ABQINDUSTRIAL DC-8000 Coating Thickness Gauge Instruction Manual

ABQINDUSTRIAL DC-8000 Coating Thickness Gauge

Product Information

Specifications

• Product Name: DC-8000 Coating Thickness Gauge
• Manufacturer: ABQ Industrial LP
• Model: Three available models – DCF-8000, DCN-8000, DCFN-8000
• Display: Large backlit graphics display (128 x 64 dots)
• Probe: Spring-mounted probe system with a hemispherical tip

Product Usage Instructions

Theory and Type Introduction
There are three models available: DCF-8000, DCN-8000, DCFN-8000.

Measuring System

• Gauge
  The gauge features a large backlit graphics display for easy reading of readings and statistical values. It is housed in sturdy, scratch-resistant plastics.

• Operating Keys
  To operate the gauge, use the ON/OFF button to switch it on or off, Function key CAL for calibration, Function key MENU for menu access, Function key STATS for statistics and Function key CLR to delete the current value.

• Power Supply
  The gauge operates on a specific power supply (details not mentioned).

• Probe
  The probe system is spring-mounted for safe and stable positioning. The probe sleeve has a V-groove for reliable contact even on small cylindrical parts. Hold the probe by the spring-mounted sleeve with a hard and durable hemispherical tip.

User Interface

• Switch-ON and Start Screen
  Upon switching on, you will see the start screen.

• Measure Mode Screen
  This screen displays measurement readings.

• Menus
  You can access various features through the main menu structure.

FAQ

• Q: How do I calibrate the gauge?
  A: Press the Function key CAL to start the calibration procedure.

• Q: How do I delete a measured value?
  A: Press the Function key CLR to delete the current measured value.

Theory and type introduction

Three models are available:

• DCF-8000
• DCN-8000
• DCFN-8000

Designed for non-destructive coating thickness measurement. The portable gauges are suitable for non-destructive, quick, and precise coating thickness measurements. Easy to handle they are the ideal tool for the finishing industry, electroplating, ship and bridge building, aircraft construction, and the engineering and chemical industry. According to the sensor, they work on the magnetic induction principle or the eddy currents principle. According to probe type, the gauges are suitable for measuring the following substrate/coating combinations: The F sensors work on the magnetic-induction principle and are suitable for measuring non-magnetic coatings such as paint, enamel, rubber, aluminum, chrome, copper, tin, etc. on ferrous bases and steel (also on alloyed steel or hardened magnetic steel, but not on austenitic steel or weak magnetic steel).

The N sensors work on the eddy currents principle and are suitable to measure insulating coatings such as paint, anodizing, ceramics, etc on all kinds of non-ferrous metals such as aluminum, copper, zinc diecasting, brass, etc. as well as on austenitic steel. The FN sensors work on both, the magnetic induction principle as well as on the eddy currents principle. These sensors can be used for measurement on steel as well as on non-ferrous metal substrates. All models of the DC-8000 series are equipped with a USB port to enable data communication to a PC.

Measuring System

Gauge

General

• Graphics display Large backlit graphics display for convenient 128 x 64 dots reading of readings and statistical values.
• The gauge is equipped with a sturdy, scratch-acquisition of readings and resistant plastic housing.

Operating keys

• Press the ON/OFF button to switch the gauge ON or OFF.
• Press the Function key CAL to start the calibration procedure.
• Press the Function key MENU to call.
• Press the Function key STATS to call the statistics menu.
• Press the Function key CLR to delete the current measured value.

The command and navigation key block has the following functions:

• Press OK to confirm settings or select menu items.
• Press ESC to abort actions, quit submenus, or navigate through a batch.
• Use the ARROW up/down keys to navigate through a menu or to change settings.
• Press the up arrow when measuring, and the backlight will be turned on/off.

Power Supply
All models DC-8000 are powered by a set of two alkaline-manganese cells,1.5V, AA LR6 size (batteries are included in the standard supply schedule).

• Used or defective batteries or rechargeable batteries may contain hazardous substances and must be disposed of according to the legal provisions of your country.

Probe

• All probe systems are spring-mounted in the probe sleeve. This ensures safe and stable positioning of the probe and constant contact pressure. A V-groove in the sleeve of the probe facilitates reliability even on small cylindrical parts.
• The probe should be held by the spring-mounted sleeve. The hemispherical tip is made of hard and durable material.

