Coating Thickness Tester User Manual
Contents
1. le o e Coating Thickness Tester User Manual ps g Coating Thickness Tester User Manual o Contents Page 1 General information 1 1 Application 1 2 Description of the gauge 1 3 Supply schedule 1 4 Probe 1 5 Specifications 1 6 Front View 2 Preparing 2 1 Power supply 2 2 Replacing the battery 2 3 Menu System and Basic SettingS esesseseseeeee 7 3 Measuring Storage and Data processing in DIRECT and GROUP mode 4 Calibration and Measuremen 4 1 General Hints for Calibration 4 2 Special Hints for Calibration 4 3 General Remarks on Measurement BS Limit Function 6 Measurement Using Statistics NNN GuUobRERYW ps hg Coating Thickness Tester User Manual g 1 General information The DT 156 coating thickness gauges work either on the magnetic induction principle or on the eddy current principle depending on the type of probe used You can select the type of probe via MENU system or it will be work automatically The gauges conform to the following industrial standards GB T 4956 1985 GB T 4957 1985 JB T 8393 1996 JJG 889 95 JJG 818 93 Features e Measured Coatings Non magnetic coatings e g paint zinc on steel Insulating coatings e g paint anodizing coatings on no ferrous metals Operating with MENU easily Two measuring mode CONTINUE and SINGLE mode Two working mode DIRECT and GROUP mode 4 groups Statistic Display AVG MAX2. MIN NO S DEV One point calibrating and two points calibrating independently for each working mode Zero calibrating easily Memory for 320 readings 80 for each group Delete single readings and all group readings easily eHigh alarm and Low alarm for all working mode Low battery error indication USB interface for PC analysis software Disable Auto Power off function via MENU setting S Coating Thickness Tester User Manual o 1 1 Application This compact and handy gauge is designed for non destructive fast and precise coating thickness measurement The principal applications lie in the field of corrosion protection It is ideal for manufacturers and their customers for offices and specialist advisers for paint shops and electroplaters for the chemical automobile shipbuilding and aircraft industries and for light and heavy engineering DT 156 gauges are suitable for laboratory workshop and outdoor use The probe can work on both principles magnetic induction and on the eddy current principle One probe only is required for coating measurement both on ferrous and non ferrous metal substrates It is adaptable to specific tasks i e they can be used on special geometries or on materials with special properties 1 2 Description Of The Gauge For measurement on steel substrates the gauge work on the magnetic induction principle for measurement on non ferrous metal substrates it works on the eddy current principl
3. will lie within the guaranteed measuring tolerance Strong magnetic fields near generators or live rails with strong currents can affect the reading When using the statistics program for obtaining a mean value it is advisable to place the probe several times at a typical measuring spot Any false readings or outliers can be removed immediately Via MENU system The final reading derives from the statistical calculation and from the guaranteed tolerance levels of the gauge Coating Thickness D X s y lia ps hg Coating Thickness Tester User Manual g Example Readings 150m 156um 153m Mean value X 153um Standard deviation s 3um Measuring uncertainty u 1 of reading 11m D 153 3 1 53um 1m 153 5 5um 5 Limit Function Limits can be entered in DIRECT and a selected GROUP memory at any time i e before during and after a series of measurements There is practical use for limits Any reading which falls outside the set tolerance limits will be registered by a warning indication H reading above HI limit L reading below LO limit Please set the limit values using MENU system 6 Measurement Using Statistics The gauge calculates statistics from a maximum of 80 readings GRO1 GRO4 in total a maximum of 400 readings can be stored In addition readings can t be stored in DIR mode but it can calculate statistics as GRO1 GRO4 When power off or changing Work Mode see MENU system for details the
4. Continuous measurement mode 2 3 2 2 Used probe The probe can work in three modes AUTO The probe can automatically select the working mode When Placed on steel magnetic substrates it will work in magnetic induction principle When placed on no ferrous metals it will work in eddy current principle Fe The probe works in magnetic induction principle No Fe The probe works in eddy current principle 2 3 2 3 Unit settings You can switch from Metric units um mm to imperials mils In um mode the unit will switch to mm automatically when value of reading exceeds 850um see the specification section for more details 2 3 2 4 Total Reset A total reset erases data from all memories This includes all sets of readings of all work modes plus their associated statistics calibration values and tolerance limits Switch off gauge Press ZERO simultaneously The LC display sure to reset Press red bar button for YES or blue bar button for NO The gauge will restart automatically lp S Coating Thickness Tester User Manual o 2 3 2 5 Backlight You can select ON OFF in MENU system Besides in measuring mode Press the blue bar button once to switch ON OFF backlight 2 3 2 6 LCD Statistic In Menu system mode The statistic display can be selected between Average Maximum Minimum and Sdev When return to measurement mode it will be displayed on the lover right of LCD At the same time the
