TQC POWDERSAVE II User manual

Brand: TQC

Model: POWDERSAVE II

Category: Measuring, testing & control

Type: User manual

User Manual February 01, 2007

Powder thickness measuring gauge

POWDERSAVE II

Version 1/2007

Page 2 of 26

Contents

NEWS No. 1 Control survey / Correction factor 18

NEWS No. 2 Menu and Superuser-Menu 20

NEWS No. 3 PsMan2 Software – short description 21

NEWS No. 4 Firmware Version 1.3.9 25

1. Instructions for operating the instrument POWDERSAVE II and handling the

accessories 3

1.1. Important notes 3

1.2. Instrument use 3

1.3. User requirements 3

1.4. Conditions for operating & storing POWDERSAVE II and accessories 3

1.5. Opening of the instrument POWDERSAVE II and accessories 4

1.6. Handling of the probe 4

1.7. Handling of the calibration part 5

1.8. Guarantee Waivers 5

2. Description of the instrument POWDERSAVE II and accessories 5

2.1. Application 5

2.2. Front and back views 6

2.3. Key functions of the instrument POWDERSAVE II 7

2.4. LCD-display 8

2.5. LED-display on the instrument POWDERSAVE II 8

2.6. Key functions on the probe 8

2.7. LED-display on the probe 9

3. To take readings 9

3.1. General 9

3.2. Measuring 9

4. Calibration 10

5. Rechargeable Battery 11

5.1. General 11

5.2. Discharge of the Battery 11

6. Charger 12

6.1. Description of the charger 12

6.2. Charging the battery 12

6.3. Safety precautions 12

7. Operation, Maintenance, Cleaning 13

8. Fault finding and messages 13

8.1. Malfunctions 13

8.2. Error-messages 14

9. Technical data and packing list 15

9.1. Technical data 15

9.2. Upon receipt of the goods 15

10. Tips and informations 16

11. Declaration of Conformity 16

Page 3 of 26

1. Instructions for operating the instrument POWDERSAVE II and handling the

accessories

1.1. Important notes

The instrument POWDERSAVE II must not be opened under any circumstances!

- there could be a risk of an electric shock!

Calibration should only start when the probe is on the calibration part. The

instrument will otherwise be in an uncalibrated state. This could lead to incorrect

measuring results or the instrument does not working correctly!

The contraction factor for the powder polymerisation is allowed for in the

software. The thickness displayed is the final coating thickness after

polymerisation.

Do not clean with solvents.

1.2. Instrument use

The POWDERSAVE II is designed for only measuring the thickness of powder

coatings on different metallic smooth surfaces before polymerizing.

The instrument POWDERSAVE II does not replace final checking after

polymerizing with a conventional measuring instrument.

Only accessories recommended by TQC (e.g. probes, cables) may be

attached to the instrument.

If the gauge shows signs of damage (e.g. caused by drops) or the cover is

deformed and the instrument no longer works. It has to be sent back to the

manufacturer!

1.3. User requirements

The gauges may only be operated by trained staff!

These operating instructions must be read through thoroughly in order to carry

out correct measurement of the coating thickness.

1.4. Conditions for operating and storing the instrument POWDERSAVE II and

accessories

The POWDERSAVE II corresponds to the EC Guidelines 89/336 EEC

“Electromagnetic Compatibility”. The measured thickness of coating values are

not affected by the maximum values for disturbances mentioned in the EN

50081-1 and EN 50082-2 standards (referring to the standards EN 55022, ENV

50140, IEC 1000-4-8, EN 61000-4-8, IEC 1000-4-2 and EN 61000-4-2).

It is well protected against strong electromagnetic fields (e.g. motors, high-

voltage cables, radio broadcasting masts).

Page 4 of 26

The instrument and its accessories are designed for operating at temperatures

between 5°C and 40°C. The storage temperature can be between 5°C and

60°C.

Temperatures which are above 60°C can easily be reached in sunshine behind

glass windows (e.g. in the car)! In order to avoid damage through high

temperature, it is advisable not to keep or store the instrument or accessories in

such places.

The instrument and accessories (particularly the plug power supply) should not

come into direct contact with fluids because of the risk of short circuits! The

instrument or accessories may only be operated, kept or stored in places where

the relative humidity is between 30% and 90% (not condensing).

Since the instrument and accessories are not acid proof, any direct contact with

acid or acidic liquids must be avoided!

The instrument and accessories are not suitable for operating in explosion

endangered surroundings!

1.5. Opening of the instrument POWDERSAVE II and accessories

Except for the battery, the POWDERSAVE II and its accessories do not contain

any components which need to be maintained by the user.

