ABQINDUSTRIAL GalvanoTest 3000 Use and care manual

GalvanoTest 3000
Technical Reference and Operating Manual
AdvancingwithTechnology ElektroPhysik
Distributed by: ABQ Industrial LP USA
Tel: [phone] eFax: [phone]
Web: https://www.abqindustrial.net E-mail: [email protected]
Distributed by: ABQ Industrial LP USA
Tel: [phone] eFax: [phone]
Web: https://www.abqindustrial.net E-mail: [email protected]

ElektroPhysik GalvanoTest 3000 12/2003 0-1
Table of Contents
1. Description .......................................... E-1
1.1 Data processing unit (Front view)............E-1
1.2 Data Processing Unit (Back view)............E-2
1.3 Measuring stand with integrated circulation
pump ........................................................E-5
1.4 Measuring cell 3000 and fasteners .........E-7
2. Introduction ......................................... E-8
2.1 General Usage and measuring
principle ..................................................E-8
2.2 Description ................................................E-9
3. Supply schedule ............................... E-10
3.1 Standard supply ......................................E-10
3.2 Recommended accessories ................... E-11
4. Taking Readings.............................. E-12
4.1 Adjusting the instrument ......................E-12
4.1.1 Metal coating material (METAL) ... E-12
4.1.2Measuringarea(AREA)................. E-12
4.1.3 Deplating speed control (SPEED).. E-13
4.1.4 Sensitivity (SENS) ........................ E-13
4.1.5Calibration(CAL) ........................... E-14
4.1.6Measuringunit (UNIT) ................... E-14
4.2 Preparing measurement ........................E-15
4.2.1 Cleaning the sample ...................... E-15
4.2.2 Postitioning the sample ................ E-15
4.2.3 Elektrolyt selection table ............... E-16
4.2.4 Choosing electrolyte and
measuring cell................................ E-17
4.2.5 Filling in the electrolyte solution .... E-17
4.3 Taking readings .......................................E-17
4.4 After measurement .................................E-18
4.4.1 Electrolyte saturation..................... E-19
4.4.2 Y-T writer output ........................... E-19

0-2 12/2003 ElektroPhysik GalvanoTest 3000
4.5 Printing out readings ..............................E-20
4.5.1Print-outofvoltagecurve................ E-20
4.5.2 Readings and statistics ................. E-21
5. Measuring stand and accessories .E-22
5.1 Centering device .....................................E-23
5.2 Positioning arm .......................................E-23
6. Small parts holder ............................ E-24
7. Electrolyte cup.................................. E-24
7.1 Variable measuring area........................E-25
7.2 “C” Mask ...............................................E-28
8. Special applications.........................E-29
8.1 Convex surfaces .....................................E-29
8.2 Concave surfaces ....................................E-30
8.3 Gold coatings (Au) ...................................E-30
8.4 Multi-layer coatings................................E-30
8.5 Chromed zinc coatings ..........................E-31
8.6 Diffusion layers ........................................E-32
8.7 Currentless nickel....................................E-32
8.8 Nickel on copper on steel .....................E-33
8.9 Copper on zinc ........................................E-33
8.10 Tin on brass............................................E-33
8.11 Thick coatings ........................................E-33
9. Calibration ......................................... E-34
9.1 Calibrating by means of a coating thickness
standards................................................E-34
9.2 Calibrating by means of a factor ...........E-35
9.3 Range of calibration factor ....................E-35
9.4 Reset to standard calibration (1.000).....E-35

ElektroPhysik GalvanoTest 3000 12/2003 0-3
10. Sensitivity (SENS) .......................... E-36
10.1 Reset to standard sensitivity.................E-36
11. Measuring uncertainty ................... E-37
11.1Error sources ..........................................E-37
12. Statistics mode................................ E-37
12.1 Recording a measuring series and
statisticscalculation..............................E-38
12.2 Recalling and print-out of statistics .....E-38
12.3 Print-out of readings and statistics ......E-38
12.4 Deleting a previous reading.................E-38
12.5 Deleting a measuring series incl. statistics
12.6 Exceeding storage capacity.................E-39
13. Date and Time.................................. E-39
14. Language selection ....................... E-40
15. Error messages .............................. E-40
16. Further sources of error .................E-41
17. Maintenance ................................... E-42
18. Data Printer MiniPrint 4100........... E-43
19. RS 232 C Interface.......................... E-43
20. After sales service .......................... E-43
21. Hints for using electrolyte
solutions .......................................... E-43
22. Technical specfications.................. E-44
22.1 Measuring uncertainty ..........................E-45
Index....................................................... E-46

