Coatmaster Flex User manual

1
coatmaster Flex
User Manual
coatmaster.com
Version: 05-2023

coatmaster Flex
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© 2019-2023 coatmaster AG
Distribution and duplication of this document, and utilization and communication of its contents other
than for legitimate purposes, are not permitted without the express permission of coatmaster AG.
Violations will result in legal action.
All rights are reserved
Subject to technical
are not to be
in the event of patent grant or utility model registration (ISO 16016).
changes and printing errors, the values given are approximate and
understood as legally warranted characteristics. These values may
vary according to component tolerance.
Last update: 05/2023

coatmaster Flex
Table of contents
1. Technical Data ............................................................................................................................5
2. Customer Requirements and Device Specification..................................................................7
3. Applications.................................................................................................................................8
4. Functionality and Measuring Principle .....................................................................................9
5. Safety and Responsibility....................................................................................................... 10
5.1. Warning Symbols............................................................................................................................... 10
5.2. Signs and Icons ................................................................................................................................... 11
5.3. Improper Use...................................................................................................................................... 11
5.4. Product Safety.................................................................................................................................... 13
5.5. Compatibility with flame detectors ................................................................................................. 13
6. Delivery Scope......................................................................................................................... 14
7. Set-up ....................................................................................................................................... 15
7.1. Battery................................................................................................................................................. 15
7.1.1. Battery Charging ........................................................................................................................................15
7.1.2. Battery Installation......................................................................................................................................16
7.2. Navigation Panel ............................................................................................................................... 17
7.3. Turning the Power On/Off ............................................................................................................... 17
7.4. Language Selection ........................................................................................................................... 18
7.5. Wi-Fi Settings ..................................................................................................................................... 18
7.6. Activation............................................................................................................................................. 20
7.7. Operation with coatmaster® Local server ..................................................................................... 21
8. Operating Instructions ............................................................................................................. 23
8.1. System Settings................................................................................................................................... 23
8.1.1. Network Troubleshooter.............................................................................................................................23
8.1.2. Select license and server ...........................................................................................................................24
8.1.3. User Level.....................................................................................................................................................25
8.1.4. Measurement Unit .......................................................................................................................................26
8.1.5. Auto power off............................................................................................................................................26
8.1.6. Contact information ....................................................................................................................................26
8.1.7. Factory Reset...............................................................................................................................................27
8.1.8. Automation mode........................................................................................................................................27
8.2. Main Menu .......................................................................................................................................... 27
8.3. Block Menu .......................................................................................................................................... 30
8.3.1. Select a block..............................................................................................................................................30
8.3.2. Create a new block....................................................................................................................................30
8.3.3. Rename a block...........................................................................................................................................31
8.3.4. Remove a block...........................................................................................................................................31

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8.4. Application Menu ............................................................................................................................... 31
8.4.1. Delete an application.................................................................................................................................33
8.4.2. Favorite an application..............................................................................................................................34
8.4.3. Advanced calibration report.....................................................................................................................34
8.4.4. Calibration Menu ........................................................................................................................................35
8.4.5. Quick Application .......................................................................................................................................35
8.4.6. Manual Application ....................................................................................................................................36
8.4.7. Reference Measurements...........................................................................................................................37
8.4.8. Calibration Report......................................................................................................................................40
8.4.9. Rename application....................................................................................................................................41
8.4.10. Edit Materials Properties or Display Options.........................................................................................41
8.4.11. Materials Properties...................................................................................................................................42
8.4.12. Display Options...........................................................................................................................................42
8.4.13. Display Options (Bounds)...........................................................................................................................43
8.4.14. Setting Bounds.............................................................................................................................................44
8.4.15. Example of a Calibration Process............................................................................................................46
8.4.16. Offset calibration .......................................................................................................................................47
9. Measurement............................................................................................................................ 48
10. Data Transfer/Cloud .............................................................................................................. 49
10.1. Login ................................................................................................................................................ 49
10.1.1. Applications .................................................................................................................................................52
10.1.2. Monitor .........................................................................................................................................................52
10.1.3. Export ...........................................................................................................................................................53
10.1.4. Help ..............................................................................................................................................................54
11. Troubleshooting and Best Practice......................................................................................... 55
11.1. Error Messages .............................................................................................................................. 55
11.2. Error Codes..................................................................................................................................... 56
11.3. Frequently Asked Questions (FAQs)............................................................................................ 58
11.4. Hotline ............................................................................................................................................. 58
12. Storage and Transportation................................................................................................... 58
13. Maintenance and Repair........................................................................................................ 59
13.1. Replacement of the Inlet Filter ..................................................................................................... 60
13.2. Cleaning and Care........................................................................................................................ 60
13.3. Warranty........................................................................................................................................ 60
14. API-Interface Description........................................................................................................ 61