Attention: The instrument should not be opened under any circumstances there

is the risk of getting an electric shock!

1.6. Handling of the probe

The measuring probe has to be handled with care. It must not be dropped or

mechanically damaged in any way. To keep the wear on the probe as low as

possible, observe the following:

Do not place the probe on hot or acidic surfaces, do not immerse into fluids!

Store in dry surroundings!

Powder residues on the active sensor area must be avoided. (Responsible

handling and correct storage prolong the life of the probe mechanism).

Never blow out with a direct stream of compressed air!

Page 5 of 26

1.7. Handling of the calibration part

The good condition of the calibration standard is essential for correct

calibration and correct measurement.

To ensure the good condition of the calibration standard, the following has to

be taken into consideration:

The bottom of the cylinder of the calibration standard has to be clean and free

from grease.

The calibration standard has to be placed at right angles to the probe and up to

the stop.

1.8. Guarantee Waivers

TQC does not guarantee the following:

- The instrument or accessories when not used as per these instructions.

- Improper handling (such as in explosive areas or hot surroundings).

- Ignoring the references in these operating instructions.

- Mechanical damage to the instrument and sensor.

- Dirtying or sticking together of the active sensor surface by powder residues.

2. Description of the instrument POWDERSAVE II and accessories

2.1. Application

For the contactless measurement of the thickness of powder coatings on

aluminium, steel or metal surfaces with powders usual in the trade, applied by

Tribo or Corona in usual coating-conditions, before sintering.

Page 6 of 26

2.2. Front and back views

Illustration: View of the probe housing

Energy-Indicator

Distance-Indicator

Measuring-button

Display

Operating button

Bush for

Battery-charger-lead

Page 7 of 26

2.3. Key functions of the instrument POWDERSAVE II

The following pages contain an overview description of the functions of each

button:

Button Function

GO A) Switches the instrument POWDERSAVE II on

The button has to be pressed for at least 1 second

B) Activates measuring

HOME A) Back out of every menu to the main menu.

B) Press the Home button for approx. 2-3 sec. for switching off the

instrument.

Button for choosing a menu (forwards)

(each menu is shown on the display)

Button for choosing a menu (backwards)

(each menu is shown on the display)

st press: Start Calibration (Calibration)

The calibration is started using this menu item.

Attention: Calibration can only be commenced when the

calibration part is placed on the probe, otherwise the instrument will

remain in an uncalibrated state. This could lead to incorrect

measuring results or the instrument would no longer work correctly!

After placing the calibration part on the probe press GO.

nd press: Correction factor

By changing the correction factor, you can adjust your

POWDERSAVE II device to the different parameters and influences

(temperature etc...) of your powder coating environment. Those

influences can change the contraction factor of the powder.

Pres + or – button to changing the correction factor.

Page 8 of 26

rd press: Set Lower limit (Lower Boundary)

The current lower limit will be displayed. Through pressing the + or –

butten you can change the limit. The largest selectable value is

always smaller than the current upper limit. The lowest selectable

limit is 30 µ.

th press: Set Upper limit (Upper Boundary)

A red LED will show (second from the right in the upper row) if a

reading is greater than the set upper limit. A red light will show

(second from the left in the upper row) if the reading is lower than

the set lower limit. In all other cases, with the exception of a faulty

measurement, the value within these limits will be shown by means

of a green LED (middle LED in the upper row).

These limits can be adjusted with the menu items -u- and -L- .

The current upper limit will be displayed. If a new value needs to be

set, then this can be set with the + or - button. The selected value is

automatically stored. It does not need to be saved separately. The

smallest selectable limit is always greater than the current lower

limit. The greatest selectable limit is 110 µ.

Equipment switches after 60 seconds without use off.

2.4. LCD-display

The battery must be loaded as soon as possible if the energy bar of the battery

appears low at the right side of the display; otherwise correct measurements

may not be made.

2.5. LED-display on the instrument POWDERSAVE II

A small arrow at the right side of display indicates the distance from the sensor

to the measure object.

Please read section 3, Measuring, for a more precise description of the LED

display.

2.6. Key functions on the probe

The probe has a GO button, which has exactly the same function as the GO

button on the instrument.

Page 9 of 26

2.7. LED-display on the probe

The LED displays on the instrument are replicated on the probe with DISTANCE

on the left, ENERGY on the right.

