Model 100 Series Ultrasonic Multi-layer Coating Thickness Gage Instruction Manual version 4.
Page 2 100 Series
DeFelsko Corporation USA 1999 All Rights Reserved • Patents applied for • Printed in U.S.A. This manual is copyrighted with all rights reserved and may not be reproduced or transmitted, in whole or part, by any means, without written permission from DeFelsko Corporation. DeFelsko, PosiTector and PosiSoft are trademarks of DeFelsko Corporation registered in the U.S. and in other countries. Microsoft. Windows NT, Windows 95 and Windows 98 are registered trademarks of Microsoft Corporation.
SAFETY, CARE AND MAINTENANCE ......................................................................6 QUICK START ......................................................................................................7 PHYSICAL OVERVIEW ..........................................................................................8 Packing List ....................................................................................................8 Gage Description .....................................................
ADVANCED FEATURES .......................................................................................29 Zeroing the Probe..........................................................................................29 Restarting the Gage.......................................................................................30 Gage RESET......................................................................................................... 30 Gage INITIALIZATION ..............................................
Safety, Care and Maintenance Screen care • The LCD is protected by a solvent-resistant lens. Be careful not to scratch this lens. Do not use ink pens or any other sharp object. • Take care not to break the glass lens. Do not subject the Model 100 to a strong impact or to extreme temperatures. • We suggest cleaning the lens only with a soft dry cloth – such as a cloth made for cleaning eyeglasses.
The Model 100 hand-held, electronic Gage uses an ultrasonic technique to nondestructively measure the thickness of coatings on various substrates quickly and accurately. The probe emits an ultrasonic pulse into the coating. Reflections from the coating/substrate interface, coating/coating interfaces and other conditions are picked up by the probe. The travel time is converted into a thickness value shown on the display.
Physical Overview Packing List The Model 100 comes complete with: • one (1) ultrasonic probe, either B, C or D (pg.9) • Cordura carrying case with shoulder strap • this instruction booklet • two (2) “C” alkaline batteries (pg.37) • wire stand for desktop operation (pg.8) • precision plastic shim set (pg.28) • ultrasonic couplant (pg.
AC port - An optional AC adapter can be purchased from your dealer to supply continuous 7.5 volts DC power from an AC source. (pg.35) RS232 Port - An RS232 compatible port is provided via this RJ45 interface to send stored measurements or measurements-as-they-are-taken to a serial printer, data collector or computer. Transmission is at 9600 baud, 8 bits, nonparity, 1 stop bit. Active only on Gages with the Memory option (pg.13). RESET Button - causes a “soft” or “safe” RESET as described on page 30.
LCD Display Information is displayed in one of four areas on the LCD: the top STATUS BAR, the bottom MENU BAR, the left MEASUREMENTS area and the right STATISTICS/GRAPHICS area. Status Bar An area along the top of the LCD is reserved for status information. This includes the name of the current application (pg.19), the system date and time (pg.33), the current units of measurement (pg.33), the current batch name and number of readings.
Measurements Area The left hand side of the screen displays up to five (5) individual coating layers as set by the Setup q Application Setup menu option (pg.19). Each layer is described in its own box. The number appearing in the top left of each box is the layer number. The top box, layer 1, represents the surface layer. The bottom box represents the layer closest to the substrate. The coating name appears beside the layer number.
The top (A) and bottom (B) Gate values (pg.32) are displayed as two horizontal lines at the top and bottom of the graphics area. Their current values are shown to the right of each line. Gate A, the lower limit, is at the top. Gate B, the upper limit, is at the bottom. Echoes or peaks (thickness values) outside these Gates are ignored. GATE values are set and modified using the Setup q Application Setup menu option. This GRAPHICS display can be manipulated with the Setup q Gate/Zoom Control menu option.
Memory When the Modes q Memory ON menu item is selected, a symbol and a counter (n=0) appears in the upper center of the display. If the graphics screen is OFF a box will appear beside every layer box containing the average (mean) χ and standard deviation σ values. If the graphics screen is ON statistics calculations are done in the background and results are still stored into memory. As each measurement is taken, the readings are displayed and the counter is increased.
Operation Overview The Model 100 is an ultrasonic coating thickness Gage. As such it shares characteristics with ultrasonic wall thickness gages and with magnetic and eddy current coating thickness gages. Like ultrasonic wall thickness gages, the Model 100 uses a transducer in the probe to send pulses into the material to be measured and then measures the time taken by that pulse to return to the probe tip.
Once you have checked Gage operation on a known thickness of material and have modified current Application settings to most closely match your coating/substrate combination you are ready to measure. Be sure to apply sufficient couplant to fill voids in the surface and to fully wet the probe tip. Multiple measurements in the same location may require additional couplant every so often. Hold the probe steady when measuring and release the probe switch after hearing the double BEEP.