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Foreword
Dear Customer,
with the purchase of a coatmaster® Flex, you have acquired a high-quality, precision product. In this
manual we provide you with some instructions to help you to work successfully and productively with
this device for many years. coatmaster AG has made every effort to manufacture a safe and high-
quality device that complies with all applicable regulations. Our strict quality control procedures
ensure high quality standards even for high volume production. Please apply your own controls and
treat the device with care. Should you have any questions regarding the use of the equipment, please
do not hesitate to contact us.
We wish you success and ‘a perfect coating’.
The Founders Prof. Dr. Nils A. Reinke and Andor Bariska
coatmaster AG
1. Technical Data
Characteristics Tolerance/ Description
Measuring distance range 20 -150 mm
Measurement angle / tolerance ±70°
Measuring point size 2 mm2 at 75 mm distance
Measuring range thickness 10 - 500 µm (depending on coating type)
Standard deviation Typical < 2% of the thickness
Measuring time Typical 300 ms (depending on setting for coating thickness)
Storage conditions -10 - 50°C max. 80% humidity (non-condensing)
Power supply Bosch GAL 18V-40
2x Bosch ProCore 18V, 4 Ah
Number of measurements Up to 1.300 measurements per battery charge (4 Ah)
Operating conditions Temperature: 0 - 35°C, Rel. humidity: 10% -75%
Weight (without battery) 1.3 kg
Dimensions 374 x 91 x 203 mm
IP protection type IP50
Table 1: Technical data

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2. Customer Requirements and Device Specification
Measuring the coating thickness early in the process is the key to documenting and controlling coating
processes, saving coating material, improving coating quality, and reducing production time and scrap.
Coating processes are highly sensitive to changes in environmental conditions; therefore, it is crucial
to have access to a thickness gauge that is easy to operate and works well in an aggressive (dust, high
temperature) industrial environment.
The patented measurement process used by the coatmaster® Flex is non-contact (as opposed to
systems based on magnetic induction or ultrasound) and non-destructive. It can be applied on wet,
powder, and cured coatings, regardless of the coating material, thickness, or color (including white).
In contrast to magnetic induction-based systems, the Flex device permits measurement of coating
thickness early in the process, i.e., directly after the application of the coating material, before drying
or curing. This allows:
•Savings of 10% - 30% coating material
•Reducing time for color changes
•Accelerating training of new personnel
•Avoiding cost intensive rejects & reworks
•Documenting coating processes
•Reducing environmental impact
•Establishing industry 4.0 standards
•Online-connection to ERP-System
coatmaster® Flex is the most advanced measurement gauge for non-contact thickness measurements.
It outperforms any other photothermal, LED/laser-based, and ultrasound systems on the market in all
industrial relevant aspects. It requires minimal calibration and is insensitive to the angle and distance
of measurement. Its superior reliability, user-friendliness, safe usage, cost-effectiveness, precision, and
accuracy is highly appreciated by major coating-line manufacturers, large paint manufacturers,
renowned experts and most importantly by coaters around the globe.

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3. Applications
The coatmaster® Flex is a flexible and robust handheld device for non-contact measurement of
coatings.
The coatmaster® Flex is unique and versatile and can be used in a wide variety of industries and
industrial sectors:
•Automotive
•Rail
•Aerospace
•Building Industry
•Furniture
•Profiles
•Wind Power
•Pipelines
•Medical/Technical
The coatmaster® Flex is particularly suitable for the following applications:
Powder paints
Due to control of coating thickness measurement with Flex, up to 30% of powder
quantity can be saved. Measurement early in the process prior to curing also saves
time and reduces rework rates.
Wet paints
Precise measurements are possible even before drying. The measuring equipment
capability is guaranteed. This saves material and time and ensures quality.
Functional coatings
Thickness measurement of functional coatings (i.e., e-coats, adhesives, anti-
corrosive coatings) in wet and dried state. Highly accurate measurement even on
rough surfaces and for soft coatings.