3. To take readings

3.1. General

Over the different points of menu can be adjust/stopped average values,

upper and lower bounds as well as measurements or a calibration. With the

arrow key can be jumped to the next point of menu. As soon as the last point of

menu is reached, through pressing the HOME button or the - button the

equipment can be led to the first point of menu. Inside of a menu point the

menu can be changed by pressing the + or - keys. To show you in which point

of menu you are, the display is showing you the point of menu on the display

and the adjusted value. With the HOME key the menu can be left at each time.

3.2. Measuring

Pressing the GO button for a minimum of 1 second turns the instrument on. Hold

the probe about 18 mm away from the part to be measured and press short the

GO button on either the probe or the instrument to start the measuring process.

The right arrow on the display or the left row of LED on the probe indicates the

distance of the probe from the object. The optimal measuring distance is

reached and the measurements can be registered as soon as the green light

on the probe comes on (in the middle). The two probe red LED’s on the right will

light up if the distance to the object is too great, and the two red LED’s on the

left if too close.

The lower or left row on the of LED’s on the probe indicates the energy of the

echo. In order to obtain maximum energy, the sensor should be held at 90° to

the object. The optimal energy is reached when on the probe the red LED on

the extreme right flashes.

During the measuring process measuring signals are constantly being taken and

analysed. The instrument stores five of these echoes. When the energy of the

actual echo is larger than the energy of the weakest echo, then this is

replaced. Therefore, it is automatically optimised.

Attention: Optimum measurement will be reached, when the echoes are at their

greatest. During measurement, the distance and the angle should be varied

slightly to make all 5 LED’s on the energy indicator light frequently (or the arrow

on the right display side is in the middle of the distance bar). If the right hand

LED does not light, you have achieved the best measurement position.

Page 10 of 26

End the measurement process by pressing the GO button again.

The gauge now calculates the average of the best 5 readings (this takes

approx. 3 to 6 seconds). The instrument then displays the thickness of the

coating in µm or mils.

Attention: The contraction factor for the powder polymerisation is allowed for in

the software. The thickness displayed is the final coating thickness after

polymerisation!

The instrument switches off automatically after 60 seconds if no measurements

have been taken. Switch on again by pressing GO

The next measurement is started by pressing GO

4. Calibration

Air temperature, atmospheric humidity and the natural ageing of the electric

components are corrected for by the calibration procedure.

If you are not satisfied with the measurement results or the surrounding

conditions have changed, the instrument should be recalibrated.

A correct calibration part is essential if correct measurements are to be made.

To ensure the faultless state of the calibration standard, the following has to be

taken into consideration:

The bottom of the calibration part has to be clean and free from grease.

The calibration part must be placed on the probe straight and up to the stop,

with the opening against the probe for calibration. The probe and the

calibration part must be held vertically in the air, so that the calibration

standard sits correctly on the probe.

Now the 1st level must now be selected with the right arrow button (press one

time). Press the GO button.

During the whole calibrating process the probe must be held vertically, until the

process is finished.

If a measuring wasn't executed correctly and an error message (E21) is

announced after the calibration, the whole calibration sequence of operations

must be started again.

Page 11 of 26

5. Rechargeable Battery

An ACCUMULATOR, NiMh 2100 mAh, has been used in the POWDERSAVE II.

For charging the accumulator you do not have to remove the accumulator

from the device. To charge the accumulator, plug the battery-charger cable in

to the loading up hollow below at the device.

The full loaded accumulator stays approx. 8 - 72 h.

The loading time of the accumulator is approx. one hour.

5.1. General

Nickel Metal hydride Accumulator

Powdersave II is equipped with a metal hydride accumulator. NiMh Accu's

have a high energy and a high life span.

The Akku type, which is used in Powdersave II, is from a top manufacturer and

cut off in test with excellent results.

NiMh Accu's want to be "used", because only when regular loading and

unloading they keep their full efficiency.

If a NiMh Accu is not used for a long time, the own discharge leads to it, that

the Accu is empty after approx. 1-2 months. Not “using” of the Accu for a

longer time (Loading, Unloading) increases additionally internal resistance.

An Accu with increased internal resistance cannot be loaded fully any longer.

After longer storing (>2 months) thus the Accu capacity is no longer at the

disposal; the Accu became "sluggardly".

Such a "sluggardly" Accu can be regenerated again with 2 - 5 load/unloading

cycles.

All these characteristics are NiMh Accu specifically and have nothing to do with

the way the Akku is used in the Powdersave II.

Overloading is very harmful for the Accu. Load therefore the Accu only if it is

really necessary!

Users who use their equipment regularly (daily), will never be affected by

this negative NiMh Accu characteristics.