5. DIR statistics will be lost The following statistical values are calculated NO Number of readings in Work Mode AVG Average value Sdev Standard deviation MAX Maximum reading MIN Minimum reading ps g Coating Thickness Tester User Manual o 6 1 Statistical Terms Average value X The sum of readings divided by the number of readings X Ex Nn Standard Deviation Sdev The sample standard deviation is a statistic that measures how spread out the sample is around the sample mean The sample standard deviation increases with increasing spread out The standard deviation of a set of numbers is the root mean square of the variance gt The variance of a list is the square of the standard deviation of the list that is the average of the squares of the deviations of the numbers in the list from their mean divided by the number of readings 1 2 Variance S 5 x x n 1 Standard deviation S S NOTE Deletion must take place immediately after an outlier or erratic reading has been taken See the Delete function in MENU system 6 2 Storage Capacity Overflow In GROUP mode If the storage capacity is exceeded statistics will not be updated although measurement can continue If the memory is full subsequent readings will omitted from the statistics They will be marked with FULL in LCD In single measuring mode In DIRECT mode if the memory is full The newest reading will replace the ol
6. statistic number of measuring readings is displayed on the lower left of LCD Via statistic view item in MENU system you can look through all statistic values for current group 2 3 2 7 Measurement view Via Measurement view in MENU you can look through all measurement readings for current group 2 3 2 8 Auto power off You can disable Auto power off via MENU system or the gauge will power off automatically for about 3 minutes 3 measuring Storage And Data Processing In Direct and Group Mode This gauge offers two operating modes DIRECT and GROUP mode The GROUP mode includes GRO 1 4 DIRECT mode is intended for quick occasional readings In this mode individual readings are logged to memory provisionally When Power off or Switch to GROUP mode all readings will be cleaned But the statistic values won t be changed until logging new measurement readings The readings and statistical values can be shown on the LC display The statistical analysis program can evaluate 80 readings When the memory is full new readings will replace old readings In this mode it has individual calibration values and limit values In GROUP mode every group memory can store a maximum of 80 single readings and 5 Statistic values Calibration values and limit values can individually be set and stored for every group When the memory is full measuring will make sequentially but not be stored and statistic values won t be changed If need you c
7. 21mils 0 49 21mils Guaranteed tolerance 0 850um 0 850um of reading 3 1um 3 1 5um 850um 1250um 850um 1250um 5 45 0 33 46 mils 0 33 46mils 3 0 039mils 3 0 059mils 33 46mils 49 21 mils 33 46mils 49 21 mils 5 5 Precision O 50um 0 1pm 0 50um 0 1m 50um 850um 1 um 50um 850um 1m 850um 1250um 850um 1250um 0 01mm 0 01mm 0 1 968mils 0 1 968mils 0 001 mils 0 001mils 1 968mils 33 46mils 1 968mils 33 46mils 0 01mils 0 01mils 33 46mils 49 21 mils 33 46mils 49 21 mils 0 1mils 0 1 mils Minimum curvature radius 1 5mm 3mm Diameter of Minimum areal 7mm 5mm Basic critical thickness 0 5mm 0 3mm Working temperature O C 40 C 32 F 104 F Working relative humidity 20 90 lp S Coating Thickness Tester User Manual o Size HxDxW 110x50x23mm Weight 100g 1 6 Front View 1 Probe 2 Power ON OFF key 3 Zero Calibration key 4 Down Right key 5 Blue key for ESC NO BACK function in menu mode or backlight ON OFF In working mode 6 Main display for coating thickness 7 Measuring unit 8 NFe indicates readings on non ferrous metals Fe indicates readings on ferrous metals 9 Indicates the probe working principle AUTO Magnetic induction or Eddy current 10 Indicates that the gauge is currently controlled via pc 11 USB connecting port 12 Low battery 1 13 Working mode indication DIRECT or GROUP 14 Statistic display AVG MAX MIN SDEV 15 The statistic number of measuring re