A visual inspection, such as that obtained by microscopically viewing a crosssectional cut of the material, often reveals useful information about your application. It may also explain why the Gage behaves the way it does when measuring your part. Finally, you are always welcome to contact us at techsale@defelsko.com with your inquiries.
Since a potentially large number of echoes could occur, the Gage will choose the strongest echo for use in coating thickness measurements. The assumption is that the coating/substrate interface will provide the largest distance corrected echo within the bracketed echo window (as defined by Gates A and B). The coating thickness is calculated from the measured propagation time and the velocity of propagation (sound velocity constant, vs) of the coating material.
How to take a measurement Apply a sufficient amount of couplant to the surface of your part. After power-up, place the probe FLAT on the surface. Depress the probe switch and hold the probe steady. While measuring, a “ticking” clock ∅ may momentarily appear in the top status bar. The time required to take a reading will vary. When measuring a new application for the first time the Gage may take up to 5 seconds to acquire a reading. Subsequent readings are faster.
Applications The Model 100 has the unique ability to store various settings for individual jobs or coating thickness applications.
Select an Existing Application Use the ↓ ↑ buttons located below the list box to move the highlighter to your choice. Notice that details on the currently highlighted application appear immediately in the left side of the LCD. Only applications created for the currently connected probe are visible. Select the Setup q Application Setup q Select an App menu item. Press the OK button to complete the selection process. The application is now open to accept changes or stored readings (memory option only).
Recording and Downloading Measurements (available only on Gages with the Memory option) The Model 100 can store measurement results for later downloading to a printer, datacollector or PC. These values are stored in the currently selected application, grouped by batch (file). These batches are unique to an individual application and an application can have many batches. Creating Batches • To begin recording measurements into a new file choose the Batch q Create New menu option.
Viewing and Editing Batches The Batch q View/Edit screen not only allows the user to view stored readings but also to delete and modify those readings. It also allows new measurements to be added without having to return to the main screen. To delete an existing measurement use the ↓ ↑ buttons to move the highlighter to your choice and press the Delete key. Notice that all layers in a multiple layer measurement are deleted. Deleted readings can not be recovered, however they are not actually erased.
Charting Batches The contents of the current batch can be viewed in graphical format by selecting the Batch q Chart menu item. A line chart or histogram is available for a single layer or for all coats. The batch name is “LabSample”. The application “PlasticFender” is set to measure two layers. Ten readings were taken but two were deleted.
Calibration and Optimization The Model 100 is factory aligned and does a self check each time it takes a measurement. Periodically calibrate the Gage against known thickness calibration standards to verify correct operation and determine if the Gage is within tolerance. Calibrate ⇒ Optimize ⇒ Measure Overview The operation of an ultrasonic coating thickness Gage is based on the transit time of an ultrasonic pulse through a coating.
The need to optimize is dependent upon a number of factors. If you are using standard materials in your coatings and can select from the menu there is probably no reason to optimize the Gage. On the other hand, if you need very accurate measurements and are using non-standard materials it is suggested that you optimize the Gage to your coating material prior to making actual measurements. Check standards may be made following the instructions given in Appendix A.
CALIBRATION INTERVAL Start with a recommended interval of one year and adjust that interval according to your individual usage and environment. Optimization Thickness measurement error is minimized by ensuring that the Gage has the correct velocity value for the particular coating system being measured. This is done by following a 2-step procedure: 1. SELECT A CATEGORY 2.
Since the substrate can often affect the return echo, all probes also provide the user with a selection of substrate categories including concrete, wood, glass, plastic, metal, ceramic and none to further refine the optimization. To select these categories choose the Setup Application Setup menu item. Use the ↓ button to move the highlighter down to the Substrate: line. A substrate list box will appear containing the currently available list of substrates.
If the average is not within tolerance, optimize the displayed value up(+)or down(-) to match the check standard thickness using the Setup – Adjust Reading menu option. Measure and adjust until you are satisfied that the average of a series of readings equals the check standard thickness. Optionally if you know or have previously recorded a sound velocity constant for this The thickness value was changed from 1.2 mils to 1.4 mils.
Advanced Features Zeroing the Probe The probe must be periodically zeroed using the Setup q Zero Probe menu item to compensate for both temperature and probe wear effects. (This is not to be confused with measuring an uncoated substrate to get a 0.0 reading!) Allow the probe to reach ambient temperature. Wipe the probe clean of gel. Temperature changes directly affect Gage measurements by expanding and contracting the probe’s plastic delay tip.
Restarting the Gage As with any electronic device, harsh temperature, electromagnetic environments or rough handling may alter the performance of some Gage components causing the Gage to exhibit unusual behavior. Two features enable the Gage to recover from many of these disturbances without the necessity of returning the Gage for service: RESET and INITIALIZATION. These actions help overcome a lock-up condition or other erratic Gage behavior. They also help prevent costly service delays.