5.2. Discharge of the Battery

The firmware version 1.3.9 supports new a controlled unloading of the Accu.

The function “Discharge Batt“ is in the Super-User Mode (press “-“, “+“ and

“GO“ together) on the last page.

Change to this site and start the function through pressing the “GO“ button.

The Accu will be discharged and the equipment will switch off after

discharging.

Page 12 of 26

Afterwards you can not switch the equipment on because of the empty Accu.

Now charge the Powdersave II with the charger. After termination of the

loading procedure on the Accu meter (right above on the display) can be

read how much energy could to be invited. The Accu meter should

announcement fully, if this is not the case, then the Accu is defective, aged or

"sluggardly".

Important: After choosing the menu “Discharge Batt” leave the instrument till

itself switches off (do not press any button like HOME etc. !) !

6. Charger

6.1. Description of the charger

This charger is microprocessor-controlled and automatically recognises the type

of battery to be charged. The input voltage is either 230 Volts or 115 Volts +/-

10 % AC, 50 or 60 Hz (see label on the bottom of the charger). It has approval

for usage in a dry environment by relevant authorities.

6.2. Charging the battery

1. Make sure that your local mains voltage conforms with the details on the

label on the bottom of the charger before the first usage.

2. Connect the charger to the wall socket with the power cable included.

3. Now the red LED will be on permanently until the charging process is

completed. When the red LED is flashing the battery is full loaded.

4. Charge end: With reaching the full charge, the red LED is blinking. The

Battery has now its full capacity. If the equipment remains attached, tis

constantly supervises the charge of the Battery and undertakes

independently reloading for the compensation of the self discharge.

The load time of a completely empty Battery (capacity 2100 mAh) amounts

to approx. 1 hour, for a part discharge Battery accordingly less.

6.3. Safety precautions

• Do not open the charger (electrical hazard, loss of warranty)

• Keep the unit dry. Allow for warm-up before usage after storage in cold

environment (condensed humidity).

Illustration: Battery-charger

Page 13 of 26

7. Operation, Maintenance, Cleaning

The batteries are supplied uncharged. They have to be charged with the

battery-charger (supplied) before the instrument can be used.

Calibration should have to take place before operation.

It is always advisable to check before first using. No maintenance is necessary.

Regular cleaning is recommended.

The instrument case is made from aluminium and must not be cleaned with

abrasive substances. To prevent damage to the keyboard, the probe and

plastic parts, cleaning should only be done using soapy water or if very dirty

with light methylated spirit.

Attention: Do not use thinners!

8. Fault finding and messages

8.1. Malfunctions

Fault Possible Cause Procedure

No display Instrument is not

switched on

Switch on using GO

Battery is discharged Recharge Battery

Instrument switches itself

off straight away

Press GO button for longer

time

Distance display is not in

the green area

- while measuring Sensor is not vertical to

the surface

Hold sensor vertical

Distance is not correct Adhere to correct

distance (18 mm)

- while calibration Sensor in the sensor tube

moved

Equipment check by

specialist necessary

Inaccurate

measurements / different

results

Sensor does not receive

good echoes for a

reading

Read chapter 3

„Measuring“

Parts or powder are

measured, which cannot

be recognised by

POWDERSAVE II

Read chapter 1.2

„Instrument use“

Page 14 of 26

8.2. Error-messages

99ERR

During the measurement

an error was arising

Measure again

Repeated occurrence of

99 ERR

Calibrate

A coating under 30 μ was

attempted to be

measured

A coating over 110 μ was

attempted to be

measured

Page 15 of 26

9. Technical data and packing list

9.1. Technical data

Size of gauge L x W x H: 230 mm x 105 mm x 355 mm

Weight: 1186 gms (incl. battery and probe)

Housing: aluminium, dust-proof

Display: Graphic LCD, 128 x 64 points with

background lighting

Power supply: Rechargeable battery

(NIMH 2100 mAh)

Energy requirements: max. 4 W

Processing performance: 180 megaflops (a million floating points /

second)

Measuring speed: 16 pulses / second

Computing time per measuring point: 3 – 6 seconds

Interface: RS 232

Transducer: air ultrasound, piezoceramic

Measuring distance to object: approx. 18 mm

Measuring spot diameter: approx. 1 mm (1/32")

Measurement range: 30 µm - 110 µm (1.2 mils – 4.3 mils)

Measuring uncertainty: +/- 5 µm (0.2 mils)

Measurable layers: Powder layers on all smooth metallic

surfaces

9.2. Upon receipt of the goods

All packing material and contents should be checked for possible damage upon

receipt. If the packing material, instrument or accessories are found to be

damaged, the packing material should be kept in case a compensation claim is

made against the forwarding agents.