ElektroPhysik E-1
1. Description
1.1 Data processing unit (Front view)
4,000
START
STOP
SET
PRINT
STATS
CLEAR
VOLTAGE
THICKN
GalvanoTest 3000
Physik
Ni B 5,4 mm²
M
E
T
A
L
A
R
E
A
S
P
E
E
D
S
E
N
S
.
C
A
L
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U
N
I
T
1 2 3 4 5 6 7 8 9
17 16 15 14 13 12 11 10
18
Fig. 1

E-2 ElektroPhysik
1.2 Data Processing Unit (Back view)
GalvanoTest CE
Geräte N.
Typ Version 1.00
G-Test 2000 3020001
G-Test 3000 3040001
ElektroPhysik Köln Made in Germany
19
20
24 23 22 21
Sicherungs-
halter
Fig. 2

ElektroPhysik E-3
1analog meter for monitoring test voltage at
measuring cell
24-digitfloating point display for showingreadings
316-digit alphanumerical display
4STATS-key for activating statistics
5ARROW-keys for setting
- substrate material
- measuring area
- de-plating speed
- sensitivity
- calibration
- thickness of coating thickness standard
- measuring unit
- date and time
- language
6SET-key:
for setting parameters selected byARROW-keys
7START/STOP-key:
for manual launching and stopping measuring
process
8THICKNESS/VOLTAGE-key for
- switching display to cell voltage view during the
measuring process
-printing-out voltage curveon MiniPrint4100data
printer
9PRINT-key for printing out
- date and time
- readings
- statistical values

E-4 ElektroPhysik
17 cable socket:
to connect gauge to measuring stand
18 pump-keys:
for filling or emptying the inner measuring cell
19 mains switch
20 nameplate
21 socket for Y-Twriter
22 socket for MiniPrint 4100 data printer or RS 232C
23 power socket
24 fuse holder with supply voltage control
220V/50Hz or 110V/60Hz
Switching from 220V to 110V:
Remove fuse holder (24), turn 180 degrees and put
in place again.
10 CLEAR-key for
- deleting the last reading
- setting default de-plating speed, default
sensitivity and default calibration
- interrupting printing process
- for error reset
10+ 4 CLEAR + STATS-keys:
- for deleting current statistics memory
11 UNIT:selected measuring unit
12 CAL: selected calibration
13 SENS: selected sensitivity
14 SPEED: selected de-plating speed
15 AREA: selected measuring area
16 METAL: selected coating material

ElektroPhysik E-5
1.3 Measuring stand with integrated
circulation pump
34
38
36
37
35
31a
30
31
33
32
Fig. 3
30 pressure device: to ensure constant contact
pressure on the measuring cell
31 measuring cell holder
31a recess: to ensure a fixed position of the
electrolyte bottles when filling the inner
measuring cell
32 circulation pump: to ensure a steady circulation
of the electrolyte solution during measurement
33 adjusting screw: to adjust circulation (Important
note: Please do not change factory setting!)
34 stopper of measuring cell holder (vertical
adjustment)
35 working surface: for positioning the measuring
sample
36 cathode plug: to be connected to the outer
measuring cell (42a)
37 cable: to be connected to the cable socket (17)
38 clamp: to be fixed to the measuring sample

E-6 ElektroPhysik
Fig. 3a
34
38
36
37
35
31a
30
31
33
32
Suction hose: to be connected to the circulation pump (32)
Suction pipe

ElektroPhysik E-7
41 clamping fork: for sealing the inner measuring cell
42 outer measuring cell: holds the inner measuring
cell
42a bore hole: current supply point
42b nut for clamping fork
42c rubbergasketholder:maybereplacedbythewire
holder (46)
43 inner measuring cell, type I: to be filled with the
electrolyte solution (vertical drain of solution)
44 inner measuring cell, type II: to be filled with the
electrolytesolution(diagonaldrainofsolution,see
Electrolyte solution selection table)
44a Max/Min marking: limit for electrolyte solution
45 Circular rubber gasket: to delimit and seal the
measuring area (prevents electrolyte solution
drain off)
46 wire holder: for measuring wires in the electrolyte
cup
47 sealing device for inner measuring cell
1.4 Measuring cell 3000 and fasteners
41
41
40
42
42a
42b
42c
43 44
44a
43 44
45
46
47
max
min
Fig. 4
40 pump tube

