MEGA-CHECK 20-ST COATING THICKNESS METER

Transcription

1 MEGA-CHECK 20-ST COATING THICKNESS METER OPERATIONAL MANUAL Bms Bulut Makina Sanayi Ve Ticaret Ltd. Şti. İkitelli Organize Sanayi Bölgesi Dolapdere Sanayi Sitesi Ada 4 No : 7-9 İkitelli / İSTANBUL-TÜRKİYE Phone : / Fax : web : bms@bulutmak.com

2 DESCRIPTION... 3 FUNCTIONS OF THE KEYS - SHORT INSTRUCTIONS IMPORTANT NOTICE Measurements On Small Or Curved Objects Zero Adjustment On Rough Surfaces Thickness Of Base Material Keep Readings And Calibration Stored When Changing Battery Switch Over The Unit Of Measurement (Microns - Mils) Power Supply Battery Control Automatic Switch Off I M P O R T A N T... 6 I.OPERATING INSTRUCTIONS Connect The Probe To The Instrument Switch On The Instrument With Key ON-OFF Zero Setting Calibration With Measuring Foil... 7 II.MEASURING PROBES... 7 III.APPLICATION MEMORIES Function Switch Over The Application Memories... 9 IV.STATISTICS V.DISPLAY READINGS VI.BACKLIGHT-GRAPHIC LCD DISPLAY VII.CLEAR MEASUREMENTS Clear A Wrong Measurement Clear One Application Memory Clear Application Memories A98 + A99 DUPLEX Function Clear All Application Memories VIII.SCAN FUNCTION IX.SWITCH OVER THE MEASURING MODE (AC NE) X.DUPLEX FUNCTION XI.SET REFERENCE VALUE, DATE AND TIME XIII.OPERATION WITH PRINTER Print Out Statistics XIV.SOFTWARE TECHNICAL DATA DATA PRINTER MEGA-PRINT Technical Data Insert A New Paper Roll...17 Rev:00 2 / 17

3 DESCRIPTION The Coating Thickness Meter MEGA-CHECK 20-ST includes two measuring techniques: Magnetic Induction (FE) On base material iron and steel all non-magnetic coatings, such as varnish, paint, plastics, enamel, rubber, ceramics and galvanic layers except niquel can be measured. Eddy Current (NFE) On non-ferrous metals (aluminium, brass, bronze, zinc, lead, copper and non-magnetic steels) all non-conductive coatings, such as varnish, paint, plastics, rubber and anodizing can be measured. The instrument can be equipped with eight measuring probes which differ from the measuring technique (magnetic induction and/or eddy current) and measuring range (see II. Measuring Probes). MEGA-CHECK 20-ST is provided with 100 different application memories with a total capacity of 2000 readings allowing evaluation on the display, printer or computer.!, Special Features A reference value can be entered. When the measured value is above or below a beep sounds. Statistics and a bar diagram can be printed on Printer MEGA-PRINT. A Data Transfer and Graphical Evaluation software is available on request. Rev:00 3 / 17

4 FUNCTIONS OF THE KEYS - SHORT INSTRUCTIONS - Key Function 1 Function 2 (2 sec) Function 3 (4 sec) Function 4 (6 sec) ( Display ) (Key Function 1) (Key Function 2) (Key Function 3) (Key Function 4) Switch ON/Off Switch over µm/mm - mils ( Display) Version No./ OFF µm - mils MEAN ZERO Set zero point Set mean zero point (on rough surfaces ( Display ) SET ZERO MEAN ZERO CAL Foil calibration (with keys set foil value) ( Display ) SET CAL CLEAR DEL APPL.No. ALL APPL. + LIMITS ( Display ) Clear last reading CLEAR last value Clear application memory CLEAR Appl. Memory Clear all application memories and reference values C L R SELECT S C A N AC NE DUPLEX LIMITS + TIME + DATE ( Display ) Enter SCAN Function (Mean value on rough surfaces) SCAN mode Switch over AUTOMATIC Eddy Current (NE) (Coatings on galvanized steel) AUTO - NE Enter DUPLEX Function (Individual display of coating + galvanizing on steel) DUPLEX-VALUE Enter reference value, date and time in the application memory SETPOINTS APPL.: ON OFF Appl ( Display ) DISPLAY STATS EDIT BACKLIGHT ON - OFF (Display ) Switch ON/OFF Application memory Appl.Memory On/Off Display statistics of actual application memory Appl.Memory A Numbers Select application memory with keys (A for DUPLEX Function only) APPL.MEM. A Display readings of actual application memory. Scroll with keys. Appl.Memory A Numbers Switch ON/OFF backlight BACKLIGHT On-Off PRINT STATS READINGS BAR DIAGRAM ( Display ) Print statistics, date and time of actual application memory PRINT STATISTIC Pring readings of actual application memory PRINT READINGS Print bar chart of actual application memory PRINT BAR CHART Rev:00 4 / 17

