Extech Instruments CG204 Manual de usuario

User's Guide

Extech CG204

Coating Thickness Tester

www.burntec.com

CG204-EU-EN V2.1 3/11

Introduction

Congratulations on your purchase of the Extech CG204 Coating Thickness Tester. The

CG204 is a portable meter designed for non-invasive coating thickness measurements.

The meter uses two measurement methods: magnetic induction (for ferrous metal

substrates) and eddy current (for non-ferrous metal substrates).

The meter is easily configured using the intuitive push-button programming menu. Five (5)

film reference samples and two (2) metal substrates are provided. The meter is also

equipped with a USB PC interface port and PC software.

Proper use and care of this meter will provide many years of reliable service.

Description

Meter Description

1. USB jack for PC interface

2. Measurement probe

3. Backlit LCD display

4. SET /OK /YES /MENU /SELECT button

5. UP /LEFT ARROW button

6. Power ON/OFF button

7. CANCEL /ESC /NO /BACK button (menu mode)

and Backlight ON/OFF (normal mode)

8. DOWN ARROW /RIGHT button

9. ZERO calibration button

Note: Battery compartment on rear of meter

Display Icon Description

NFe Non-ferrous metals

Fe Ferrous metals

AUTO Automatic substrate recognition

F or N Calibration icons

DIR DIRECT mode

GRO1…4 GROUP Mode

μm Micrometers unit of measure

mils mils = millimeters * 2.54/100

mm Millimeters unit of measure

AVG Average reading

MIN Minimum reading

MAX Maximum reading

SDEV Standard Deviation reading

NO Number of data points

Low battery

USB Connection

Note: The unit of measure icon flashes when in the CONTINUOUS mode of operation.

The unit of measure icon is stable when in the SINGLE mode of operation.

[AUT

[NO ALRRM]

cal n o(1 or 2) zero n o(yes)

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CG204-EU-EN V2.1 3/11

Quick Start Instructions

Meter Power

Press the power button to switch the meter ON. The display will switch ON. If the

display does not switch ON, replace the batteries.

Measurements

Use the supplied film references and zero reference metal substrates to learn how the

meter operates before moving to a professional application. The round metal substrate is

the ferrous (magnetic) substrate and the rectangular shaped metal substrate is the non-

ferrous (non-magnetic) substrate. The meter automatically senses ferrous or non-ferrous

substrates.

1. Place a reference film (250μm, for example) on the round, ferrous substrate.

2. Place the spring-loaded meter sensor against the reference film.

3. In the single mode the meter will emit an audible tone indicating that the

measurement has been taken.

4. In the continuous mode the display will continually measure and update the display

5. The LCD will show the reading (250μm) at the center of the display area.

6. A typical display will also show the following:

•NO = 1 (reading number one) on the lower left of

the LCD

•AVG = 250μm (running average) on the lower right

•DIR = DIR mode of operation on the upper left

•Fe = Ferrous substrate on the upper right of the

LCD

Experiment with the remaining reference films and the substrate before using the meter

professionally.

Automatic Power OFF

In order to conserve battery life, the meter will automatically turn off after approximately 3

minutes. To defeat this feature use the programming menu detailed in the next section

(menu parameter AUTO POWER OFF under OPTIONS).

LCD Backlight Button

The LCD is equipped with backlighting for easier viewing, especially in dimly lit areas.

Press the backlight button to turn the backlight on. Press again to turn the backlight off. To

enable/disable the LCD backlighting, use the BACKLIGHT parameter under OPTIONS in

the programming menu.

Factory Default Reset

To restore the meter to its original factory default settings:

1. Turn the meter OFF.

2. Press and hold the ZERO button while switching the meter ON.

3. When the meter powers up, the display will prompt for a YES or NO.

4. Press the SET button for YES or the CANCEL button for NO.

5. Note that all data in all memory locations will be erased, in addition to statistics,

calibration values, and alarm limits.

DIR

AVG=250

NO=1

250

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CG204-EU-EN V2.1 3/11

Programming Menu

The meter can be configured and calibrated through simple button presses in the

programming menu. Press the MENU button to access the menu and refer to the menu

‘tree’ below. The menu uses UP/DOWN, SELECT, BACK, & ESC presses for navigation

and selection. In the table below the factory default settings are in bold with an asterisk.

Each parameter is explained in detail in the subsequent sections.

