Constant Download Cable

Note: Small scratches should be expected on the ValiDator working surface due
to extensive quality control process utilizing measurements with multiple gauges.

Application Overview

Verification & Calibration Process

There are several steps necessary to accomplish a gauge verification and

calibration. Gauge calibration verification is the most fundamental use of the
ValiDator device. Position a density gauge on top of the ValiDator device, take
a four (4) minute density reading and evaluate the resulting density using the
laminated gauge specific ValiDator Density Data Table provided.

The steps below describe a procedure within the Verification and Calibration
process. Density and Moisture gauge data is required by the VeriFier Software
and should reflect the most recent calibration. If not available, this data may
be obtained from the organization that completed this calibration.

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Calibration constants are used by the gauges to perform the calculations

necessary to process raw count data into a density. Density and moisture tables
may be used for any gauge, but are more common with units that do not have
internal memory or an internal processor. Gauge manufacturers use NVRAM
(Non-Volatile Random Access Memory) or EPROM’s (Erasable Programmable
Read-only Memory) in their gauges.

Calibration constants may be entered into a gauge (CPN MC3, MC3 Elite, MC1
Elite, Humboldt EZ and SD, InstroTek 3500 and Troxler 3430, 3440, 3430 Plus and
3440 Plus) using the operating keypad. Units that employ EPROM’s (Troxler 3411
and Humboldt 5001 series) may operate using density tables while an EPROM is
programmed and mailed for installation. InstroTek can program EPROM’s for
your gauges. Simply fax or mail the Calibration Constants Report and InstroTek
will program and ship your EPROM by Priority Mail for a nominal charge. You
can also purchase a Prom Programmer Package to burn proms at your facility.
VeriFier allows creation of hexfiles for Troxler 3411B and Humboldt 5001C gauges.
There is an option available on 3401 and 3411 gauges that you can use to allow
direct entry of constants through the keypad. SmartPanel from InstroTek is a
“drop in” replacement for the existing 3401 and 3411 scalars. SmartPanel
upgrades the 3401 and 3411 gauges with many features, including direct entry
of calibration constants through the keypad. For more information on the
InstroTek SmartPanel, please visit our website at www.InstroTek.com.

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3. Software Installation

Computer Requirements: Windows operating system

Installing VeriFier Software on a PC

Object: Allow the operator to access the software and re-calibrate a nuclear
gauge.

Support: Before loading any software, consult with your organization PC

Manager or operating system manuals.

Locate your flash drive included with your ValiDator system. Please
read license agreement before opening software package. This
software should only be loaded on one computer. Access codes will
be needed to complete installation.

NOTE: ValiDator and its’ associated software is licensed to a single user. Use
of the ValiDator and its’ associated software is not allowed for
calibration of gauges from other organizations.

Windows

1. Download VeriFier software from USB flash drive provided by InstroTek.

2. Follow prompts, click finish when complete.
3. Call InstroTek for registration codes:
 Enter Main Registration Code
 Click on Calibrate and enter Calibration Registration Code
 Enter Password “calibratenow” or “calnow”
 Provide Product Key to InstroTek service Representative
 Enter Product Code

Upgrading Software Version

You may load the new software version directly over the existing version and not
lose your existing data.

 Close all Windows programs.

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 Follow the Install instructions.

 Follow prompts.

Moving Software

 VeriFier software may only be installed on one computer.

 Moving to another computer is possible. Please contact InstroTek for procedures

and access codes.

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4. System Operation

Calibration Accuracy Verification & Calibration Process

Verification Process

Verification of the gauge is necessary to determine the status of the gauge

calibration. Gauges are calibrated when they are shipped from the manufacturer.
Without performing periodic verification, it is not possible to assess the accuracy of
your gauge calibration. ASTM and AASHTO standards require gauges to be verified
for calibration accuracy at least once every 12 months and also the calibration is
checked on newly acquired or repaired nuclear gauges. With the ValiDator,
gauges may be verified to meet this requirement.

Verification

Definition: Use the reference densities assigned to a ValiDator device for

evaluating the calibration accuracy of a density gauge.

Resources: ValiDator Device, Gauge Field Evaluation Form, ValiDator Calibration

Tables, *Density Gauge, **Stable surface.

Important: Follow the requirements of your nuclear materials license when

operating, maintaining and using your gauge.