5 IMPORTANT NOTICE 1.Measurements On Small Or Curved Objects When measuring on small or curved objects both zero adjustment and calibration must be performed on a geometrically identical uncoated test object. Also when measuring on base materials with different structures (cast iron, special steels) this calibration should be perfomed. For measurements of small objects on steel we recommend the probes F-1A and F-3T. 2.Zero Adjustment On Rough Surfaces To set zero exactly on rough surfaces, the probe can be set at various spots and the instrument itself calculates the average. Press key -0- until Key Function -2- appears on the display. Now carry out zero setting. Repeat this procedure several times at different measuring spots. After each step the mean value is displayed. Then press key -0- again to store the mean value. To cancel the mean function perform the standard zero setting. For correct measurements on rough surfaces we recommend to use the SCAN Function (see VIII.). 3.Thickness Of Base Material Ferrous base material (FE): > 0.3 mm Non-ferrous base material (NFE): > 0.2 mm 4.Keep Readings And Calibration Stored When Changing Battery Readings and calibration remain stored after switching off the instrument and even during a battery change provided this is carried out within five minutes. If the instrument is stored for a longer period of time without battery, the indication CLr..start! is displayed when the instrument is switched on. This means that because of the long interruption in the flow of current data have been lost and the instrument must be recalibrated. 5.Switch Over The Unit Of Measurement (Microns - Mils) In its basic setting the instrument measures in microns. To switch over to mils the following steps are necessary: Switch on the instrument. Press key ON/OFF until the indication Key Function -4- appears. The instrument automatically is switched off and the calibration data entered are canceled. After switching on the instrument again the display shows the measuring unit mils. Now carry out calibration according Item I Rev:00 5 / 17

6 6.Power Supply The instrument is supplied with a 9V battery (IEC 6 LF 22). It can also work with a rechargeable battery Ni-MH 9V with charging unit. The charger is connected to the 24 V plug of the device. Charging time: 8 10 hours. The charging unit may be connected continuously! 7.Battery Control With the instrument switched on as soon as the symbol Lo Bat appears on the display the battery must be replaced or charged. 8.Automatic Switch Off The instrument switches itself off two minutes after the last measurement. 9.I M P O R T A N T The probe should not be drawn across the testing surface but reset at different spots, i.e. after each measurement hold the probe in the air for about 1 sec. In doing so the stored calibration is automatically checked and corrected if necessary. Only in the SCAN Function the probe can be drawn carefully over the surface. Make sure that the probe surface and the base plates are kept clean and polished at all times. I.OPERATING INSTRUCTIONS IMPORTANT When starting operation for the first time and when measuring on small or curved objects it is absolutely necessary to carry out calibration with the measuring foil supplied (approx. 300 microns). In case the instrument has already been in operation the last calibration value entered is automatically adjusted to possible temperature fluctua-tions when switching on. A new calibration is only necessary when measuring on small and curved objects. 1.Connect The Probe To The Instrument 2.Switch On The Instrument With Key ON-OFF When switching on the software version is displayed, then comes PROBE-EEP loading (probe data are entered). 3.Zero Setting Press key -0-, indication appears. Place the probe on the bare base plate (blue = steel, iron; red = non-ferrous metal) or on an uncoated test object. Only when the indication 0.0 is displayed and the beep signal sounds may the probe be removed. Important! Zero setting with probe F-15 (thick coatings) must be performed on a bare steel plate of at least 60 x 40 mm. Rev:00 6 / 17