Top level Sub level 1 Sub level 2 Notes

AVG* Average of a series of readings

MIN Lowest of a series of readings

MAX Highest of a series of readings

NO Number of sampled readings

STATISTICAL VIEW

SDEV Standard deviation of a series

Single* One reading at a time

Measure mode Continuous Continuous measurements

Direct* Readings are not stored in groups

Working mode Group 1…4 Store readings in groups

Auto* Meter automatically selects mode

Fe Ferrous measurement mode

Probe used

No Fe Non-ferrous measurement mode

μm* Micrometers

mils Mils = mm * 2.54 / 100

Unit settings

mm Millimeters

ON* Enables backlight operation

Backlight OFF Disables backlight operation

AVG* Average of a series of readings

MAX Lowest of a series of readings

MIN Highest of a series of readings

LCD Statistics

SDEV Standard deviation of a series

Enable* Allows auto power off to operate

OPTIONS

Auto Power OFF Disable Defeats the auto power off feature

High Limit High Alarm alerts user when reached

Limit settings Low Limit Low Alarm alerts user when reached

LIMIT

Delete Limits Clear the alarm limit values

Current Data Delete current data

All Data Delete all stored data

DELETE

Group Data Delete data stored data plus alarm

and calibration data

MEASUREMENT

VIEW View stored data in all groups

Enable Allow calibration access

Disable Lock out the calibration mode

Delete Zero N Clear the zero cal. data (non-ferrous)

CALIBRATION

Delete Zero F Clear the zero cal. data (ferrous)

NOTE: Disable the Auto Power OFF feature before lengthy programming to avoid

inconvenient automatic power down while programming.

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CG204-EU-EN V2.1 3/11

STATISTICAL VIEWS Menu

1. Press the MENU button to access the programming menu

2. Press SELECT to choose STATISTCAL VIEW

3. Use the UP and DOWN buttons to scroll through the AVERAGE, MINIMUM,

MAXIMUM, NUMBER OF DATA, and SDEV (Standard Deviation) values for the stored

readings.

4. ‘NO DATA’ will display if no readings are available for the meter to analyze. Stored

readings will clear when the meter powers down unless the GROUP feature is used

(refer to GROUP function explanation later in this section).

5. Press the BACK and then the ESC soft-keys to return to the normal operating mode.

OPTIONS Menu

1. Press the MENU button to access the programming menu

2. Use the DOWN ARROW button to scroll down to OPTIONS

3. Press SELECT to choose OPTIONS

4. Use the UP and DOWN buttons to scroll to the MEASURE MODE, WORKING MODE,

PROBE USED, UNIT SETTINGS, BACKLIGHT, LCD STATISTICS, AND AUTO

POWER OFF parameters. Use the SELECT soft-key to select the desired parameter.

Each parameter is detailed below:

a. Measure Modes

Select CONTINUOUS or SINGLE under MEASURE MODES in the OPTIONS Menu

using the arrow buttons and the SELECT soft-key.

In the CONTINUOUS measurement mode the meter displays a running average of

readings as they are taken. Note that the audible measurement ‘beep’ is not active in

this mode.

In the SINGLE measurement mode measurements are taken one at a time. Single

mode measurement readings are accompanied by an audible tone.

b. Working Modes

Select DIRECT or GROUP 1, 2, 3, or 4 under WORKING MODES in the OPTIONS

Menu using the arrow buttons and the SELECT soft-key.

In DIRECT mode, individual readings are logged to memory. When power is switched

off or if the meter is switched to GROUP mode, all DIRECT readings will be cleared.

However, the statistical analysis data will remain. The statistical analysis utility can

evaluate up to 80 readings. When the memory is filled, new readings will replace old

readings. Lastly, this mode has its own calibration and alarm limit values.

In GROUP mode each group memory can store a maximum of 80 readings and 5

statistical values. Calibration and alarm limit values can be individually set and stored

for each group. When the memory is filled, measurements will continue to be taken but

readings will no longer log (previously logged readings are not affected); in addition,

statistical data will no longer update. If desired, the group data, statistical values,

calibration data, and alarm limit values can be deleted using the programming menu.

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CG204-EU-EN V2.1 3/11

c. Probe Used

Select AUTO, Fe, or No Fe under PROBE USED in the OPTIONS Menu using the

arrow buttons and the SELECT soft-key.