E-8 ElektroPhysik
2. Introduction
2.1 General Usage and measuring principle
The coulometric or electrochemical de-plating technique
according to DIN 50955 / ISO 2177 is suitable for the
measurement of electroplated coatings on practically all
substrate materials, i.e.: on steel, on non-ferrous metals
and also on insulating materials, e.g. nickel on steel,
zinc on steel, tin on copper, silver on copper and copper
on epoxy.
This method is also suitable for measuring the individu-
al coatings of multi-layer systems such as chrome on
nickel on copper on steel.
Themeasuring principle is based onFaraday’sLaw.The
oppositeof the electroplating method applies,thecoating
being electro-chemically removed from the sample.
On this purpose, a stainless steel measuring cell is
placed on the sample to be measured. The cell is filled
with an electrolyte solution which is selected according
tothecoating / base combination.Arubbergasket placed
between the cell and the sample defines the area of
measurement, e.g. 4 sq. mm. The measuring set-up is
electrically connected to the electronic processing unit.
When switched on, a constant current flows through the
electrolyte to remove the metallic coating electro-
chemically.
Throughout the entire de-plating process, a defined
voltage can be observed between measuring cell and
object to be measured. As soon as the metallic coating
has been completely removed, a characteristic voltage
jump occurs. This voltage jump is registered by the
measuring gauge to interrupt the voltage supply and to
stop the timer. Thickness is immediately displayed in
mils or microns.
=
U
Measuring cell
Elektrolyt
Rubber
gasket
Measuring
area Coating
Substrate
material
Electro-
lyte

ElektroPhysik E-9
2.2 Description
GalvanoTest 3000 includes 10 different metal selections
which are preset: chrome, nickel, Copper, brass, zinc,
silver, tin, lead, cadmium and gold. Zinn, Blei, Kadmium
und Gold.
In addition, 8 user-definable metal memories (M1....M8)
are available.The instrument can be used with three
defined measuring areas of different sizes. In addition,
the electrolyte cup allows to measure a variable
measuring size (K).
rubber gasket Nr. B4,00 mm² (∅2,26 mm)
mask Nr. C1,00 mm² (∅ 1,13 mm)
mask Nr. D0,25 mm² (∅0,56 mm)
electrolyte cup Kfor small parts and wires
The de-plating speed is adjustable in a wide range from
0,3 to 40 µm/min.
The readings may be processed in the statistics pro-
gram. The portable data printer MiniPrint 4100 provides
data print-outs including all single readings and up to 6
statistical values including date and time of print-out
(quartz controlled time clock).
Typical voltage curve
Voltage jump
Switch-off point
Cell voltage U
Time interval t
(Coating thickness)
V: de-plating volume
Coating thickness Time interval
V
= Measuring area x Coatinng Thickness
Time interval x Current

E-10 ElektroPhysik
Special feature: individual print-out of single
measurements together with their characteristic voltage
curves and switch-off points on the data printer MiniTest
4100.
The instruments allows storage of settings such as
calibration or statistics which preset the unit when
recalled.
Anyoperating error will beshownonthe alpha-numerical
display in English, German or French (operator
selectable).
Equipped with an RS 232 C interface, the instrument
can be linked to an IBM PC or any compatible computer
or printer.
3. Supply schedule
3.1 Standard supply
-GalvanoTest 3000 processing unit
-interface for MiniPrint 4100 data printer or PC
-socket for Y-T-writer
-measuring stand 3000 with integrated circulation
pump
-outer measuring cell and inner measuring cell,
type I
-sealing device
-2 rubber gaskets B(4,00 mm²)
-2rubbergaskets(∅1,5mm)for sealingthemasks
-20 masks C(1,00 mm²)
-20 masks D(0,25 mm²)
-rubber pencil
-pipette
-5x100mlelectrolytesolution,asortedtocustomer
requirements
-1 bottle for used electrolyte solution, 100 ml
-1 washing bottle, 100 ml
-1 package absorbant paper
-operating instructions including works certificate