8. a oa le s Coating Thickness Tester User Manual g effect of scattering which occurs during calibration of upper and lower values The calibration foils may be used in any order Zero point calibration according to section 4 2 1 The first point calibration according to section 4 2 2 Repeat the step 2 Take readings by placing the probe on the coating to be measured and raise it after the beep The reading is shown on display NOTE Apply the probe to test sample several times The thickness of the foil should be roughly equivalent to the estimated coating thickness Even while a series of measurements is being taken foil calibration can be carried as often as necessary The old calibration will be overwritten the ZERO calibration remains in memory until make the zero point calibration See one point calibration for more information 4 2 4 Shot blased Surfaces The physical nature of shot blased surfaces results in coating thickness reading that are too high The mean thickness over the peaks can be determined as follows not that the statistics program is of great benefit in this procedure Method A The gauge should be calibrated according to 4 2 2 or 4 2 3 Use a smooth calibration sample with the same curvature radius and the same substrate as the later measuring sample Now take approx 10 readings on the uncoated shot blased sample to produce the mean value Xo After this take approx 10 further readings
9. adings 12 16 Red key for OK YES MENU 3 SELECT in menu mode 17 Up Left key ps s Coating Thickness Tester User Manual g 2 Preparing 2 1 Power Supply For checking the battery s state of charge please press o key No LC display Battery missing or battery charge too low to illuminate display Display gauge switches off after about one second Replace battery immediately Note that the gauge will make faulty measurements if the voltage is very low 2 2 Replacing The Battery Place the gauge upside down on a suitable surface Remove the screws from the battery compartment with a cross tip screwdriver Raise the lid of the compartment Remove battery Insert new battery Close the lid and fasten with screw Caution Make sure the anode and cathode are correctly positioned 2 3 Menu System and Basic Settings 2 3 1 Menu System Press to power on the gauge will work in measuring mode Press red bar button into MENU mode See following MENU system arranges NOTE MENU system arranges need to be known well for your works Menu gt Statistic view gt gt Average view gt gt Minimum view gt gt Maximum view gt gt Number view gt gt Sdev view gt Options gt gt Measure mode gt gt gt Single mode gt gt gt Continuous mode ps g Coating Thickness Tester User Manual s gt gt Working mode gt Limit gt gt gt Direct gt gt Limit settings gt gt gt Group 1 gt gt gt High l
10. an delete group data and statistic values and reset calibrate values and limit values ps s Coating Thickness Tester User Manual g You can select DIRECT and GROUP mode in MENU system NOTE in order to work in GROUP mode e g to calibrate take readings set limit the word GROX must appear on the LC display if not you can set measurement mode in MENU system Press 4while holding the probe in the air The gauge will work in DIRECT mode And the last reading will be shown if available 4 Calibration and Measurement 4 1 General Hints for Calibration 4 1 1 Calibration methods There are four different methods available for calibration Basic calibration recommended for measurement on even surfaces and if the measuring object has the same material size and curvature as the zero plate attached in the casing Zero point calibration recommended if measuring errors up to 3 of reading plus constant error of probe are permitted Example for constant of probe be error Fe 1um no Fe 1 5um One point calibration calibrating using a calibration foil recommended if readings to be expected will be close to the calibration value and if the permitted error of probe will be max 1 3 of reading plus constant probe error Two point calibration using a set of two calibration foils A Recommended for measurements on rough surfaces B Recommended for precise measurements on smooth surface if the thickness to be expec
11. dest reading And the statistics will be updated 7 Delete Functions In MENU system you can find following function Delete current data If you find the last measuring reading is wrong you can delete it via this function At the same time the statistics will be updated Delete all data You can delete all data and statistics of the Current Work Mode Delete Group data this function includes Delete all data function lia ps bg Coating Thickness Tester User Manual g In addition This function will delete HIGH alarm Low alarm and One amp Two point calibrations 8 Gauge Control Via PC All measuring readings of all work modes can be downloaded to PC via USB port for data analysis See software guide for more details 9 Trouble Shooting The following list of error messages explains how to identify and eliminate faults Err1 Err2 Err3 Connecting of probe fault Deviant signa Err1 Eddy current probe Err2 Magnetic induction probe Err3 Both probes Err4 5 6 reserved Err7 Thickness fault ps g Coating Thickness Tester User Manual s Information in this document is subject to change without notice 2012 M amp I Instruments Inc All Rights Reserved M amp I Instruments Inc 7035 Maxwell Road Unit 8 Mississauga ON Canada L5S 1R5 Tel 1 416 558 1088 Fax 1 905 670 8243 Website www microinstruments ca Email sales microinstruments ca Rev 100315
