OptiSense PaintChecker Mobile Bedienungsanleitung

PaintChecker Mobile

User Manual

EN Version 23.08

2 | PaintChecker Mobile

Table of Contents

1. Overview, Measuring Method and Models....................................................................................................................................4

1.1 How to use this manual ..............................................................................................................................................................4

1.2 Challenges for today's coating companies..........................................................................................................................4

1.3 The PaintChecker Mobile - Quick Reference ......................................................................................................................4

1.5 The photothermal coating thickness measurement ........................................................................................................5

1.6 The model range............................................................................................................................................................................6

1.7 PaintChecker Mobile Delivery Contents ...............................................................................................................................7

1.8 Accessories.......................................................................................................................................................................................7

2. Safety and Responsibility ......................................................................................................................................................................8

2.1 Warning symbols and other guidelines ................................................................................................................................8

2.2 Correct use .......................................................................................................................................................................................8

2.3 Safety markings..............................................................................................................................................................................8

2.4 Intended use....................................................................................................................................................................................9

2.5 Unintended use ..............................................................................................................................................................................9

2.6 Danger from optical radiation..................................................................................................................................................9

2.7 Dangers due to invisible light radiation from the sensor ........................................................................................... 10

2.8 Risks caused by electricity.......................................................................................................................................................11

2.9 Fire hazards................................................................................................................................................................................... 11

2.10 Hazards when handling Li-ion batteries ......................................................................................................................... 11

2.11 Residual hazards....................................................................................................................................................................... 11

2.12 Responsibility of the operator............................................................................................................................................. 11

2.13 Requirements for personnel ................................................................................................................................................ 12

3. Setup and first steps ............................................................................................................................................................................ 13

3.1 Charging the batteries.............................................................................................................................................................. 13

3.2 Insert batteries............................................................................................................................................................................. 13

3.3 Connecting sensor and controller........................................................................................................................................ 14

3.4 Switching the device on and off ........................................................................................................................................... 14

4. Operation ................................................................................................................................................................................................. 15

4.1 Display............................................................................................................................................................................................. 15

4.2 Keys.................................................................................................................................................................................................. 15

4.3 Menu navigation......................................................................................................................................................................... 16

4.4 Instrument Settings ................................................................................................................................................................... 16

4.5 PC connection and OS Manager .......................................................................................................................................... 18

5. Measuring with the PaintChecker Mobile ................................................................................................................................... 19

5.1 Performing a measurement .................................................................................................................................................... 19

5.2 Measurement with spacer cap and tripod........................................................................................................................19

5.3 Measuring with OS Manager .................................................................................................................................................20

5.4 Measurement batches .............................................................................................................................................................. 20

5.5 Create a new batch .................................................................................................................................................................... 20

5.6 Recording a batch ...................................................................................................................................................................... 21

5.7 Evaluating a batch ...................................................................................................................................................................... 21

5.8 Appending to a batch............................................................................................................................................................... 21

5.9 Deleting a batch.......................................................................................................................................................................... 22

5.10 Setting limits .............................................................................................................................................................................. 22

5.11 Changing the application...................................................................................................................................................... 22

5.12 LARES® – Safety redefined.................................................................................................................................................. 23

6. Applications............................................................................................................................................................................................. 24

6.1 Creating a new application ..................................................................................................................................................... 24

6.2 Applications for measuring uncured coatings ................................................................................................................26

PaintChecker Mobile | 3

6.3 Editing an application ............................................................................................................................................................... 26

6.4 Deleting an application ............................................................................................................................................................26

6.5 Editing applications with OS Manager...............................................................................................................................26

7. Maintenance, error messages and best practice ...................................................................................................................... 27

7.1 Transport and storage............................................................................................................................................................... 27

7.2 Cleaning and Care......................................................................................................................................................................27

7.3 Periodic Check ............................................................................................................................................................................. 27

7.4 Services........................................................................................................................................................................................... 27

7.5 Error messages ............................................................................................................................................................................ 28

7.6 Disposal .......................................................................................................................................................................................... 28

7.7 Customer service and service hotline................................................................................................................................. 28

7.8 FAQ – Frequently asked questions.......................................................................................................................................29

7.9 Material Matrix - Best Practice .............................................................................................................................................. 30

8. Technical Data......................................................................................................................................................................................... 31

4 | PaintChecker Mobile

1. Overview, Measuring Method and Models

1.1 How to use this manual

Thank you very much for purchasing the Paint-

Checker Mobile. The device is based on the outstand-

ing technology and high standards of OptiSense and

offers maximum precision mobile coating thickness

measurement.