GAGE INITIALIZATION This is a destructive action. It not only restarts the internal software program, but it also erases all stored user settings or data and returns the Gage to a known out-of-the-box condition.
Gates A & B Each probe has a measuring range as shown in the chart on page 41. For example, the C probe can measure polymer coatings in the range of approximately 2 to 175 mils (50 to 4500 microns). However, there are times when it is not desired to inspect this full range of thickness. Gates are used to narrow the range of thickness that the Gage examines. Gate A sets the minimum thickness limit and Gate B the maximum.
Measurement Units The currently selected units of measurement are displayed in the top right corner of the LCD status bar. This can be changed from inch to metric or vice versa using the Admin q Microns Thou/mils menu item. The displayed reading(s) and all stored readings are converted. System Clock (available only on Gages with the Memory option) The Model 100 records the date and time as each measurement is stored. This information is downloaded along with the measurement information.
Communications – (memory option only) Model 100 “memory” Gages can communicate with other devices such as PC’s, serial printers and data collectors via either the built-in infra-red port or the RS232 connector using the supplied serial cable. Printing Stored measurements (from one “application” at a time) can be sent formatted to an infra-red or serial printer and can be captured on a computer using a COM program such as Windows HyperTerminal or MacTerminal.
Serial Communications Configuration Existing communication software can be used, providing it can capture data from a COM port. By selecting "PRINT ?" on the Gage MENU, your computer will accept the measurements in the printer format.
Measuring Notes Rough Substrates In smooth coating/substrate conditions where there is a distinct interface, the echo is clear and sharp. This results in a repeatable measurement with a sharp, narrow peak on the graphical display. When the substrate has a surface consisting of many peaks and valleys, numerous and varied echoes are received from the interface. In this occurrence, the Gage received the strongest echo from the peaks and measured the coating thickness as 25.7 mils.
Maintenance and Troubleshooting Battery Management The Model 100 obtains power from three potential sources: • two 1.5v ‘C’ size Alkaline-Manganese Dioxide batteries. If they run low, the Gage will save all user settings and readings, then power-down. • an optional AC adapter (pg.35) supplying 7.5 volts DC power. While in use, two alkaline batteries should remain in the Gage in case of a power interruption.
Troubleshooting Gage does not turn on The Gage powers up but fails to stay on The screen appears too light or too dark. Gage does not yield accurate or consistent results Batteries don’t last as long as they used to.
Service Before returning the Gage for service, attempt to clear the problem by… • installing new, “C” alkaline batteries (pg.37), and • performing a RESET (pg.30), and if still necessary • performing a Gage INITIALIZATION (pg.31) to restore factory settings and to return the Gage to an “out-of-the-box” condition.
When measuring surfaces much hotter or colder than ambient, lift the probe off the surface for several seconds between measurements and zero the probe periodically to assure the most accurate readings. NOTE: Discard the first measurement taken in a notably different temperature condition. Table 1: Physical Characteristics Dimension Measurement * Width 9 inches (23 cm) Height 8 inches (20 cm) Depth 1.5 inches (4 cm) Weight 2.2 lbs.
Table 4: Range and Resolution Matrix The measuring range for the Model 100 is determined by the sound velocity constant of the coating(s). Both the low and high limits of the Gage’s measuring range increase for materials with high velocity constants such as aluminum, and decrease for materials with low velocity constants such as rubber. Note: These ranges and resolutions are default acoustic properties. Optimization adjustments may alter the ranges and resolutions available.
Safety and Regulatory Information For your protection, this instrument has been tested to various national and international regulatory standards. This regulatory testing includes electrical/mechanical safety, radio interference, ergonomics, acoustics and hazardous materials.
100 Series Page 43
Appendix A - Making Your Own Check Standards Once you have calibrated your Gage you may wish to make some Check Standards for use at the work site. These Check Standards should be made of the particular material you are using on the job to best match the measurement conditions. The linearity and accuracy of the Gage are verified during calibration against a known thickness and coating material. Once the Gage is calibrated it can be adjusted to a new sound velocity constant without effecting its accuracy.
Preparing Your Standards 1. 2. 3. 4. 5. 6. 7. Measure a suitable substrate (uncoated ) with a calibrated micrometer (± 0.1 mil, ±2.54 microns or better). The substrate does not have to be the same material to which your coating will be applied. It should be smooth as possible to give a good clean reading. The sample substrate should also be at least four times the thickness of the coating being applied.
Appendix B - Sample HP IR or serial printout One batch containing 4 readings taken on a 2-layer coating system.
100 Series Page 47
Warranty The manufacturer fully warrants its products against defects in workmanship or materials for a period of one year from date of purchase. In the event that a Gage is found to be defective, return the product to your dealer and the defective product will be repaired or replaced at the manufacturers option. No responsibility is assumed for incidental or consequential damages. The warranty is voided if the Gage has been opened. Data subject to change without notice. 802 Proctor Avenue, P.O.