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4. Functionality and Measuring Principle
The coatmaster® works according to the principle of advanced thermal optics (ATO). The surface of the
coating is heated with a light pulse. After brief heating by a few degrees, the surface is cooled by heat
conduction to deeper areas of the coating and the substrate. The cooling process on the surface
depends on the thermal properties of the coating and the substrate. The thinner the coating, the faster
the surface temperature decreases, provided it has a lower thermal conductivity than the substrate.
The thickness and thermal properties of the coating are derived from the dynamics of the surface
temperature.
Figure 1: Illustration of the measuring principle
①Flash lamp
②Pulsed heat input
③Coatings
④Substrate
⑤IR radiation
⑥IR sensor
Generally, coatings have a very irregular surface. Powder coatings prior to curing have an even rougher
surface but can nevertheless be measured with the coatmaster® Flex. The properties of this roughness
are influenced by various factors, such as pre-treatment, the type and roughness of the substrate, the
type of coating (e.g., particle size, distribution, and chemical composition), and the exact conditions
(temperature distribution, baking time) during curing. The diagram below shows a microscopic sketch
of this roughness. The ATO automatically compensates for the roughness described above, using an
optical averaging process. This allows a reliable determination of the coating thickness, even with
changing parameters.
2
1
Figure 2: Sketch of surface roughness of a powder coating after curing
①Substrate
②Coating

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5. Safety and Responsibility
This section provides an overview of all relevant safety features for optimum personal protection and
safe and trouble-free operation. Keep the operating instructions with the safety instructions so that
you can refer to them later.
5.1. Warning Symbols
For your safety, it is important to read and fully understand the following table showing the different
warning signs and their definitions!
Symbol Definition
DANGER
Warning of an immediate danger that, if not avoided, will result in death or
very serious injury.
•Measures to avoid the danger.
WARNING
Warning of an immediate danger that, if not avoided, will result in serious
injury.
•Measures to avoid the danger.
CAUTION
Indication of a hazardous situation that, if not avoided, may result in minor
or moderate injury.
•Measures to avoid the situation.
Warning of optical radiation.
Warning of electrical voltage.
Warning of hazards associated with charging batteries.
CAUTION
Indication of a hazardous situation that, if not avoided, may result in
property damage; however, no action is required with regard to personal
injury.
•Measures to avoid the damage.
Table 2: Warning symbols

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5.2. Signs and Icons
Symbol Definition
This symbol means that your device meets the safety requirements of all applicable EU
directives.
This symbol means that you may only dispose the device at an approved local disposal
site.
Information: A highlight containing particularly important information for better
understanding.
Table 3: Signs and icons
Intended Use
The coatmaster® Flex is intended exclusively for the measurement of coating thicknesses.
The device should only be used as a handheld device. The device should not be mounted on a robot or
fixture or operated for an extended period of time.
The instrument may only be operated and cleaned by trained personnel. The intended use also
includes compliance with these instructions and the maintenance intervals must be observed.
Have your device repaired only by qualified personnel and only with original spare parts. This ensures
that the safety of the device is maintained.
The device is not approved for operation in environments with potentially explosive atmospheres.
Keep the device away from rain or moisture. Penetration of water into an electrical appliance increases
the risk of electric shock. Do not place the measurement device in a place where components could
come into contact with corrosive gases or salty air.
Do not block ventilation openings. The ventilation openings prevent the interior of the unit from
overheating.
Remove the battery before cleaning. Do not use solvents for cleaning, to avoid damaging the housing
surface. Use a clean, dry cloth.
In accordance with Directive 2012/19/EU, please take old parts to the appropriate recycling facilities
for proper disposal, reprocessing, and reuse. Never throw electrical equipment into the household
waste! By properly disposing of the electrical appliances, you help to protect valuable resources and
prevent possible negative effects on health and the environment, which could otherwise occur due to
improper waste disposal. Accessories and packaging should also be recycled in an environmentally
friendly manner.
5.3. Improper Use
Use not mentioned above or use that does not comply with the technical specifications, is considered
to be improper use. The operator is solely responsible for any damage caused by improper use.

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The following applications are prohibited:
•Use of the equipment in environments where liquids may get into the device.
•Introduction of any objects into the coatmaster® Flex or similar devices.
•Unauthorized opening the device, other than for standard maintenance operations
(see section 13.), voids the warranty and the manufacturer assumes no liability.
The following safety instructions point out dangers of a general nature that may occur when handling
the device. The user must observe all the instructions listed to minimize possible hazards.
Additional warning messages can be found in this manual whenever the actions described could result
in hazards.
Symbol Description
Integrated light source.
The coatmaster® Flex with SpectralBlue®contains a Xenon flash lamp. The
Evaluation of the photobiological safety of a Xenon flashlight according to IEC-
62471:2006 shows that the coatmaster® Flex flash lamp falls
under the
exempt group and thus does not pose any photobiological hazard.
CAUTION
Device damage may occur if the battery is changed during operation.
Never change the battery during operation, as this can lead to the device being damaged.
Always switch off the device before changing the battery.
Table 4: Warning –improper use