ElektroPhysik E-11
3.2 Recommended accessories
-inner measuring cell type I or II, for working with
a second electrolyte solution
-sealing device
-positioning arm
-spare pump tube
-electrolyte cup incl. connecting cable
-wire holder for measuring wires
-small parts holder
-bottle stand for holding up to 7 electrolyte solution
bottles, 100 ml each
-coatingthicknessstandards (s.also section 4.2.3,
index ST)
-electrolyte selection
-spare rubber pencil
-centering device (Z2)
-spare pipette
-spare rubber gaskets B(4,00 mm²)
-masks C(1,00 mm²)
-masks D(0,25 mm²)
-modified rubber gasket D/Au (0,25 mm²)
-external accu battery powered data printer
MiniPrint 4100
-connecting cable for MiniPrint 4100 data printer
-connecting cable for Y-T-writer
-RS 232 connecting cable for PC or printer
-MSoft7000 data transfer program
-measuring cell stand for holding up to 5 inner
measuring cells

E-12 ElektroPhysik
4. Taking Readings
4.1 Adjusting the instrument
Before starting operation select supply voltage with the
voltage control switch (24). After switching on, the
anlaogue meter (1) lights up. The previous setting is
shown on the alpha-numerica display (3), e.g.:
The instrument can be adjusted by pressing SET (6)
and ARROW-(5) keys. For setting into selection mode,
press SET-key. The position of the red cursor on the
alpha-numerical display indicates the parameter which
is to be set (e.g. de-plating speed or metal selection).
Use the ARROW-keys for setting the required param-
eter. The parameters set by the ARROW-keys will be
directly accepted. For quick setting, keep SET- or
ARROW-key pressed down continuously (Quick
function).
4.1.1 Metal coating material (METAL)
Position the cursor to METAL (16) by pressing SET-key.
Use the ARROW-keys for setting your metal selection.
The options are shown in the following order:
Cr, Ni, Cu, Ms (brass), Zn, Ag, Sn, Pb, Cd,Au.
Aset of further 8 metal memories (M1...M9) is free-
programmable.
4.1.2 Measuring area (AREA)
Position the cursor to AREA (15) by pressing SET-key.
Use the ARROW-keys for setting the required area (B,
C, D or K). The size of your measuring area selection is
shown on the reading display (2) while the correspond-
ing unit is displayed on the alpha-numerical display (3)
in sq. mm or thousands of sq. inch. The measuring area
K is only selectable in combination with the electrolyte
cup (see section 7 „Electrolyte cup“).
Note:
Another measuring area can only be selected if there
are no data stored in the statistics memory. Otherwise,
the following message will appear: “Memory
overcharged” (see section 12.5 „Deleting a measuring
series incl. statistics“).
START
SET
PRINT
STATS
CLEAR
VOLTAGE
THICKN
Ni B 5,4 µm
Cursor
METAL AREA
SPEED
SENS
CAL UNIT

ElektroPhysik E-13
4.1.3 Deplating speed control (SPEED)
Position the cursor to SPEED (14) by pressing SET-key
and use ARROW-keys for your de-plating speed
selection. The de-plating speed is indicated in steps of
50% (ARROW-DOWN-key) or 100% (ARROW-UPkey).
In general, the de-plating speed should be selected so
that a measuring time between one and three minutes
can always be ensured.
The de-plating speed ranges between 0.3 microns/min
at minimum and 40 microns/min at maximum. When try-
ing to set higher or lower, the message “MAXIMUM” or
“MINIMUM” appears.
The de-plating speed indication on the reading display
(2) is more accurate than on the alpha-numerical dis-
play (3). The corresponding measuring unit microns or
mils are displayed on the alpha-numerical display.
To reset to default de-plating speed press CLEAR-key
(10). This default value depends on the metal selection.
Note:
The de-plating speed also depends on the range of
source of electricity powering the instruments.
For special applications the de-plating speed is limited.
The de-plating speed for Chrome in combination with
the measuring area B, for instance, must not exceed 40
microns/min. The message “MAXIMUM” may occur.
4.1.4 Sensitivity (SENS)
Position the cursor to SENS (13) by pressing SET-key.
The current sensitivity is shown on the reading display
(2) and the voltage being displayed alphanumerically.
Use the ARROW-keys for sensitivity control. Press
CLEAR-key to reset to default sensitivity selection.
If the required sensitivity is equal to the default sensitiv-
ity, there willl be an empty space above the cursor.
Ni B 5,4 µm
METAL AREA
SPEED
SENS CAL UNIT