User Interface

Switch-ON and Start screen

• At the switch-on, the start screen appears showing the gauge model and sensor version being connected.
• Approximately 2 seconds after switch-on, the gauges switch to the measuring mode of the last activated batch.
• If an FN sensor is connected and no readings have been taken so far, you can choose the measuring principle via the keyboard.
• Press the arrow up key for Ferrous (F) (magnetic induction method).
• Press the arrow down key for non-ferrous (N) substrates (eddy currents method).
• If you press OK, the Auto F/N mode (with automatic substrate identification) will be activated.
• If you make no selection at all, the Auto F/N mode will be adjusted automatically after approximately 5 seconds. In the Auto F/N mode, the gauge automatically identifies the substrate material to adjust to a suitable measuring principle (magnetic induction or eddy currents).

Measure Mode Screen

Menus
The numerous features can be accessed via the hierarchic structure of the main menu. The main menu is subdivided into three submenus: “CAL” (calibration menu), “Menu” (main menu), and “STATS” (statistics menu). These menus can be accessed via the CAL, Menu, and STATS keys. Press the Function key Menu to access the main menu.

• Use arrow keys to select an item from the menu, e.g. “Database “. Press OK to confirm your selection.
• A submenu will open or a function will be called.
• To go back to the previous menu level press ESC.

The parameters and data grouped as grouped under the various menus and submenus may be divided into three categories:

• predefined parameters that may be selected from a list
• numerical parameters that may be adjusted within predefined limits
• fixed parameters that may only be viewed but not changed

Measuring

Necessary Settings
Before taking readings, it is necessary to make a few settings in the “Database” menu and the “Batch” submenu.

Batch
With the DC-8000 series, readings are grouped into batches. A reading that has been taken will be listed and stored in the currently active batch. After a switch-off, the gauge will call the last used batch so that you can conveniently continue to take readings in the last used batch.

You can choose from the following batch actions：

• Continue to take readings in the active batch
• Create a new batch in the database
• Select an existing batch from the database

Preparing Measurement

Calibration
Measuring accuracy depends on the selected calibration method. Please refer to section 5.2 for more details on this issue.

The following calibration methods are available:

• Factory calibration
• One-point calibration (Zero calibration)
• Two-point calibration

Taking readings

Taking readings without using the sensor stand

• All sensor systems are spring-mounted to ensure a safe contact pressure on the measuring object without tilting. The V-groove of the sensor ensures the correct positioning of the sensor on cylindrical objects.
• To take readings, As soon as the sensor has been placed onto the object, a reading will be displayed the reading will be stored in the active batch. Lift the sensor briefly and take the next reading.
• When taking readings, the measuring screen shows the current statistics of the active batch in a separate window.

High-precision stand
For taking readings on small objects and small geometries, it is recommended to use the external sensor in connection with the high-precision stand.

Calibration

General remarks
The DC-8000 series offers several calibration methods to meet the individual requirements of various applications, procedures, and industrial standards. If a batch is being created you can select a suitable calibration method for this batch. The calibration can be carried out immediately after you have created a batch or at a later time in the measuring mode. To call up the calibration function in measure mode, press function key CAL A calibration is made in the currently active batch and is directly related to this batch.

To ensure an optimum calibration, the following points should be observed:

• Correct calibration is vital for accurate measurement. For calibration, a sample similar to the later object to be measured should be used, i.e. both, the calibration sample and the object to be measured should be of the same shape and geometry. As a rule, you can say that the more similar the calibration sample and the later object to be measured are, the more accurate the calibration and thus accuracy of readings will be.
• Make sure the calibration sample and the later object to be measured have the same characteristics such as
  • identical curvature radius of the surface
  • identical substrate materials (such as magnetic permeability, and electrical conductivity; in the ideal case, they should be made of the same material)
  • identical substrate thickness
  • identical size of measuring area
• Before starting calibration, make sure the calibration spot, the sensor tip, and the calibration standard are clean. Any impurities might affect the calibration and lead to erratic calibration.
• Make sure the calibration position and the measuring position are always the same, this applies especially for measurement on small parts and measurements at edges and corners.
• Keep away from strong magnetic fields during the calibration procedure.
• For maximum accuracy of calibration and later measurements, choose the thickness of the calibration standard within the same thickness range as the later measuring sample.
• If using calibration foils, make sure they are placed in a plane position on the substrate material. Any air gap below the foils must be avoided as this would lead to erratic readings.

Please note:
If the gauge switches off during the calibration procedure due to a low battery, the calibration procedure must be repeated after batteries inserting fresh batteries.

Calibration methods
According to your setting of task, you may use different calibration methods. Measuring accuracy depends on the selected calibration method.