In the AUTO mode, the meter automatically activates the probe measurement method

(ferrous or non-ferrous) based on the metal substrate that is being measured. When

the probe is placed on a magnetic substrate it will work in the magnetic induction

mode. If the probe is placed on a non-ferrous metal it will work in the eddy current

mode.

In the Ferrous (Fe) Mode the Magnetic induction measurement mode is activated.

In the Non-Ferrous (No Fe) Mode the eddy current measurement mode is activated.

d. Units of measure selections

Select mm, μm, or mils under UNIT SETTING in the OPTIONS Menu using the arrow

buttons and the SELECT soft-key (mm = millimeters; μm = micrometers; mils =

mm*2.54/100)

e. Backlight

Select ON or OFF under BACKLIGHT in the OPTIONS Menu using the arrow buttons

and the SELECT soft-key. If OFF is selected the LCD backlighting will be completely

disabled. If ON is selected, the user can turn the light on or off using the backlight

button (CANCEL button).

f. LCD Statistics

Select AVERAGE, MINIMUM, MAXIMUM, or SDEV (Standard Deviation) under LCD

STATISTICS in the OPTIONS Menu using the arrow buttons and the SELECT soft-

key. This selection determines which statistic is shown as default on the LCD display.

g. Auto Power OFF

Select ENABLE or DISABLE under AUTO POWER OFF in the OPTIONS Menu using

the arrow buttons and the SELECT soft-key. When enabled, the meter automatically

switches OFF after 3 minutes of inactivity. When disabled, the meter will only switch

OFF with a button press or when the battery power is weak.

LIMIT Menu

High and Low Alarm Limits cab be set When an Alarm Limit is reached the meter displays

an Alarm Alert icon (Hfor High Alarm and L for Low Alarm).

1. Press the MENU button to access the programming menu

2. User the DOWN ARROW button to scroll down to LIMIT and press SELECT

3. Press SELECT again to choose LIMIT SETTING

4. Press SELECT again to choose HIGH LIMIT

5. User the ARROW BUTTONS to set a High Alarm value

6. Press OK to store the limit and press BACK to return to the menu

7. Perform the same steps for the LOW LIMIT

8. Use the DELETE LIMIT parameter to clear Alarm Limit values

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CG204-EU-EN V2.1 3/11

DELETE Menu

The DELETE menus allows for deleting current data, all data, and group data. The

following parameters are available in the DELETE Menu:

Delete Current data: Deletes the current reading and updates the statistics (AVG, MIN,

MAX, etc.)

Delete All data: Delete all reading and statistical data.

Delete Group data: This function duplicates the “Delete all data” function with additional,

deletions of High alarm, Low alarm, and one- and two-point calibrations.

1. Press the MENU button to access the programming menu.

2. User the DOWN ARROW button to scroll down to DELETE.

3. Press SELECT to open the DELETE function.

4. User the ARROW keys to scroll to CURRENT, ALL, or GROUP.

5. Press SELECT again to choose CURRENT, ALL, or GROUP.

6. The meter will prompt with an ‘are you sure?” confirmation.

7. Press YES or NO as desired.

MEASUREMENT VIEW Menu

The Measurement View menu allows for scrolling through the readings in all of the

groups.

1. Press the MENU button to access the programming menu.

2. User the DOWN ARROW button to scroll down to MEASUREMENT VIEW.

3. Press SELECT to open the MEASUREMENT VIEW parameter.

4. User the ARROW buttons to scroll through the stored readings.

CALIBRATION Menu

The Calibration menu allows the user to enable/disable the calibration utility. The

Calibration menu also allows the user to delete Zero calibration data for both ferrous (Zero

F) and non-ferrous (Zero N) modes.

1. Press the MENU button to access the programming menu.

2. User the DOWN ARROW button to scroll down to CALIBRATION.

3. Press SELECT to open the CALIBRATION parameter.

4. User the ARROW to scroll through the available parameters detailed below.

•ENABLE: Enable the calibration mode

•DISABLE: Disable the calibration mode.

•DELETE ZERO N: Delete ZERO calibration data for non-ferrous probe

•DELETE ZERO F Delete ZERO calibration data for ferrous probe

Measurement Considerations

1. After calibration, measurements should meet the published accuracy specifications.

2. Strong magnetic fields can affect the readings.

3. When using the statistical analysis functions for obtaining a mean value, take several

readings of the same measurement area. False readings or outliers can then be

removed (deleted) using the programming menu.