Calibration

Calibration is a process of calculating new parameters for the nuclear gauge.

Only advanced users with a high degree of experience and understanding of
gauge measurement and operations should perform this process. It is
recommended that one individual in an organization be responsible for the
calibration process. The Verifier Software with counts taken on the ValiDator can be
used to generate new moisture and density calibration constants for the gauge.

Resources: InstroTek VeriFier Software, PC, Completed Evaluation Form, *Density

Gauge, Gauge Calibration Constants, **Stable surface

Note: The VeriFier Software used for calibrating your gauge assumes that the
current gauge calibration information is obtained and entered
accurately.

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Moisture Calibration

The ValiDator is engineered to provide moisture verification and calibration in

pcf or kg/m³. The nuclear gauge moisture calibration process differs from
density in that the moisture calibration is a straight line and rarely will need to be
re-calibrated. However, the VeriFier software provides the capability for the
moisture calibration of the gauge.

*Density Gauge: A gauge qualified for evaluation should meet the requirements
below:
 Gauge base should be free of asphalt or debris that would cause the
unit to rock,
 Pass the manufacturers recommended statistical stability and drift
tests, and
 Pass a standard count at the evaluation site.
 No other nuclear gauges should be within thirty (30) feet.
 Make sure proper recommended maintenance steps are taken prior to
calibrating gauges.

**Stable Surface:
 Be at least three (3) feet (1M) from any vertical structure.
 Dry and level,
 Have a density of greater than100pcf (1602 Kg/m3).
 Parking lots and construction sites are ideal surfaces for testing.

Unacceptable surfaces would be as follows: trailer floors, truck tailgates, second-

story floors, wet surfaces with standing water or carpeted floors.

Verification Procedures

Gauge Evaluation

 The gauge base should be free of dirt and debris, no other nuclear gauges
near-by, 3 ft. (1 m) from any vertical structure, and on a stable surface.
 Pass the manufacturers statistical stability test or ASTM and AASHTO
recommendations in D6938, D7759 and/or AASHTO T310.
 Complete and pass a four (4) minute standard count in the area where
verification tests are being conducted.

Refer to the gauge operator’s manual for gauge cleaning, routine maintenance
and evaluation procedures.

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Site Preparation and Gauge Placement

 Select a flat, level and dry surface with a density greater than 100 lb/ft3
(1602 Kg/m3) three (3) feet from any vertical structure. Note: Soil, asphalt or
concrete are good examples of the surface to place the ValiDator for
testing. Parking lots or open fields are recommended locations for testing.
 Remove ValiDator from shipping case, place unit on selected area, and
position handle at bottom stop.
 Take a Daily or Calibration Standard Count and record on ValiDator
Evaluation Form. Do not take the Standard Count on the ValiDator.
 Align the density gauge on the top of the ValiDator using the specific guides
on top of the ValiDator device. (See Gauge Placement page 8) Backscatter
readings should be measured in contact with alignment stop. After lowering
the source rod for direct transmission, position the gauge to the rear of the
ValiDator device against side stops to reduce the air void between the
source and material being read.
 Select the specific ValiDator Density data table for the model nuclear gauge
under test.

NOTE: Do not take standard counts on top of the ValiDator.

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Verification Procedure for Gauges Not Supported by the Validator

For gauges not supported you can establish a history and determine when each
individual gauge falls outside a ±1% limit. Observe the following procedure to
establish a verification process for gauges not supported.

Example:

Depth A B C D E F
Date 12/7/2017 6/7/2018 12/7/2017 6/7/2018
S/N 7022 S/N 7022 Difference Dif.
PCF E-D
B-A
BS 150.2 150.6 0.4 5.6 5.7 0.1
2 118.5 117.6 -0.9
4 136.2 135.2 -1.0
6 132.1 132.0 -0.1
8 125.0 125.5 0.5

1. Send your gauge to a calibration facility for a calibration.

2. When you receive the gauge, take a four-minute Standard Count. Use the
following form or generate your own spread-sheet program.
3. Take four minute WD and M readings on the ValiDator at each depth and
enter in column A and D for density and moisture, as baseline readings.
4. At a later date, for example, every six months take readings and store in B
and E.
5. Compare A to B and D to E, and determine differences between C and F.
6. If any of the WD numbers are outside of ±1.5 lb/ft3 (±24 Kg/m3) difference or
M outside ± 1.0 lb/ft3 (±16 Kg/m3), take readings again. If it fails again, the
gauge needs to be calibrated.