12. e Measurement values and user information are shown on LCD A display back light ensures easy reading of screen data in dark conditions Two different operating modes are available DIRECT mode and GROUP mode DIRECT mode is recommended for simple quick occasional measurements It provides statistical analysis Single values are not saved The statistical analysis program can evaluate 80 readings GROUP mode permits measurement and storage of readings in a free programmable memory A maximum of 400 readings and 4 series of measurements can be analyzed according to various statistical criteria 1 3 Supply Schedule Gauge with two 1 5V battery plastics carrying case operating instructions English steel and aluminum substrate USB connecting cable Program disc for Windows 98 2000 xp Vista 7 bd le s Coating Thickness Tester User Manual g 1 4 Probe The Probe systems are spring mounted in the probe sleeve This ensures safe and stable positioning of the probe and constant contact pressure A V groove in the sleeve of the probes facilitates reliable readings on small cylindrical parts The hemispherical tip of the probe is made of hard and durable material Hold the probe by the spring mounted sleeve and put on measuring object 1 5 Specifications Sensor probe F N Working principle Magnetic induction Eddy current principle Measuring range 0 1250um 0 1250um 0 49
13. imit gt gt gt Group 2 gt gt gt Low limit gt gt gt Group 3 gt gt Delete limit gt gt gt Group 4 gt Delete gt gt Used probe gt gt Current data gt gt gt AUTO gt gt All data gt gt gt Fe gt gt Group data gt gt gt No Fe gt Measurement view gt gt Unit settings gt Calibration gt gt gt um gt gt Enable gt gt gt mils gt gt Disable gt gt gt mm gt gt Delete Zero N gt gt Backlight gt gt Delete Zero F gt gt gt 0N gt gt gt 0FF gt gt LCD Statistic gt gt gt Average gt gt gt Maximum gt gt gt Minimum gt gt gt Sdev gt gt Auto power off gt gt gt Enable gt gt gt Disable ps s Coating Thickness Tester User Manual g 2 3 2 Basic Settings Please refer to the MENU arrange According to the LCD indication Press red bar button for OK YES MENU SELECT operating functions Press blue bar button for ESC NO BACK operating functions Press the UP DOWN button to switch the selected item 2 3 2 1 Measure mode Continuous measurement mode It can sometimes be of advantage if the probe does not need be raised between each measurement so that there is a running display of readings In continuous mode readings are not accompanied by a bleep All readings taken in this mode will automatically be entered into the statistics program as long as sufficient memory is available Single mode In Single mode readings are accompanied by a bleep Besides Others are same as
14. ing and raise it if steady lt may be necessary to delete calibration e g after entry of a faulty calibration value MENU gt delete gt delete group data NOTE It will delete all data limit data one point and two point calibrations except for zero point calibration This will reactivate the default basic calibration for use on even surfaces NOTE The meter calculates the mean of 5 calibration readings furthest When full the newest calibration value will replace the oldest calibration value Press blue bar button to exit current calibration Or else after about 30 seconds the calibration will be become effective automatically Press Zero button to make current calibration effective compulsively Even while a series of measurements is being taken foil calibration can be carried out often as necessary The old calibration will be overwritten the Zero calibration remains in memory 4 2 3 Two point Calibration Suggest that gauge is in single work mode If necessary switch to the mode as MENU system This method requires the use of two different foils The thicker one should be if possible 1 5times as thick as the thin one For best results the thickness to be expected should be somewhere between the two calibration values This method is especially suitable for taking measurements on rough shot blasted surfaces or for high precision readings It is advisable to take a mean for several times This considerably reduces the li