7 4.Calibration With Measuring Foil indispensable: - when starting operation for the first time, - when measuring on small or curved objects (see Important Notice Item 1.), - after changing battery (see Important Notice Item 4.) Once zero setting is performed: Press key CAL. The last calibration value entered will be displayed and a cursor flashes. By pressing the keys CAL Δ (up and down) the correct calibration value for the probe (see page 7) can be entered. (Pressing the key once changes the value by 1 digit, pressing it for a longer time causes the value to move down or up continuously.) Place the measuring foil or plate on the base plate and the probe on the foil. Indication CAL calibration value beep signal. As soon as the beep signal sounds the probe can be removed. Now the instrument is ready for operation. II.MEASURING PROBES Probe characteristics and calibration data Eight probes, which differ in measuring principle (magnetic induction and/or eddy current) and measuring range, can be connected to the instrument (see table). The probe characteristics and calibration data are stored in the probe. When changing probes the latest calibration will be activated when connecting the probe to the device. (No recalibration necessary). IMPORTANT When the device is switched on without probe, PROBE-EEP empty is flashing. Switch off the instrument, connect the probe and then switch on again to load the probe data. When disconnecting the probe while the device is switched on, the instrument switches off by itself. WHEN CONNECTING A NEW PROBE THE DEVICE MUST BE SWITCHED OFF. THEN CONNECT THE PROBE AND SWITCH ON THE DEVICE. Table of available probes with calibration values Measuring Techniques: F = magnetic induction on ferrous base material (steel) N = eddy current on non-ferrous metals FN = magnetic indcution and eddy current on ferrous and non ferrous metals Rev:00 7 / 17

8 Probe Calibration value F microns F microns Measuring Range F microns F mm Application Standard springloaded single-pole probe (on steel) with interchangeable pole-tip, suitable for SCAN function. Special two-pole probe (on steel) compensated against external magnetic fields. F - 1 A 100 microns with special brass shims F - 3 T 300 microns F mm N microns N mm FN - 52 A 300 microns FN - 52 AT 300 microns F microns F microns F 0-15 mm N microns N 0-8 mm N microns F microns N microns F microns Special single-pole probe for thin layers on small objects of steel, not suitable for SCAN function and rough surfaces! Special single-pole probe 90 for small objects of steel, not suitable for SCAN function and rough surfaces! Special two-pole probe suitable to measure thick coatings on steel. Special probe for coatings on slightly magnetic stainless steel. Springloaded probe for thick layers on nonferrous metals, with inter-changeable pole-tip. Universal springloaded probe (ferrous + non-ferrous) with inter-changeable pole-tip, suitable vor SCAN + DUPLEX function. Universal springloaded probe (ferrous + non-ferrous) with swinging facility by 90, inter-changeable pole-tip, suitable for SCAN + DUPLEX function. Rev:00 8 / 17

9 III.APPLICATION MEMORIES 1.Function The instrument is provided with about 100 different application memories to store and evaluate statistically series of measurements. A maximum of 2000 readings can be stored. The max. capacity of readings in one application memory depends on the number of memories occupied. A maximum of 1000 readings with one measuring technique (FE or NFE) can be stored in each application memory. Example: The data memory already contains readings based on the magnetic induction technique (e.g. FE). If one tries to enter a measurement using the eddy current probe (FNE) the display BASE! appears to indicate that the memory already contains readings based on the magnetic induction technique and that the measurement taken with the eddy current probe can therefore not be accepted. The reading is not stored. When switching off the instrument, calibration and all readings entered remain stored, i.e. they are available at any time when switching on the instrument again. Important The application memories A98 + A99 are exclusively determined for readings stored with the DUPLEX function. 2. Switch on the instrument with key ON-OFF. Press key APPL. once and wait until PLEASE WAIT! is indicated and the number of the application memory last recorded. From now on all readings are stored. The memory is switched off by pressing key APPL. again. Subsequent readings are not stored. It is necessary to leave the data memory when during a series of measurements the calibration is to be checked to prevent the calibration values from entering the memory. When the memory has reached its limit (max readings) the indication APPL.FUL! (full memory) appears on the display. 3.Switch Over The Application Memories Press key APPL. until Key Function -2- appears on the display. The current application memory is displayed. By pressing the keys Δ a new application memory can be selected. Then press key APPL. again. The notice PLEASE WAIT! appears and the instrument is ready for measuring. The application memories A98 + A99 are exclusively determined for readings stored with the DUPLEX function. They are activated automatically when DUPLEX function is selected. Rev:00 9 / 17