Note: This procedure assumes that the Calibration received is accurate. For re-
calibrating these gauges contact InstroTek.

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Gauges Not Supported

Verification History Profile
Gauge Model Date:
Gauge S/N: Operator:
ValiDator S/N:

(A) Baseline (B) Test (C) % Diff. (D) (E) Test (F)
Date Depth Density Density B-A Baseline Moisture Diff.
Moisture E-D

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Verification Measurements and Data Evaluation

Reports may be generated using the optional VeriFier Software.

 Complete a single four (4) minute reading at the desired depth(s) under
evaluation, and record the Wet Density (WD) Density Count (DC) Moisture
(M) Moisture Count (MC) on the ValiDator Evaluation Form (Introduction
page 10). Note: For better precision at Depth 0 (BS) and 12, it is
recommended that you take (2)-four minute counts and record the average
on the form.

 Use the ValiDator Density Table to evaluate the Wet Density and Moisture of
the depth being tested for the pass/fail range. If the Wet Density and
Moisture fall within this range the gauge passes the verification process.
Note: All gauge moisture measurements are performed from the
backscatter position. The ValiDator moisture value is determined using the BS
measurement stop.

 If a failure is indicated, repeat the testing process reviewing the precautions

listed on page 7.

 Failing a second time would indicate an inaccuracy in the gauge calibration

and the need for calibration.

 Before moving on to Calibration, complete a statistical analysis using

manufacturer recommendations or ASTM Standard Test Methods detailed in
6938 and D2950 sections on standardization and reference checks. Record
this information on the ValiDator Evaluation Form page 10. (The Analysis is
commonly referred to as a Statistical Stability Test or Stat Test. If this test
passes you may use the Density and Moisture Average for your Calibration
Standard Count.) Before calibration, make certain the gauge meets gauge
manufacturers requirement for routine maintenance and care.

 Utilize VeriFier Software (if available), to perform a new calibration.

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Verification Using VeriFier Software

To utilize the features of the VeriFier Software, you must enter the current gauge
calibration and ValiDator density data into the software. Follow Step I: Entering
Gauge Calibration Data on page 25 and Step II entering ValiDator Densities on
page 26.

Step I: Verification Data Entry

1. Enter the current gauge calibration data into VeriFier software. (Follow
procedure Step I page 25)
2. Enter the ValiDator densities from laminated sheet. (Step II, page 26)
3. Enter counts from ValiDator Evaluation Form taken by the gauge on the
ValiDator.
3.1. Daily Density and Moisture Standard Counts
3.2. Verification Date
3.3. Failure Cutoff, default value is 2pcf (32 Kg/m3)
4. Enter Gauge Counts from Evaluation Form
4.1. Enter Moisture Count at Backscatter
4.2. Enter Density Count at all depths
5. Click on Calculate to display the Calculated Density and Error. This density
should be similar to the WD from the ValiDator Evaluation form.
6. To change measurement units, click on Options and select desired units.
7. To print a Verification report, click on Report.
8. To customize your report click on Options, then Customize.

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Calibration Procedures

The calibration process utilizes the optional VeriFier Software. Contact InstroTek
to obtain your specific password for operating this program. Note: Only trained,
qualified and experienced users should perform the Calibration and you should
follow the requirements of your nuclear materials license for operating,
maintaining and using your gauge.

The nuclear gauge’s current calibration data is necessary to complete the

calibration process. If not available at your organization, contact the gauge
calibration facility that performed this calibration for a copy.

For loading the Verifier Software see Chapter 3: Software Installation.

Note: If the gauge is not maintained nor has service problems, Calibration is not
going to resolve any service or maintenance problems. Contact your service
center to address any service issues with the gauge.

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Step I: Entering Gauge Calibration Data

(An example of the Gauge Calibration Sheet may be found on page 11)

1. From the Gauge pull down menu, select New if this is the first time this
gauge data is being entered.
2. Enter Password. (This was obtained from InstroTek on installation. Please
contact InstroTek if lost.)
3. Enter Gauge General Information; Make, Model (Select the model
defined on page 3), Serial Number, Factory Calibration Standard Count
(This is the Calibration Standard Count on the Gauge Calibration Sheet of
the Gauge under test.)
4. Enter Gauge Calibration Data.