This manual has been specially designed to guide

you step by step through the features and options of

your PaintChecker Mobile.

Please read the following section first!

• Before using your PaintChecker Mobile, read the

entire manual and all safety instructions to ensure

safe and proper operation

• The instructions in this manual refer to your

device at default settings

• The pictures and images used in this manual may

differ from the actual product

• The content of this user manual is subject to

change without notice. The latest version of this

manual can be found on the OptiSense website at

www.OptiSense.com

• The available functions may differ depending on

the particular device and software

• Keep this manual for future reference.

1.2 Challenges for today's coating companies

The challenges on coating companies are growing:

More individual products, smaller batch sizes and

more frequent colour changes. Added to this are the

growing documentation requirements and more and

more orders where the coating thickness is function-

ally relevant.

The PaintChecker mobile helps you to meet all these

requirements by checking coating thickness at an

early stage in the process – even before baking –

without contacting the part.

The mobile handheld device is particularly suitable

for random sample measurement as well as for coat-

ing inspection of large components or small batches.

1.3 The PaintChecker Mobile - Quick Reference

The OptiSense PaintChecker Mobile models support

accurate measurement of wet, powdery and solid

coatings on various substrates without contacting

the surface. The compact, lightweight, handheld

devices are designed for continuous, fatigue-free use

in the laboratory and on the production line.

The PaintChecker systems use the photothermal

measuring process to determine the thickness of

coatings on a wide variety of substrates.

As with other non-destructive coating thickness

measurement methods, e.g. ultrasonic, eddy current

or induction, photothermal coating thickness is not

measured directly, but calculated from measurement

signals. It is therefore important to consider the indi-

vidual thermal properties of coating material and

substrate.

The measurement is carried out without contact from

a distance of several centimetres. This means that wet

and sticky coatings can be measured just as easily as

soft and sensitive surfaces. A contamination of the

part or the carry-over of coating material is thereby

excluded in principle.

mentioned in this user manual are the property of

their respective owners. The use of brand names and

trademarks is for descriptive purposes only.

PaintChecker Mobile | 5

1.5 The photothermal coating thickness

measurement

1.5.1 Key technology for coating thickness checking

The photothermal coating thickness measurement is

a contactless measurement method for paints,

powder coatings and glazes on metallic and non-

metallic substrates. The different thermal properties

of coating and substrate are used to determine the

coating thickness.

The surface of the coating is warmed up by a few de-

grees with a short, intense light pulse and then cools

down again by dissipating the heat into deeper areas.

The thinner the coating, the faster the temperature

drops. The temperature curve over time is recorded

with a highly sensitive infrared sensor and converted

into coating thickness.

Fig. 1: The photothermal measuring method 1

1.5.2 Reproducible measurement results even with

most demanding coatings

Thick, heavy coatings need more energy to heat up

and cool down more slowly than thin, light coatings.

During the measuring process, it is therefore import-

ant, as in photography, that the strength of the light

source and the measuring time are optimally adjus-

ted to the respective situation, in order to obtain ac-

curate and reproducible measurement results.

In the case of powder coatings and paintwork, there

is also the fact that the user often does not want to

know the thickness of the powder or wet film that has

just been applied, but the later, final thickness after

baking or drying. For this purpose, the PaintChecker

Mobile takes the expected shrinkage of the coating

material during curing into account.

Thanks to the precise measuring spot, the method is

also suitable for the smallest components. The coat-

ing thickness can even be determined on bending

edges, corners and curved surfaces, where conven-

tional measurement technology reaches its limits.

Disturbances caused by rough surfaces or material

grains are compensated for by optical averaging, so

that even pastes and powders can be checked before

baking.

Fig. 2: The photothermal measuring method 2

6 | PaintChecker Mobile

1.6 The model range

OptiSense is the world's leading provider of photo-

thermal measuring systems for coating thicknesses

on a wide variety of substrates.

A common feature of all mobile handheld devices is

their ability to measure a still soft powder layer on

substrates such as metal, wood, glass or plastic, re-

gardless of colour and type. With a simple measure-

ment the very cost-intensive rework of under- or

overcoating can be avoided.

The sensor head is detached from the control unit

and connected with a flexible cable. The lightweight,

ergonomically designed sensor can be carried com-

fortably in a holster and guided precisely and effort-

lessly to the component without touching or dam-

aging the sensitive coating.

LED sensors feature a larger measuring spot making

them ideal for freehand measurements on rough sur-

faces.

1.6.1 PaintChecker Mobile Gun-B

Fig. 3: PaintChecker Mobile Gun-B

The mobile OptiSense Gun-B is designed for contact-

less testing of freshly applied powder coatings prior

to burn-in.