10 IV.STATISTICS Evaluation of the stored readings is carried out with key DISPLAY. Evaluation can be done with the application memory switched on or off (key APPL.). If one presses key DISPLAY once the number of stored measurements (Numbers) appears. Press twice = minimum value (MIN) Press three times = maximum value (MAX) Press four times = mean value (MEAN) Press five times = standard deviation (STD.DEV.) When pressing the same key once again the instrument returns into the measuring mode. When a measurement is taken while a statistic value is indicated, it will be ignored. V.DISPLAY READINGS To display the readings stored in the current application memory proceed as follows: Press key DISPLAY until Key Function -2- appears (EDIT). Then Appl.Memory A.. and Numbers:... is displayed, a cursor flashes and the latest reading stored is indicated. With keys Δ scroll up and down. With key CLEAR (DEL) the current reading displayed can be cleared. With key DISPLAY return into the measuring mode. VI.BACKLIGHT-GRAPHIC LCD DISPLAY MEGA-CHECK 20-ST has a backlighted graphic LCD display. To switch ON/OFF the backlight proceed as follows: Press key DISPLAY until Key Function -3- is indicated (BACKLIGHT ON-OFF). Then Backlight - ON/OFF appears and the light is switched on or off. The backlight switches off automatically 2 sec after the last measurement. When pressing any key or measuring again it switches on by itself. VII.CLEAR MEASUREMENTS 1.Clear A Wrong Measurement The last reading stored is canceled by pressing key CLEAR (DEL.) until Key function -1- appears on the display. Now DELETE last value! is indicated and the value is cleared. Rev:00 10 / 17

11 2.Clear One Application Memory All readings stored in one memory location can be canceled as follows: Select the memory location containing the readings to be cleared (see III ). Keep key CLEAR pressed until Key function -2- appears on the display (APPL.No.). Now CLEAR and Appl. Memory! is indicated. The memory is cleared Attention! If the memory contains up to 1000 readings the clearing procedure may last about 2 ½ minutes. (After the indication CLEAR Appl. Memory! wait approx. 2 ½ minutes.) 1.Clear Application Memories A98 + A99 DUPLEX Function The readings stored in the memories A98 + A99 are cleared as follows: With key SELECT enter into the DUPLEX function (see X.) and then into the application memory A98 or A99. When the selected memory is indicated press key CLEAR until Key funktion - 2- is displayed (APPL.No.). 2. Clear All Application Memories All readings stored in all 100 memory locations and the reference values can be cleared as follows: Press key CLEAR until Key function -3- is indicated (ALL APPL. + LIMITS.) Now CLEAR all Memories + Setpoint! is indicated. The calibrations entered remain stored. VIII.SCAN FUNCTION The SCAN function is used to find out the mean coating thickness value on rough surfaces or rough coatings. From Software Version V 2.1 additionally to the MEAN value also the MAX and MIN values will be indicated. Set the probe on the object to be tested and move it carefully across the coating. The instrument automatically records measurements/sec and calculates the MIN, MAX and MEAN value. This new function is much more accurate than the mean zero setting. The SCAN function should be used only on rough surfaces to avoid the pole-tip of the probe to get vasted. The pole tips of the probes F-5 / FN-52A / FN-52AT are interchangeable. The SCAN function should not be used with probes F-6 / F-1A and F-3T. Press key SELECT until Key Function -1- appears (SCAN). SCAN-mode and is displayed. Rev:00 11 / 17