4. The final reading is derived from a statistical calculation with regard to the meter’s

published accuracy specifications.

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CG204-EU-EN V2.1 3/11

Calibration

Calibration Types

The meter is factory calibrated before shipment to the customer; however the customer

should perform a zero calibration and a multi-point calibration before any critical

measurements are taken. The calibration options are listed below. Read the description

for each and select the best match for a given application.

1. Zero Point Calibration: Perform before each measurement session.

2. One Point Calibration: Use for high accuracy with repeated tests on a constant

coating thickness.

3. Multi-Point Calibration: Use for high accuracy within a known range of coating

thickness.

4. Calibration for shot-blasted surfaces.

Calibration Considerations

The calibration sample must correspond to the product sample in the following ways:

•Curvature radius

•Substrate material properties

•Substrate thickness

•Size of measurement area

•The point at which the calibration is made on the calibration sample must always

be identical with the point of measurement on the product itself, especially in the

case of corners and edges of small parts.

To achieve the highest measurement accuracy, perform several calibrations in succession

(for zero values and calibration film values).

Preparing for calibration

1. Clean the probe tip (grease, oil, metal scrap, and the slightest impurity will affect

measurement and distort readings).

2. Switch the meter ON (at a 4” [10cm] minimum distance from any metal).

3. Ready the supplied metal substrate samples and necessary films (supplied

calibration reference films).

4. Set the meter to:

a. DIR: (MENU-OPTIONS-Working Mode-Direct)

b. CONTINUOUS: (MENU-OPTIONS-Measure Mode-Continuous mode [flashing

units indicator] )

c. MAX: (MENU-OPTIONS-LCD Statistic-Maximum).

5. The meter is now ready for calibration.

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CG204-EU-EN V2.1 3/11

Zero calibration

1. Place the meter on an uncoated section of the material to be

measured or on the reference substrate provided. Use either

the Ferrous or Non-Ferrous reference as required by the

measurement application.

a. Place the probe on the uncoated substrate and watch the

LCD readings.

b. When the readings appear stable, lift the meter off the

substrate

c. Press and Hold the Zero button for 2 seconds (beep). The Zero calibration is now

complete.

2. The meter is now ready for measurements

Calibration

The meter’s accuracy can be enhanced by performing a calibration using the reference

films supplied.

1. Perform a zero calibration as stated above

2. Perform a range calibration using a reference film.

a. Place one of the reference films on the substrate.

b. Place the meter on the calibration reference film

and watch the LCD readings.

c. When the readings appear stable, lift the meter off

the substrate

d. Press “MENU” and then scroll down “▼” to

“Calibration”.

e. Press “Select” to highlight the “Enable” function

and then press “Select”.

f. Press “Esc” and the meter will enter the calibration

mode.

g. Adjust the reading to match the known value of the reference film using the ▲

and ▼buttons.

h. Turn the meter OFF to exit and save the calibration data

3. The meter is now calibrated to the base material and thickness used.

4. Perform Step 2 as needed using the other reference films.

Notes:

1. Calibration data is stored into memory, it is not erased when the meter is turned

OFF.

2. Frequently wipe the sensor contact with a clean lint free cloth to remove any

particles on the sensor tip.

3. During calibration the ▲and ▼buttons adjust the internal calibration factors with

high resolution. The display resolution may be such that it may take up to 10

presses to see a 1 digit change on the display.

Multi-point Calibration

This method requires performing two or more sequential single point calibrations. For

best results, the expected coating thickness measurements should be within the

calibration points.

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CG204-EU-EN V2.1 3/11

Calibrating for Shot-blasted surfaces

The physical nature of shot-blasted surfaces results in higher than normal coating

thickness readings. The mean thickness over the peaks can be determined as follows:

1. The meter should be calibrated according to the calibration instructions. Use a smooth

calibration sample with the same curvature radius and the same substrate as the

device to be tested.

2. Take approx. 10 readings on the uncoated, shot-blasted sample to produce the mean

value Xo.

3. Take an additional 10 readings on the coated, shot blasted test sample to produce the

mean value Xm

4. The difference between the two mean values is the mean coating thickness Xeff over

the peaks. The greater standard deviation ‘S’ of the two values Xm and Xo should also

be taken into consideration: Xeff = (Xm - Xo) ±S

NOTE: For coatings thicker than 300 μm, the influence of roughness generally is of no

importance and therefore it is not necessary to apply the above calibration methods.

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