One-point calibration（only calibrate zero point）

• “Z” is shown in the status line calibration point: zero point (directly on the substrate material)
• Calibration is to be made on an uncoated calibration sample of the same geometry and material as the later measuring object. Only one calibration point is to be taken directly on the substrate to give you the zero point.
• Zero calibration is for quick calibration if a medium accuracy is sufficient.

Two-point calibration

• “Z 1 ”is shown in the status line Calibration points: zero point (directly on the substrate material) and on the precision standard.
• Calibration is to be made on an uncoated calibration sample of the same geometry and material as the later measuring object. Two calibration points are to be taken: one directly on the substrate to give you the zero point, the other one on a precision standard which is put on the substrate.
• Compared to zero calibration, this calibration method implies a higher accuracy. Accuracy will increase if the thickness of the precision standard is close to the thickness of the later object to be measured.

How to calibrate
In measure mode, press the function key CAL to call the calibration mode.

Calibrating FN sensors

If the measuring method “Auto-F/N” has been defined for a batch you may calibrate for both the ferrous and the non-ferrous base. In this case, the calibration procedure will be performed twice. You will automatically be asked to select the first base for which you wish to calibrate. Use the arrow up and down keys to make your selection and press OK to confirm. After the calibration for your selected base has been completed, you will be asked to choose the next one. Use the arrow up/down keys to make your selection and press OK to confirm. Perform calibration accordingly. After this, you will be asked again to select a base. If calibration for both bases has been completed, you can quit calibration by pressing “ESC”. You will go back to the measure mode.

Zero point calibration
Press CAL to start calibration and put the sensor on the blank/uncoated calibration sample. Wait for the signal to sound and lift the sensor.

Repeat this procedure several times (approx. 3 to 10 times) on the same measuring spot. The average will be shown. Accuracy will increase with an increasing number of readings. Press OK to confirm zero calibration. Press OK once again to complete the calibration procedure.

You will be asked to calibrate on the first precision standard. Press OK to jump to this step.

A list will appear to show you the points that have been calibrated. Press OK to go back to the measure mode. In the Auto F/N calibration, you will go back to the base selection.

Two-point calibration
Firstly, process the procedure of the Zero point calibration.

After that, according to the information, put a precision standard on the uncoated calibration sample. Place the sensor on top of it, wait for the signal to sound, and lift the sensor. Repeat this procedure several times (approx. 3 to 10 times) on the same measuring spot. The average will be shown.

If the set point (Cal) as displayed is not identical to the thickness of your precision standard, use the arrow up and down keys to adjust accordingly. Press OK to store the calibration point. Press OK once again to complete the calibration procedure.

A list will appear to show you the points that have been calibrated. Press OK to go back to the measure mode. In the Auto F/N calibration, you will go back to the base selection routine.

Interrupt or abort a calibration procedure
Press ESC to interrupt or abort a calibration procedure. If a calibration value has not yet been taken, the previous calibration will remain active.

Delete a calibration point

• After a calibration procedure has been completed, you may delete individual calibration points or delete the whole calibration. Use the arrow up and down keys to select the calibration point to be deleted.
• Press CLR to delete.
• If you delete the zero calibration point, the complete calibration will be deleted.

Note:
Readings stored in a batch will remain valid even if you delete all or only some of the calibration points.

How to recalibrate
If measuring conditions have changed, it may become necessary to recalibrate without changing the calibration method. This can be done at any time, even if readings are stored in the relevant batch (Please note that it is NOT possible to change the calibration mode of an existing batch with stored readings).

Data Management

Batches

General remarks

• With all models of the DC-8000 series, readings, calibrations, statistics, and parameters are stored as a set of data in a batch, i.e. apart from the readings, a batch includes its calibration, setting parameters, and statistics. If you open an existing batch, the calibration and parameters stored in this batch will become active.
• Go to the main menu and select “Database” to view all batches. The batch names (BATCHxx) are predefined. The DC-8000 model features 10 batches.
• If you are in measure mode, the currently active batch is shown in the status line (upper display line). It is referred to as “BATCHxx“. xx = the current number of batches.

Memory Size
The memory of the DC-8000 models is designed to store a total of 10,000 readings. With all models, the memory can be memorized into any batches according to customer requirements. The space of each batch will be 1000 readings.

Parameters
All measuring series includes the following parameters: “Block size”, “Upper limit” and “Lower limit”.