It is also recommended to keep the packing material in case it is needed to

return the instrument at a later date.

Check that all items on the packing list below are included. If not please

contact TQC immediately.

Page 16 of 26

9.3 Packing list

The following items should be received in the shipment:

• POWDERSAVE II with integrated rechargeable battery

• 1 carrying strap

• Probe and cable

• Calibrating probe

• Battery charger with power cable

• Operating instructions (behind the foam material in the top of the case

• Carrying case

10. Tips and informations

Have a look on our homepage

www.tqc.eu

11. Declaration of Conformity

Ramseier Technologies

Aktiengesellschaft

Flughafenstrasse 45

CH-2540 Grenchen / Switzerland

Declares, that the Powder thickness measuring instrument POWDERSAVE II

complies with the following standards:

- EN 50081-1

- EN 50082-2

Grenchen, November 2, 2005

Ramseier Technologies AG

Jürg Moser

CEO

Page 17 of 26

POWDERSAVE II No.: 1

Control survey/ Correction factor

Initial Position

Due to different parameters and environmental influences (temperature etc.) in different

coating plants, a systematic shift of the measured value can occur with the measuring

instrument POWDERSAVE II. This can be customized by means of the measurement and

correction described in the following chapter.

Setting the correction factor

a) on the POWDERSAVE II device

1. Change into the 2. menu (capture 2.3). First switch equipment on and press the

right arrow button.

2. Keep pressing the + or - key to change the correction factor.

Performing check measurements

In order to adapt the equipment to the specific plant of the customer, best results

are accomplished with check measurements between 40µ and 80µ. Proceed as

follows:

• Switch the equipment on

• press two times the arrow key to the right

• note the indicated value [old correction factor * 1%]

• switch the equipment off (press for about 2-3 sec. the HOME button)

• switch the equipment on

• calibrate the equipment

• accomplish approx. 10 measurements on coated plates and note the results (the

places where the individual measurements were made have to be found again

later)

• burn in the coated plates

• use an eddy current device and control the places which were measured with

POWDERSAVE II, (take several measurements per place, then form the average

value)

• enlist all results in the chart stated below

• delete all measurements which are over 80µ or under 40µ from the chart

• delete all measurements, in which the POWDERSAVE II value deviates strongly from

the eddy current value, from the chart

• add the remaining values of the last column and calculate an average

• enter the new correction value

The equipment is now adapted to your coating technology and environmental

influences.

We wish you a lot of fun with the application of POWDERSAVE II.

Page 18 of 26

Appliance: data chart

Layer thickness range : 50µ 70µ 90µ

Measuring point Eddy current POWDERSAVE II Eddy current /

POWDERSAVE II

sum:

average:

Old correction factor * average = new correction factor d1

___________________ * ____________ = _______________________

Page 19 of 26

POWDERSAVE II No.: 2

Menu and Superuser-Menu

Important note:

To be able to work with several parameter sets you need our PC software 'PsMan2'.

The menu items in the menu and superuser menu concern general equipment

settings and settings which only find application if you are working with parameter -

sets.

If you are working with several parameter - sets it will be necessary for you to enter

both the regular menu and the superuser menu.

The data and the settings which are dependent on a certain parameter-set can only

be entered if you access the menu or superuser menu from the desired parameter

set!

Getting into the menu

Press by a switched off equipment together the buttons “-”, “+” and “GO” at the same

time.

Leaving menu and superuser-menu.

Equipment is switching itself off after 60 sec without use or press the button HOME for

approx. 2-3 seconds. By switching the gage on, you will find yourself automatically in

the normal working level.

Page 20 of 26

POWDERSAVE II No.: 3

With the PsMan2-Software and programming cable

PsMan2 Software – short description

The PC software offers you the simple possibility of the customization of basic

parameters as well as independently carrying out of controls and equipment tests.

Moreover, you are given access to your readings which you can further process in

other programs.

Because of the extended performance range the setting possibilities also have been

expanded correspondingly.

You can directly carry out all settings on the POWDERSAVE II or very simply with the

PsMan2.

The following main emphases are in the software integrated (PsMan2 K)

Settings

You can carry out all necessary settings and controls simply at the PC.

Page is loading ...

TQC POWDERSAVE II User manual

Brand: TQC

Model: POWDERSAVE II

Category: Measuring, testing & control

Type: User manual

Download PDF

report

TQC POWDERSAVE II User manual

TQC POWDERSAVE II User manual

Other documents