15. mple zero coating thickness vertically and rapidly The LC display lt x x m gt Operating is different in continuous mode and single mode See the work mode section for more details Then raise the probe rapidly far from metal substrate at least 10cm Press and hold Zero button for about 1 5seconds the LC display 0 0 um The calibration is finished Repeat this procedure several times The calibration system always saves the mean value of the previous calibration point NOTE You can delete the old zero point calibration before making a new zero point calibration via MENU system if existent The meter always calculates the mean of 5 calibration readings furthest When full the newest calibration value will replace the oldest calibration value We suggest that you make a Zero calibration when starting a measurement lp S Coating Thickness Tester User Manual o 4 2 2 One point Calibration This method is recommended for high precision measurements measurements on small parts and on hardened and low alloy steel Zero point calibration according to section 4 2 1 eLay the calibration foil on an uncoated sample apply the probe and raise it if steady Press UP or DOWN to adjust required foil thickness The thickness of the foil should be roughly equivalent to the estimated coating thickness Repeat step 2 several times It will get the mean value of previous calibration readings Now take readings by placing the probe on the coat
16. on coated shot blasted test sample to produce the mean value Xm The difference between the two mean values is the mean coating thickness Xeff over the peaks The greater standard deviation s of the two values Xm and Xo should also be taken into consideration Xeff Xm Xo S j ps g Coating Thickness Tester User Manual o Method B Carry out a zero calibration of 10 readings on a shot blased uncoated sample Then carry out a foil calibration on the uncoated substrate The foil set should consist of a number of individual foils of max 50 microns thickness each and should roughly correspond to the estimated coating thickness The coating thickness can be read directly from display and should be averaged from 5 10 single measurements The statistics function is useful here Method C This method also gives reliable results Simply follow the two point calibration method using two foils as described in section 4 2 3 For a maximum approach to the respective nature of surface the foil value can be reached by using several foils 50um each The mean coating thickness should be calculated from 5 10 readings The Statistics program is very useful here NOTE For coatings thicker than 300 um the influence of roughness generally is of no importance and it will not be necessary to apply above calibration methods 4 3 General Remarks on Measurement After careful calibration has been made all subsequent measurements
17. ted lies between that of the two calibration foils 4 1 2 Storing Calibration Values If the gauge is calibrated for a particular purpose the calibration values will be stored in memory until changed NOTE The calibration procedure should be restarted from the beginning if sAn incorrect reading has been taken An incorrect command has been entered The gauge has switched off lia ps ad Coating Thickness Tester User Manual o 4 1 3 Calibration Example Calibration is the most important requirement for accurate measurement The more closely the calibration sample matches the product sample the more accurate the calibration and therefore the reading will be If for instance a product is to be measured on a steel cylinder quality ST37 mild steel diameter 6mm the calibration of the uncoated sample must take place on a steel cylinder of similar quality with the same diameter The calibration sample must correspond to the product sample in the following ways Curvature radius Substrate material properties Substrate thickness Size of measuring area The point at which the calibration is made on the calibration sample must always be identical with the point of measurement on the product itself especially in the case of corners and edges of small parts 4 1 4 High Accuracy Calibration To achieve high accuracy readings it is advisable to log calibration values both zero values and calibration foil values se
18. veral times in succession In this way the gauge will automatically establish a mean calibration value For more details see 4 2 special hints for calibration The high accuracy calibration is an obvious advantage when calibrating on uneven e g shot blasted surfaces 4 1 5 Cleaning the Measuring Point Before calibration the measuring point the probe tip must be free from grease oil scraps of metal etc The slightest impurity will affect measurement and distort readings lia ps s Coating Thickness Tester User Manual g 4 2 Special Hints for Calibration The basic calibration stored in the gauge should only be used for measurements on even surfaces i e on steel components made of conventional steel mild steel or on aluminum components Firstly you can turn into Calibration Mode via MENU Menu gt Calibration gt Enable system Then the LC will display Cal n or 1 2 Zero n or y The n means not any point calibration and Zero calibration and y means there is Zero calibration Cal 1 2 means There is One or Two point Calibration After finishing all Calibration task we advise that you disable calibration via MENU system Preparing to make calibration Switch the gauge on far from any metal at least 10cm Substrate sample and necessary foils calibration standard Set woke mode continuous or single via MENU 4 2 1 Zero point Calibration no need to enable calibration Place the probe on uncoated sa
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