Caution: If this data is entered incorrectly, the gauge calibration may be

inaccurate.
Caution: Do not use the AC depth in the Verifier program for CPN Gauges.

a) Calibration Constants: The A, B, and C values used by the gauge to

calculate Wet Density and E and F or A and B for CPN gauges to
calculate Moisture (M pcf).
b) Calibration Block Densities: Note: Calibrations completed at
facilities other than the specific gauge manufacturer may require
correcting the densities before re-calibrating using the ValiDator.
If the densities for your Mg block indicated on your calibration sheet
is less than 110 pcf (1762 kg/m3 or 1.762 g/cm3), then the densities
need to be normalized. To normalize the densities, divide the Mg
block density by 0.988, divide the Mag/Al block density by 0.974,
and divide the Alum block density by 0.964. If the units on the
calibration report are in kg/m3, then divide the density values by
16.018 and follow the above normalization procedures, dividing
mag density value by 0.988, Mag/alum density value by 0.974 and
Alum density value by 0.964. If the units are in g/cm3, then multiply
by 62.4 and follow the above normalization procedures, dividing
mag density value by 0.988, Mag/alum density value by 0.974 and
Alum density value by 0.964.
c) Calibration Block Counts: These are the Density counts from the
gauge calibration sheet.
d) Moisture Constants: Depending on the gauge manufacturer, these
are the E and F, or A and B for CPN gauges used by the gauge to
calculate Moisture in pcf or Kg3/m3.

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5. Change data or Select a Different Gauge:

a) From the Gauge pull down menu, select Modify if the gauge data
requires updating or correction.
b) From the Gauge pull down menu, select Pick to review and select a
specific gauge.

CPN MC3, MC1, MC3 Elite and MC1 Elite

If density value for magnesium (low block) provided on the calibration
report is less than 110 pcf (1762 kg/m3), enter the values indicated for all
three blocks on the report for calibration density values. If the values are
110 pcf (1762 kg/m3) or higher, multiply the magnesium (low block)
density by 0.976, magnesium/aluminum (mid block) by 0.954 and
aluminum (high block) density by 0.974 and multiply granite density by 1.

Step II: Entering ValiDator Calibration Densities

(Use the laminated ValiDator Density Data supplied with your ValiDator. These
sheets are manufacturer, model, and ValiDator specific. For large organizations,
a multiple ValiDator function is available. Insure that before a calibration is
attempted that the correct ValiDator is selected.)

1. Select ValiDator from the pull down menu, and Select New. Enter the
ValiDator Serial number, and From the Model pull down, select the
appropriate model from the laminated ValiDator Calibration Table.

2. Enter the Moisture content from the laminated sheet and all the depths and
densities found on your sheet. You may enter Pcf or Kg3/m, but not both.
The options menu allows you to change units.

3. To change ValiDator Densities, choose Modify.

4. For selecting another ValiDator, select Pick.

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Enter the ValiDator serial number

from the ValiDator Density Sheet

Select the appropriate Make and

Model for the gauge under test.

Moisture Content from laminated

sheets supplied with the ValiDator

Density Assigned to ValiDator

Calibration supplied with ValiDator

Step III: Entering Calibration Counts

(This procedure will calculate new Calibration constants from the counts taken
on the ValiDator. It is extremely important to accurately input this data.)

1. From the Calibration pull down menu, select CaliBrate and enter the
Password at the prompt. Contact InstroTek for a misplaced password.
2. Enter the Calibration Standard Count that you established while collecting
Verification data.
3. Enter the Calibration date. This is the date you collected the data on the
ValiDator for calibration.
4. Enter the Gauge count for the appropriate depth in the first column. This
is the Density Count (DC) from the ValiDator Evaluation form.
5. Enter the Moisture count taken at Backscatter. This is the (MC) from the
evaluation form.
6. After the Gauge count data is entered, click on the 3 or 5 block calibrate
button depending on the number of blocks used in the previous
calibration. Generally, CPN, InstroTek and Troxler gauges use a three (3)
block calibration, while Humboldt gauges are five (5) block calibrated.

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7. Print the Calibration report by Selecting Calibration from the Verifier

screen and click on Report.