Data base

General remarks

The database is for the management of your batches. You can create new batches, define their calibration methods and parameters as requested, or open existing batches to start a measuring series.

Create a new batch

Press the function key MENU to call the main menu. Press OK to confirm the preselected menu point “database”. Please note: At the initial switch on or after a total reset, batch # 00 with a preset factory calibration becomes active.

Use the arrow up/down keys to select an “empty” batch. Press OK to confirm. The selected batch will open. If you wish to make new parameter settings, the parameter settings routine will be called. Now you can view and change all parameters one after the other.

Parameter: Upper limit/Lower limit

• You can set upper and lower limits to monitor deviations from the set point. Readings beyond the specified limits will be signaled through the LCD flashing. In addition, a signal tone will sound. Readings beyond the tolerance limits will be marked on the list of single readings.
• Tolerance limits can be set at any time before, during, or after reading.
• User arrow up/down keys to change the parameter settings as requested. Press CLR to delete.

Parameter: Block size

• Subsequent readings of a batch can be divided into blocks, each of the same size (block grouping of readings). The number of readings per block can be adjusted from 1 to 100.
• To complete the batch setting procedure, an overview of your parameter settings appears on the screen.
• For your quick reference, this overview can also be selected via the main menu. Select “Database” followed by “Overview”

Select a batch for taking readings

• Press the function key MENU and select “Database”. Press OK to confirm. The currently active batch is marked by an arrow. Use the up/down arrow keys to select the requested batch. Press OK to confirm. Your selected batch is now active. The display shows the name of the batch, the date and time of the batch setting, and the last modification. You can select from the following options: change, overview, or delete.
• If there are no parameter changes to be made, you can directly proceed with the measurement. Place the sensor onto the measuring object. The gauge changes to measuring mode and the reading you have taken is being displayed.

Change a batch

• Press the function key MENU and select “Database”. Press OK to confirm.
• The currently active batch is marked by an arrow. Use the up/down arrow keys to select the requested batch.
• Press OK to confirm. Select “change” and press OK to confirm.
• The parameters can only be changed as long as there are no readings stored in your batch. As soon as there are readings stored in the batch, a lock symbol will appear on the screen to indicate that the requested parameter cannot be changed.
• If you still wish to have this parameter changed, (e. g for using this measuring series for a new application), you first have to delete the readings of this batch.

Parameter Overview

• Press the function key MENU and select “Database”. Press OK to confirm.
• Use the up/down arrow keys to select the requested batch. Press OK to confirm. Use the arrow up/down keys to select “overview” and press OK to confirm. The display will show the parameter settings of the active batch.
• Parameters – List of symbols and their meanings：
  • Upper limit:
  • Lower limit:
  • Block size: Block size = 5

Delete a batch

Press the function key MENU and select “Database”. Press OK to confirm. Use the up/down arrow keys to select the requested batch. Press OK to confirm. Select “delete” and press OK to confirm.

Attention!
Once you have deleted the readings and settings of a batch, they cannot be restored.

Statistics/Statistical Evaluation

General remarks
From measuring mode, press the function key STATS to access the statistics menu. In this menu, you can view, print out, and delete statistical and single values or transfer them to a PC.

View statistics

View statistics with the disabled block option

The statistics refer to the whole batch. If you press the function key STATS from measuring mode, the statistics menu will be called. Press OK to confirm. As an alternative, you can call this function from the measuring mode by pressing the function key STATS twice.

The batch statistics include the following values:

• BLK = number of readings
• = mean value
• ↑= Maximum
• σ= standard deviation
• ↓= Minimum

View single readings

Press function key STATS from measuring mode to call the statistics menu. Use the arrow up/down keys to select “Readings” and press OK to confirm. The list of single readings appears. As an alternative, you can call this function from the measuring mode by pressing the function key STATS three times.

Use the arrow up/down keys to scroll through the list of single readings of your batch. The list shows the serially numbered readings along with the measuring principle that has been used for the acquisition of the reading. If you have set tolerance limits, readings off tolerance will be marked accordingly (> above limit; < below limit).

View statistics if readings are grouped into blocks

These statistics refer to the whole batch. If readings are grouped into blocks (block size > 1), the batch statistics will be calculated from the results of the different block statistics. Press function key STATS from measuring mode to call the statistics menu. Select “Statistics” and press OK to confirm. As an alternative, you can call this function from the measuring mode by pressing the function key STATS twice. The block value statistics includes the following values:

• BLK = number of readings
• = mean value
• ↑= Maximum
• σ= standard deviation
• ↓= Minimum

View single readings and block statistics

The group readings into blocks (block size >1) option has been enabled, press the function key STATS to call the statistics menu. Use the arrow up/down keys to select “Readings” and press OK to confirm. As an alternative, you can call the list of readings from the measuring mode by pressing the function key STATS three times.