1.6.2 PaintChecker Mobile Gun-R

The Gun-R model is particularly suitable for compon-

ents made of plastic or rubber.

Fig. 4: PaintChecker Mobile Gun-R

1.6.3 PaintChecker Mobile Laser Pen

Fig. 5: PaintChecker Mobile Laser Pen

The OptiSense mobile laser models are mainly used

for smooth coatings on metallic substrates. With their

tiny measuring spot the slim laser sensors are partic-

ularly suitable for coating thickness testing on delic-

ate small parts, corners and edges. A special version

with an extra short working distance allows you to

measure in very confined spaces or on coatings con-

taining high amounts of metal.

All OptiSense mobile models are eye-safe thanks to

the patented LARES® technology.

PaintChecker Mobile | 7

1.7 PaintChecker Mobile Delivery Contents

Your new PaintChecker Mobile is delivered in a sturdy

carrying case. Included in the scope of delivery are:

Fig. 6: PaintChecker Mobile Delivery Contents

Please note:

• The items supplied with the device have been

designed for this unit and may not be compatible

with other products.

• Other accessories may not be compatible with

your device.

❶Sensor with connection cable

❷Gray glass reference

❸Controller

❹Charger

❺USB power supply

❻Two sets of 4 rechargeable batteries

❼Shoulder strap

❽USB data cable

❾USB drive with user manual, OS Manager

software, etc.

❾

❽❼

❻

❺

❹

❸

❷

❶

1.8 Accessories

The following accessories are available for all models:

• Spacer caps

• Tripod

• Cable 2.3 m

• Calibration certificate

Use only accessories approved by OptiSense. Using

non-approved accessories may cause malfunction of

the device.

8 | PaintChecker Mobile

2. Safety and Responsibility

2.1 Warning symbols and other guidelines

This section provides you with all relevant informa-

tion for proper personal protection and for safe as

well as efficient operation. Read these instructions

carefully before operating the device. Please observe

any additional company- or country-specific direct-

ives and regulations that may apply.

For your safety, it is important that you read and fully

understand the following list of warning symbols and

their definitions! Safety instructions are indicated by

symbols and signal words. The symbol provides in-

formation about the type of hazard while the signal

word indicate it’s extend.

DANGER!

Warning of an imminent threat

that would cause death or serious

injury

DANGER!

Warning of a serious threat from

laser radiation

DANGER!

Warning of a serious threat due to

fire hazard

DANGER!

Warning of a serious electrical

voltage hazard.

ATTENTION!

Attention to a less serious hazard

category. The symbol shows an

exclamation mark.

2.2 Correct use

The PaintChecker industrial photothermal measuring

system is used to determine the thickness of wet and

dry organic coatings for quality assurance and pro-

duction-related testing. Proper use includes ob-

serving all information contained in this manual. Any

use outside or beyond proper use is considered im-

proper use.

Danger in case of incorrect use

• The light beam of the sensor must never be

directed at easily flammable materials

• The sensor must never be used in explosive areas

• The sensor must never be used to illuminate, heat

or dry other object

• The sensor must never be used for medical

purposes

• The sensor must never be immersed in liquids

• The light beam of the sensor must never be

directed at people

• Incorrect measurement parameters may result in

damage to the object being measured

2.3 Safety markings

2.3.1 Safety labelling in the working area

The following symbols and signs are located in the

work area. They refer to the immediate environment

in which they are placed.

• All safety, warning and operating instructions

must be kept in a legible condition at all times

• Damaged signs or stickers must be replaced

immediately

TIPS

This symbol highlights hints

and recommendations as well as

information for efficient and

trouble free operation

DANGER! Incorrect use of the PaintChecker

Mobile can lead to dangerous

situations

PaintChecker Mobile | 9

2.3.2 Safety marking on the measuring system

Position Warning Label 1-4: Near the light source

(Sensor lens)

Position Warning Label 5-7: Back of the controller on

the battery compartment

2.4 Intended use

The PaintChecker Mobile from OptiSense is a port-

able hand-held device intended solely for measuring

the thickness of coatings.

The device is to be operated only by persons who

have read and understood this manual. Intended use

also means that the user reads and understands this

manual, in particular the safety section.