Note: Performing a different calibration method (3 block instead of a 5

block) other than the one used for the current calibration will produce faulty
constants. If an error in the final calibration is noted you may revert back to
the original by pressing CTRL+E.

Daily Standard Count

This is an extended density and moisture
Standard Count from the average of (5) four-
minute standard counts

Calibration Date
This is the date that the calibration was done.

Gauge Count
Density Counts from each depth taken on
the ValiDator. Depths 0 and 12 are the
average of (2) four-minute readings.

Calib. Moisture Count

Moisture count taken at backscatter

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Calibration and Verification Uncertainties

ASTM DD7759 requires the reporting of verification and calibration uncertainties. The
software calculates and reports uncertainty budgets for each gauge verified and
calibrated.

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Step IV: Programming New Constants in the Gauge

MC3: Press the Step and Calib. key on the front panel. Select Wet Coefficients,
using the select key to change the depth. The A, B, C and A, B coefficients may
be entered by pressing the Enter key.

3430: Press the special key and use the arrow keys to select Calib. Constants.
Enter the code 4678 using the arrow keys. Enter the E and F constants (moisture
constants), select depth and enter the A, B and C constants. Use the arrow keys
to choose the depth.

3440: Press Shift-Special 1, then 9 and enter the code 4688. Some gauges
require a secondary code, which is 5936. Select Calibration Constants from
menu and follow the screen prompts and enter the E & F moisture constants and
select the depths for entering the A, B and C constants.

3430 and 3440 Plus: Contact Troxler to purchase codes in order to enter
constants into these gauges. Troxler charges their customers an additional fee
for performing this step.

3500, 3500 Xplorer 2 and SmartPanel: Press menu, use up and down keys, select
calibration constants, Enter code (4659) and press enter. Then enter constants
for moisture (E and F) and A, B and C constants for all depths.

3411B and Humboldt 5001: These units utilize an EPROM (Eraceable

Programmable Read Only Memory) Chip. Fax or email the new constants report
to InstroTek and we will program a chip for you. On receipt of the programmed
chip remove the old chip noting the position of the reference notch on the top.
Use a small screwdriver to leverage the chip from the socket. You may also
purchase a Prom Programmer Package for burning proms at your facility. If you
choose to purchase a PROM programmer package, you may use VeriFier to
create new hexfiles for Troxler 3411B and Humboldt 5001C gauges.

Humboldt EZ:

Changing A, B, C, E & F constants in the H5001EZ gauge:

1. Turn Power ON. (The processor will automatically initialize. Wait

approximately 5 seconds)
2. Change A, B, C, E & F constants:
a. MAIN MENU
b. F3 (ENGINEERING)
c. F1 (CALIBRATE)

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d. Enter Password (F2, F2, F2, F3, F4)

e. F4 (Change A, B, C, E or F)
f. F1 (A, B & C Parameters)
g. You will see for example A = 2.82232 and the letter ‘A’ will be
blinking. You can press F2 (INCREASE) to change from the ‘A’
constant to the ‘B’ or ‘C’.
h. By pressing F1, you can shift the cursor to the value to be changed.
i. You can then increment or decrement using the F2 or F3 keys
respectively.
j. Press F4 to go to the next depth.
k. To exit, press MAIN MENU.
l. Remove right protect jumper (JPI)
m. Press F3 (SAVE USER CONSTANTS).
n. Replace right protect jumper (JPI).

Note: JPI is a small black plastic jumper located at the upper right-hand side
between keyboard and CPU board as shown below.

JPI

Step V: Requesting EPROM Programming from InstroTek.

1. Email or Fax the following:

a) The Calibration report and Verification report insuring the
Calibration data reflects the new calibration information. From the
Verifier program.
b) Your ValiDator Evaluation Form, readings taken on the ValiDator.
c) The Gauge Calibration Sheet from the calibration in the gauge
during verification.
2. Fees: There is a fee for each gauge that requires an EPROM
Programmed.
3. Freight: InstroTek will ship using regular shipping methods (average two or
three day delivery). Air shipment is available upon request at applicable
rates.

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Step VI: EPROM Removal and Installation

(Static charges may damage silicone chips. Ground yourself while installing EPROM.)

1. Loosen the front panel for the gauge requiring EPROM installation.
2. Locate the EPROM on the circuit board of the front panel. (IC that has a
sticker with the gauge serial number and last calibration date.)
3. Make a note to the position of the notch in the top of the chip.
4. Remove the old chip with a small flat blade screwdriver or chip removal tool.
5. Reverse this process for installation.