E-14 ElektroPhysik
Ni B 5,4 µm
METAL AREA
SPEED
SENS CAL UNIT
If you have selected a calibration factor other than
1,000, an asterix (*) appears on the alphanumeric
display.Formoreinformationoncalibrationpleaserefer
to section 9 „Calibration“.
4.1.6 Measuring unit (UNIT)
Press SET-key for positioning the cursor to UNIT (11).
Use ARROW-keys for selecting metric (microns) or
American mode (mils).
If you press SET-key again, the cursor disappears. For
resetting the cursor to the first position (METAL) and
repeating the whole setting procedure, press SET once
more.
1,000
START
STOP
SET
PRINT
STATS
CLEAR
VOLTAGE
THICKN
GalvanoTest 3000
Physik
Ni B 5,4 mm²
M
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A
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A
S
P
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D
S
E
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C
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U
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Ifthe required sensitivity is different from the default sen-
sitivity an asterix will be displayed above the cursor.
For more information on sensitivity setting please refer
to section 10 „Sensitivity“.
4.1.5 Calibration (CAL)
Press SET-key for positioning the cursor to CAL (12).
The current calibration (factor) is displayed on the
reading display while on the alpha-numerical display a
crossbar is shown on the position for “unit”, i.e. the
calibration factor is indicated without unit.
UseARROW-keysfor setting calibration orselect default
calibration by pressing CLEAR-key.
If the required calibration factor is equal to the default
calibration (factor 1,000), there will be an empty space
above the cursor and 1,000 for default value can be
read.

ElektroPhysik E-15
4.2 Preparing measurement
4.2.1 Cleaning the sample
The surface of the sample should be free of grease,
lacquer, oxide or passivation films. Use ordinary solvent
for cleaning. Oxide films can be removed by means of
alcohol or by means of the rubber pencil supplied with
the instrument.
Use ElektroPhysik PE 1 solution (accessories) or the
rubber pencil for removing chromate coatings on zinc
(see also paragraph 8.5 “Chromed zinc coatings”).
4.2.2 Postitioning the sample
The sample should be placed on the working surface
(35) in a stable position. Make sure that the measuring
cell can sit a right angles to the sample. If necessary,
the small part holder can be used (section 6).
Place an apporpriate rubber gasket (45) onto the outer
measuring cell (42). i.e. rubber gasket B(4 mm²) or the
rubber gasket with ∅1,5mm if you use the mask C(1
mm²) or D(0,25 mm²).
Note:
To prevent erratic readings, the rubber gasket ∅1,5 mm
should neverbe used without mask. The rubber gasket
has an area of 1,8 mm².
Release the stopper (34) at the measuring stand and
place the measuring cell onto the measuring sample.
Push the measuring cell holder (31) down until the
distance piece of the pressuer device (30) locks into
place.
Tighten the stopper (34).
Release the distance piece.
The built-in springs now exert a constant pressure of
the measuring cell on the sample. It is thus guaranteed
that the rubber gasket always keeps the same shape
and therefore the same measuring area. This is espe-
cially important when using the rubber gasket B (4 mm²)!

E-16 ElektroPhysik
4.2.3 Elektrolyt selection table
1) For electrolyte selection and instrument adjustment please refer to
our customer support
2) see section 8.9 „Copper on Zinc“
3) see section 8.10 „Tin on Brass“
4) for Tin/Zinc 78%/22%
5) Please use the inner measuring cell type II.
8) Requires carefull measurement. Please contact our customer
support if necessary.
ST) Coating thickness standards available on stock
C oating
Substrate S ilver (A g) G old (A u) C a dm ium (C d ) C hrom e (C r) C o pp er (C u) Brass (M s) Nickel (Ni)
C urrent-
less
Nickel
Lead
(P b) Le ad / Tin Tin (S n) Tin/ Zinc4Zinc (Zn)
Non m eta l E 4 E 1;8 E 5 E11 E4 E4 E14 E 178E 158E 48E 7 E 78E 6
S ilver E 158
A lum inium E 48E 58E 118E 48E 48E 148E 178E 158E 48E 118E 68
B ronze E 88E 78
C adm ium E 78
C opp er E 8S T E1;8 E 5ST E7S T E 14S T E 158E 48E 95;S T E 78E 68;S T
Steel E 4S T E1;8 E 5ST E 11S T E 4 ST E4 E 14ST E 17 E 158E 48E 7 8 ;ST E 78E2 08 ;-
S T
Brass E8S T E1;8 E 5ST E 7ST E1 28E14ST E 158E 48E 93 ;5 ;8 ;S T E 78E 65;8;-
S T
Nicke l E 48E1 ;8 E58E 11S T E 48E 48E 158E 78E 68
Silicon E 148
Zinc E12S T;2;8
Kovar E48E 158
Argentan
silver E 88E78E 78
Zinc
diecasting E 1 28