ATTENTION! Danger with illegible signage! Over

time, stickers and signs can become

dirty or otherwise unrecognisable, so

that hazards cannot be recognised

and necessary operating instructions

cannot be followed. This creates a risk

of injury

Warning Label 1 | General warning sign

Warning Label 2 | Laser Radiation & ESD

Warning Label 3 | IR radiation

Warning Label 4 | UV radiation

Warning Label 5 |

Class 1 Laser

Warning Label 6 |

Risk Group 3 UV

Warning Label 7 |

Risk Group 3 IR

Guidelines to avoid damage to the device:

• Do not expose the PaintChecker Mobile to

extreme temperatures. Keep it away from high

humidity or moisture

• Do not place the device in locations where it is

exposed to corrosive gases or salty air.

• Keep the PaintChecker in a locked cabinet and

give it only to people who have read and

understood the manual

• Do not use harsh cleaners, abrasives or solvents

to clean the device. Use only a clean, dry cloth

• Observe the technical specifications. To operate

the PaintChecker Mobile as intended, use only

accessories tested by OptiSense

By proper disposal of electrical equipment, you will

help to conserve valuable resources and avoid poten-

tial negative impacts on health and the environment,

which could otherwise be caused by inappropriate

waste disposal (see also Directive 2012/19/EU on

remanufacturing and recycling). Accessories and

packaging should also be recycled in an environ-

mentally friendly manner.

2.5 Unintended use

Any operation that does not comply with the tech-

nical specifications is considered unintended use. The

operator is solely liable for any damage caused by

unintended use. The following is prohibited

• Operating the device in environments where

liquids can enter the device

• Unauthorised alterations, additions or

modifications to the device

• Opening the device, except for changing the

batteries

• Removing safety marks, stickers, or labels. Keep

all safety marks, stickers and labels in a legible

condition

• OptiSense does not accept any liability for

damages resulting from unintended use. In this

case, warranty claims are void.

2.6 Danger from optical radiation

WARNING! The PaintChecker Mobile uses short,

intense light pulses (partly in the non-

visible range) for measurement.

Please observe the following safety

instructions:

10 | PaintChecker Mobile

• Do not point the sensor at easily flammable

material

• In order to completely exclude irradiation, a

distance cap can be used and contacting

measurements can be taken

• Do not put a damaged sensor into operation

• The device is not approved for operation in

potentially explosive atmospheres (ATEX)

2.7 Dangers due to invisible light radiation from

the sensor

The PaintChecker Gun-B emits UV radiation!

The description of the dangers of the radiation used

here depends on the equipment. The risk class ap-

plicable to the PaintChecker is indicated on the warn-

ing label of the controller. The limits for radiation

duration given here have been determined in part by

an expert in laser technology and are not generally

applicable to devices of this safety class.

Coherent radiation of laser class 1

Radiation in the IR-B spectrum. Radiation of this class

can be dangerous if an optical instrument (magnify-

ing glass, microscope, etc.) is in front of the eye.

Glasses do not constitute an optical instrument in this

case.

ATTENTION! The accident prevention regulations of

DGUV regulation 11 as well as the reg-

ulations of the occupational health

and safety ordinance on artificial op-

tical radiation (OStrV) must be ob-

served

Irradiation of the skin near the exit aperture on the

measuring head can cause burns in the focus. The

laser radiation itself is not visible

Incoherent IR radiation of risk group 3 (RG3)

Radiation in the IR-A range: There is a low risk here.

Damage to the retina can be largely ruled out. Even

when looking into the light source for a longer period

of time, no damage occurs. Irradiation of the skin in

the vicinity of the exit aperture on the measuring

head can cause damage to the skin in the focus. The

laser radiation itself is not visible.

Radiation in the UV-B range poses a risk with short

exposure within the safety distance. Protective meas-

ures are essential here. When an individual threshold

dose (minimum erythema dose) is exceeded, the so-

called sunburn (UV erythema) occurs. The maximum

permissible irradiation of the skin is 64 seconds per

day.

If the cornea is irradiated for more than 120 seconds

within 1,000 seconds with the PaintChecker Gun-B,

an impairment according to the criteria of the EN

62471:2008 standard is to be expected.

Source: Laser diode (Pen-1.6, Pen-3.5)

Mode of operation: pulsed

λ: 1480 nm

Emax: 750 mJ (laser 16 mm)

Emax: 750 mJ (laser 35 mm)

Source: LED (Gun-R)

Mode of operation: pulsed

λ: 950 nm +- 19 nm

Emax: 750 mJ

Source: LED (Gun-B)

Mode of operation: pulsed

λ: 365 nm +- 9 nm

Emax: 750 mJ

LARES A health hazard due to invisible light

radiation of class 1 is excluded when

used correctly (see 3.2.4 LARES®). The

radiation is accessible in this system, but

so weak that any damage can be

excluded. This is important because the

light radiation is in the non-visible

wavelength range

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