Step VII: Quality Control

At any point that the Calibration is in error you may revert back to the old calibration by
pressing Ctrl+E.

1. To insure proper programming and installation of EPROM and Calibration

Constants, the gauge should be verified on the ValiDator using the ValiDator
Evaluation Form. Once the new constants are entered, place the gauge on
the ValiDator and make sure the density readings obtained with the gauge
are within the required ranges provided on the laminated ValiDator sheets.
2. An additional method to check the calibration before requesting the EPROM
or entering constants is to use the Calculate Density feature to calculate
densities using the new calibration.

Additional Features:

Select Gauge from the pull down menu to access the functions described
below.
Pick is used to choose another gauge from your database.
Modify is used to change or update the information for a specific gauge in the
database.
New is for entering new gauge data

Density Tables

Allow for the manual calculation of wet density using the gauge count ratio.

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Calculate Density

This functions as the processor of a gauge in calculating a density from a raw

count. Calculates the count ratio and uses the calibration counts to calculate
the density. Verification of field readings may be accomplished with using the
raw counts to check for operator-induced errors, (i.e. source position switch in
the wrong position) plug in the standard count and density count and calculate
the density. This function requires activation of the appropriate gauge serial
number in the Verifier software.

Gauge Management

Management: This option will allow you to manage your gauges more
effectively. The software will report the last verification date, the last calibration
date and the next leak test date. The data is sorted by the gauge’s Next Leak
Test date, and highlighted if the date is over six months for leak test and one
year for calibration.

Leak Test: The software will allow you to enter the last leak test date for each
gauge in the database. The software will keep up with this information and will
alert you of the next leak test date (six months) under the Management report
option. An overdue leak test will be highlighted in red.

Expected Standard Count: This calculation is based on the decay of the CS-137
gamma source. The limit on these standard counts is based on the gauge
manufacturer’s limit of ± 1% of the actual standard count. The software will
automatically access the most recent calibration date and standard counts for
the calculations. Note: Gauge counts may change due to many different
factors. Radioactive decay is the only variation that could be estimated
accurately and does not necessarily correct for all deviations in the gauge.

Notes: The notes function will allow you to document repairs and items used to
identify service trends or any gauge related information.

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5. Theory of Operation

Verification Theory

ASTM and AASHTO requirements dictate calibration verification at an interval of

12 months. The ValiDator is a known and stable density reference that can be
used for verification of gauge calibration accuracy. The ValiDator device is
calibrated by InstroTek, assigning reference densities to each of the
measurement depths. Gauge measurements are taken on the ValiDator and
the results compared to the documented ValiDator density range, which
indicates pass or fail. The ranges are based on a ±1.5% limit about the actual
density of the ValiDator. The limits are based on the combined errors in gauges
due to precision, composition and surface roughness errors.

If a calibration is needed, the optional Verifier Software may be used to

calculate new calibration coefficients derived from the counts taken on the
ValiDator device. New calibration parameters are calculated using a fitting
routine according to the gauge manufacturer calibration method.

Gauge Calibration Theory

Nuclear density gauges utilize two systems that are used to calculate an in-
place density and moisture content of construction materials. The density
system generally uses Cesium 137 and detector tubes which output analog
signals that are converted to counts by a micro-processor inside the gauge.
Moisture systems use a neutron source of Americium-241: beryllium and a
detector tube that also generate signals that are converted to counts. The
calibration process establishes a relationship between these raw counts and
known densities and moisture content references. In the construction density
range, the higher the density, the lower the counts. For moisture, the counts
increase with increasing moisture content.

Density Calibration

The final stage of the gauge manufacturing process is the calibration. The
density calibration method used by most manufacturers utilizes an exponential
equation that models the relationship between the known densities and the
counts. CPN, Humboldt and Troxler use an equation such as:

CR  A exp  BD  C

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Where A, B and C are gauge parameters, CR is the count ratio and D is the
material density. The A, B and C values are commonly known as calibration
constants. In the field when a count is collected on the test material, the
resulting wet density displayed on the screen is calculated by:

1  A 
D ln  
B  CR  C 

3-Block Method or 5-Block Method:

Presently there are no authorities that certify nuclear gauge calibration.