• Use arrow up/down keys to scroll through the batch. The readings are serially numbered (first figure on the left) and displayed along with the block number (second figure after the slash) and the measuring principle used for taking the reading.
• If you have set tolerance limits, readings off tolerance will be marked accordingly (> above limit; < below limit).
• Block statistics cannot be shown until a block has been completed.

Delete readings of a batch

Press the function key STATS to call the statistics menu. Use the arrow up/down keys to select “Delete”. Press OK to confirm. You will be requested to confirm deletion. If you press YES, all readings of the currently selected batch will be deleted. Once the deletion has been completed, the message “Readings deleted” will appear. Attention: Readings will be irrevocably deleted and cannot be restored.

Delete a current reading
In the single readings mode, a reading shown on display can be deleted immediately by pressing CLR.

Data transfer
All models of the DC-8000 series are equipped with a USB port, which can transfer batch readings and statistical data to a PC through Msoft software. Please read the software instructions for specific operation methods.

Care and Maintenance

Care
Use a soft damp cloth with water or a mild detergent to clean the gauge and accessories.

Caution:
Do not use solvents because they might damage the plastic parts. Do not use metal brushes or other tools for cleaning the sensor tip.

Maintenance
Please note: Repairs may only be carried out by authorized Checkline staff.

Error messages and remedy

Error message

| Cause of the problem|

Remedy

---|---|---
“Please check clock settings”| The gauge has been cut from the power supply for more than one minute. (If the gauge has been supplied without batteries or after battery change)| Check clock settings. If necessary reset the clock.
“Battery almost empty”| This message briefly appears before the batteries are completely discharged. The gauge switches off. Batteries must be replaced/recharged before you can continue to use the gauge.| Replace batteries or reload rechargeable batteries. Used batteries should not be disposed of with domestic refuse. Please dispose of used batteries according to the statutory regulations.
“Too close”| At the switch, the sensor was held too close to the metal part.| Make sure to keep a safety distance from metal parts at the switch on. The sensor should be kept at a distance from metal parts of at least 5 times the measuring range.
“No sensor found!”| After switch-on, the gauge cannot establish a connection to the sensor. Possible causes: -no sensor connected -loose sensor connection -defective cable – defective sensor| If a defective sensor is the cause of the error, please replace it with a new one or contact Checkline after-sales service.
“Unstable”| There is a strong magnetic field in the near.| Away from the powerful magnetic field

The following errors may be remedied by a Total Reset:

• no response to key action
• reading acquisition failure
• illogical readings

If you are not able to switch the gauge off via the ON/OFF button, please remove and reinsert the batteries.

Menu Quick reference

Technical Data

Gauge parameters

batch. If a printer or a PC is connected, the date and time of print-out and date of last modification of a batch will be included.
Dimension of gauge| 130×73×25mm
Weight| 162g(Including battery)

Supply schedule

• Gauge with the selected probe
• 2 batteries
• Control plate(s) with calibration
• Coils
• Certificate
• Operating instruction
• USB including Software inside.
• Soft pouch.

Recommended accessories

• Standard foil.

Industry Standard:

• DIN 50981, 50982, 50984 ISO 2178, 2360
• ASTM B499，B244 BS 5411

Statistical Terms
The statistical evaluation will help you to assess the quality of your product.

• Average (Mean):

The sum of single readings is divided by the total number of readings.

Variance
The variance of a list is the square of the standard deviation of the list, that is, the average of the squares of the deviations of the numbers in the list from their mean divided by the (number of readings minus 1).

Standard Deviation:

The sample standard deviation is a statistic that measures how “dispersed“ the sample is around the sample mean. The sample standard deviation increases with increasing spread out. The standard deviation of a set of numbers is the root mean square of the variance s²

Variation coefficient（Var.-coeff.）
The variation coefficient is the standard deviation divided by the arithmetic mean. The variation coefficient is indicated in percent.

Safety Notes

Safe operation will be ensured as far as the instructions and notes in this manual and on the gauge display will be observed.

Contact Information

• Distributed by: ABQ Industrial LP USA
• Tel: +1 281-516-9292/888-275-5772
• eFax: +1 866-234-0451
• Web: https://www.abqindustrial.net
• E-mail: info@abqindustrial.net.

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