12 Set the probe on the object and move it slowly over the coating. As soon as the probe is taken off the MEAN value is displayed. Beneath the MIN and MAX value is indicated without the corresponding measuring unit. IX.SWITCH OVER THE MEASURING MODE (AC NE) When the probe is set on the base material the measuring mode is switched over automatically. (AC = automatic, NE = eddy current). The base material (BASE = FE or NFE) is indicated together with the reading. Eddy current Non-condictive coatings on non-ferrous metals, indication BASE = NFE. Magnetic induction Insulating and galvanic coatings (except niquel) on ferrous metals, indication BASE = FE. MEGA-CHECK 20-ST has an additional feature making it possible to measure with the eddy current technique layers on zinc plated steel provided the thickness of the zinc plating is more than 20 microns thick. For this special measuring problem the automatic switch over of the measuring mode must be deactivated and the eddy current mode (NFE) is set manually. Press key SELECT unti Key Function -2- and NE base mode is displayed. Important When measuring galvanic or insulating layers on ferrous base material switch over to the automatic mode to avoid wrong readings. Press key SELECT until Key Function 2- and Automatic mode is displayed, or switch off and on again. X.DUPLEX FUNCTION The DUPLEX function is used to measure the thickness of double coatings (insulating coating on zinc plated steel). When setting the probe on the insulating coating simultaneously the thickness of the insulating coating and the thickness of zinc is displayed. Both coatings together are measured with the magnetic induction technique and automatically the insulating coating measured with eddy current will be deducted. Important To avoid wrong readings the following conditions must be complied: The zinc plating must have at least a thickness of 20 microns. If possible, zero setting should be performed on a similar object without insulating coating with the eddy current technique. DUPLEX function can only be used with probes FN-52A and FN-52AT. Press key SELECT until Key function -3- is displayed (DUPLEX). Then Duplex value is indicated. Rev:00 12 / 17

13 Set the probe on the coating and wait until measurement is confirmed by two beep signals. Both values are displayed FE value = zinc plating, NE value = insulating coating. For storing the FE and NE readings only the application memories A98 + A99 can be used. The FE readings are recorded in A98 and the NE readings in A99. With key APPL. (ON-OFF) the applications memories A98 + A99 are automatically activated when using the DUPLEX function (see III. Application Memories). XI.SET REFERENCE VALUE, DATE AND TIME A fixed reference value can be entered for each application memory with a tolerance limit MIN - MAX for statistical evaluation of the bar diagram as well as for the acoustic warning when value exceeds the tolerance level or falls short of it. If the value exceeds or falls short of the tolerance level a double beep is emitted which makes it possible to carry out a series of measurements in dark rooms, if reading the digital display presents problems. Set reference value and tolerance level Press key SELECT until Key function -4- appears on the display (LIMITS + TIME + DATE). Subsequently the last reference value entered flashes (Appl.A. Setpoint::). Using keys Δ the selected reference value can now be entered. Then press key SELECT again. Appl.A.. Setpoint:<: appears on the display, as does the last minimum value entered. Using keys Δ enter the minimum value desired, then press key SELECT. Appl.A.. Setpoint:>: appears on the display, as does the maximum value entered. Using keys Δ enter the maximum value desired. Then press key SELECT to set date and time. Confirm scrolling with key SELECT until Please wait! is indicated. The instrument is ready for measuring. Set Date and Time Press key SELECT until Key function -4- appears on the display (LIMITS + TIME + DATE). With key SELECT scroll until Year is indicated. In the sequence Y = M = D = H = M = year month date hour minute all data can be entered. Using keys Δ set the numerical values and switch over with key SELECT. After entering the last value (minutes) press key SELECT again. Please wait! is indicated. The instrument is ready for measuring. XIII.OPERATION WITH PRINTER Rev:00 13 / 17

14 The interface parameters of the instrument are set in the factory in such a way that the printer MEGA-PRINT supplied by us can be connected, without having to alter the interface parameters. Operating instruction 1. Connect the printer cable to the instrument socket (RS 232 C) and to the printer. 2. Switch on MEGA-CHECK 20-ST, the printer switches itself on automatically. 3.Print Out Statistics Press key PRINT until Key Function -1- is indicated (STATS). During the print-out -Print statistics- is displayed. Statistics, reference value entered, date and time are printed out. At the same time the interface is switched on, so that every new measurement will be printed. To switch off the interface press key PRINT until Key Function -1- is indicated and afterwards Printer PORT=OFF!. 4.Print out all individual readings Press key PRINT until Key Function -2- is indicated (READINGS ). During the print-out -Print readings- is displayed. All readings stored are printed out. 5.Bar diagram (only possible with printer MEGA-PRINT) Press key PRINT until Key Function -3- is indicated (BAR DIAGRAM). During the print-out Print bar diagram- is displayed. Statistics, reference value entered, date, time and the bar diagram of the application memory selected are printed out. The bar diagram represents the percentage deviation of the coating thickness in relation to the reference value entered. (SETPOINT). The evaluation range is between the tolerance limits entered (see also XI. Set Reference Value), provided the value is higher or lower. Otherwise the evaluation range is between the minimum and maximum value of the series of measurements. XIII. SET INTERFACE PARAMETERS The interface parameters are set for the Data Printer MEGA-PRINT (1200 baud, 8/1data/stop bits). By sending the following ASCII code to the device the data stored (statistics + readings) can be called up automatically by an application program without pressing any key. Interface is switched over automatically to the following parameters: 9600 baud - 8/1 data/stop bits ASCIIl code T+Chr (52) XIV.SOFTWARE Rev:00 14 / 17