Therefore, gauge manufacturers and numerous other calibration facilities use a
different number of blocks to facilitate the calibration process. The Validation
and Calibration process simulate counts to replicate the number of blocks used
in the most recent calibration. CPN, InstroTek and Troxler use the Three-block
method and Humboldt uses the Five-block method.

Moisture Calibration

Gauge moisture calibration is performed by utilizing at least two blocks of known

hydrogen density covering a range of moisture in the construction materials.
The two blocks routinely used for moisture calibration are magnesium (0 lb/ft³)
and a combination block of magnesium and polyethylene (~ 35 lb/ft³, ~560
kg/m³). The gauge standard count, along with the counts on these blocks, is
used in a linear equation such as:

To calculate the parameters E (intercept) and F (slope), MCR is the count ratio,
which is the ratio of the measured counts and the daily reference standard
count. The daily reference standard count is performed on a high-density
polyethylene block provided with each gauge. M is the test material moisture
content. The E and F parameters are placed in the gauge memory. They are
then used in the field with the count ratio obtained on the test material to
calculate the moisture content from the equation.

 MCR  E 
M  
 F 

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6. Index

3-Block/5-Block Method ................................. 37

A

AASHTO ...............................................2, 17-18, 36

Accessories ....................................................... 13
C

Calculate Density ....................................... 34-35

Calibration......................................................... 17

Calibration Process ................... 7, 13, 17, 24, 36

D

Data Evaluation ............................................... 22

Density .............................................. 4, 7, 9-10, 47

Density Calibration .................................... 17, 36

E

Entering Calibration Counts........................... 27

Entering Gauge Calibration Data ................ 25

Example of Gauge Calibration ..................... 11

Example of Gauge Calib. Key ...................... 12

G

Gauge Placement .............................................8

Gauge Management ..................................... 35

H

Humboldt EZ ...................................................... 32
I

Installing VeriFier ............................................... 15

M

Maintenance ........................................ 18, 22, 24

Measurements ........................................ 6, 13, 22

Moisture Calibration ........................................ 18

Moving Software .............................................. 16

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Precautions ..........................................................7

Programing New Constants ........................... 32

Q

Quality Control ................................................. 34

Quick Start Instructions .......................................6

R

Readings ...............................................................8
S

Software Installation ........................................ 15

Standard Counts .................................3, 6, 10-12

Supported Nuclear Gauges .............................3

System Operation ............................................ 17

T

Theory of Operation ........................................ 36

3-Block/5-Block Method ................................... 37

Density Calibration ............................................ 36

Gauge Calibration Theory ............................... 36

Moisture Calibration ......................................... 37

Verification Theory ............................................ 36

U

Upgrading Software ........................................ 15

User Guide Information ......................................4

V

ValiDator Evaluation Form ............................. 10

Verification History Profile ............................... 21

Verification Procedures .................................. 18

Gauges not Supported .................................... 20

Verification Process ............................... 6, 13, 17

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7. Warranty

InstroTek products are guaranteed against defective material and workmanship

for a period of 12 months from the date of receipt by the customer.

InstroTek will replace, free of charge, any part found to be defective within the
warranty period.

This warranty is void if inspection shows evidence of abuse, misuse or

unauthorized repair.

This warranty covers replacement of defective materials and workmanship only.

It does not cover shipping charges, duties or taxes in the transport to and from
the factory or authorized service center.

If return of the product is necessary please include return shipping directions,

contact name, phone & fax number and a description of the action needed.

Call InstroTek, Inc. for shipping details at (919) 875-8371.

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Contact Information

Innovators in Instrumentation Technology

www.InstroTek.com | (919) 875-8371 | [email protected]

Research Triangle Park, NC | Austin, TX | Bensalem, PA | Grand Rapids, MI | Denver, CO | Las Vegas, NV | Concord, CA

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 Contact us for top quality, best value and superior service!
email: [email protected] ª visit: InstroTek.com

Call a Location near you:

Headquarters: Research Triangle Park, NC phone: 919.875.8371
Bensalem, PA phone: 215.645.1064 ª Grand Rapids, MI phone: 616.726.5850
Denver, CO phone: 303.955.5740 ª Austin, TX phone: 512.452.8848
Las Vegas, NV phone: 702.270.3885 ª Concord, CA phone: 925.363.9770

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