15 Data Input Software TRANSFER To transfer the readings to a PC an interface cable with a 9 pins centronic plug and a data transfer diskette are available. The data TRANSFER program runs on WIN 98 / 2000 / XP and enters the readings into a data file. Data Input Software TRANSFER EXCEL Transfers the data directly in an existing Excel file. Graphic Statistics Software STAT-6 This software especially developed for the Thickness Meters MEGA-CHECK evaluates the readings stored and displays automatically statistics, bar and line diagrams. It runs on WIN 98 / 2000 / XP. With this software you can also measure online with the MEGA-CHECK 20-ST. Just connect the device to the computer and the graphic representation is updated automatically as soon as a reading is recorded. TECHNICAL DATA Measuring Techniques: DIN DIN DIN ISO 2178 ISO 2360 BS 5411 ASTM Magnetic induction on iron and steel (Probes F-5 / F-6 / F-1A / F-3T / F-15) Eddy current on non-ferrous metals (Probe N-8) Magnetic induction on iron and steel and eddy current on non-ferrous metals and V2A - V4A steel (Probes FN-52A / FN-52AT) Measuring Ranges: Indication: Resolution: Accuracy: Number of application memories: Ambient Temperature: see II. Measuring Probes Graphic LCD display with backlight and guides for operation microns: 0.1 micron microns: 1.0 micron > 2.0 mm: 0.01 mm microns: ± 1 micron microns: ± 1 % microns: ± 3 % > 2000 microns: ± 5 % max. 100 (total 2000 readings) 0-50 C Batterie Power Supply: Alkaline 9 V (IEC 6 LF 22) (rechargeable 9 V NiCad on request) Battery Capacity: Dimensions: Weight: approx. 60 hours 160 x 80 x 27 mm approx. 150 g (incl. battery) Rev:00 15 / 17

16 Interface: Data Format: serial RS 232 C (V24) (5V-TTL) with handshaking and TXD-signal Printer MEGA-PRINT: 1200 baud, 7/2 data/stopbits Interface RS 232 C: 9600 baud, 8/1 data/stopbits Warranty: Indication Unit: 12 months Measuring Probe: 3 months DATA PRINTER MEGA-PRINT Technical Data Type of Printer: Thermo printer Characters/Line: 16 Data Transfer Rate: 1200 baud Printing Velocity: max. 20 lines/sec. Interface: serial Paper: Thermo paper, 57 mm wide, max. 10 m long Power Supply: Rechargeable NiCad battery (approx. 60 hours operation/charge) Size: 110 x 80 x 45 mm Weight: approx. 240 g Charging Unit: 230 V/50 Hz / 6.0 V 0.5 A Charging the built-in NiCad Battery Before using MEGA-PRINT for the first time the built-in NiCad battery must be charged. The built-in NiCad battery is charged with the charging unit supplied with the printer. The cable of the charging unit is connected at the right-hand socket of MEGA-PRINT. The charging time should be at least 4 hours. Operating Instructions 1. The operation of MEGA-PRINT together with the Coating Thickness Meter MEGA- CHECK 20-ST is explained in the operating instructions of MEGA-CHECK 20-ST (Item XII). 2. When the printer MEGA-PRINT is connected to the Coating Thickness Meter MEGA-CHECK 20-ST, MEGA-PRINT switches on automatically (the green LED flashes every 2 sec). When switching off MEGA-CHECK 20-ST, the printer is switched off automatically (the green LED remains switched off). 3. The manual paper feed is performed with the key Paperfeed. When the printout is finished the paper stripe is transported out of the casing by pressing this key and can be neatly turned off. 4. Faulty print out Incorrect printed lines mean that the printer should be recharged. Rev:00 16 / 17

17 Insert A New Paper Roll Rev:00 17 / 17