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5.4. Product Safety
The measuring device has been designed and built with the latest state-of-the-art technology;
however, risks to users, property, and the environment may arise if the measurement device is used
carelessly or improperly, for which coatmaster AG bears no responsibility.
The following applications are prohibited:
•Use of the equipment in environments where liquids may get into the device.
•Introduction of any objects into the coatmaster® Flex or similar devices.
•Unauthorized opening the device, other than for standard maintenance operations (see
section 13.), voids the warranty and the manufacturer assumes no liability.
The measurement process is started by pressing the trigger button Ⓣ. When pressing the trigger
button to conduct a measurement, a light impulse is released.
The equipment has been tested in accordance with the safety requirements for electrical equipment
for measurement, control, and laboratory use (IEC 61010-1:2010) and the Low Voltage
Directive2014/35/EU.
To ensure photobiological safety for the user coatmaster® Flex (SpectralBlue® model) was thoroughly
tested. The operation by the end-user is classified as safe according to IEC 62471:2006.
5.5. Compatibility with flame detectors
The coatmaster®Flex has been tested and is compatible in operation with the flame detectors listed
below.
Manufacturer
Flame Detector Type
STS FL 7-64, 8-64 and 9-64. Note: must be set to UV+IR mode!
Minimax
FMX 5000 UV.
Conditionally compatible: YMX 5000 FMX EX 90° IR (for
distances > 1m)
Total Walther UV-03
Table 5: Flame detectors compatible with Flex
Before operating the coatmaster® Flex in any environment, check if the measurement area is under
surveillance of flame detectors. If the flame detector is not listed in the above table, use the Flex in
that area after receiving written confirmation either from coatmaster AG or from the supplier of the
flame detector only.

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6. Delivery Scope
The coatmaster® Flex is delivered with the following components in a robust transport case
(scope of delivery can vary):
Figure 3: Delivery inclusions
Ⓐ
coatmaster® Flex
ⒷLocal Server LS (opt.)
ⒸLocal server power supply LSPS
(opt.)
ⒹLSPS 230v mains cable (opt.)
ⒺLS antennae 2x (opt.),
Replacement filters
ⒻBattery charger
ⒻBosch GAL 18V-160 C
ⒼRechargeable battery
Ⓖ2x Bosch ProCore
18V,4 Ah
ⒽTransport case
Ⓗ
Figure 4: Overview of dimensions and components
①Trigger button
②Input panel
③Display
④Filter cover
⑤Removable battery
⑥Air intake
⑦Air outlet

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7. Set-up
To use your coatmaster® Flex, you must set it up to connect to a Flex server by Wi-Fi connection. The
Flex server can either be a coatmaster®Cloud server (through internet connection) or a coatmaster®
Local server (no Internet required). To connect to the coatmaster Cloud server, a connection to the
Internet is necessary.
Prior to the first usage of the Flex, the device must be activated using a 6-character license code and a
6-character activation key. License and key are provided by your Flex purchasing point.For the local
Server, an additional license and key are available.
Depending on the type of server, different steps are required to activate your coatmaster® Flex:
A. coatmaster® Cloud server
To connect your Flex to the coatmaster® Cloud server, you need to have a Wi-Fi network which
provides internet access. This can be your company Wi-Fi network, or any mobile Wi-Fi network
provided by routers, laptops or mobile phones (hotspots). The following steps must be carried out:
1. Select Wi-Fi network and enter network credentials (see section 7.5.)
2. Select appropriate cloud server (see section 7.6.)
3. Enter license code and activation key received from your Flex purchasing point
(see section 7.6.)
Symbol
Description
The Flex supports both WPA2 and WPA2-Enterprise secured Wi-Fi connection.
B. coatmaster® Local server
To connect your Flex to the coatmaster® Local server, you need to have a local Server device located
within reach of your Flex. The following steps should be carried out:
1. Select Wi-Fi network “flex-local” (see section 7.7.)
2. Select local server (see section 7.7.)
3. Enter local server license and key (see section 7.7.)
If you are using a local Wi-Fi network, the following steps should be carried out:
See sections 7.47.57.6

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Figure 5: Battery inserted in charger Figure 6: Standalone battery
After battery charging, double-check the status of the battery by pressing the ‘On’ button of the battery
pack. If the battery is fully charged, all 3 LEDs should be green (see Figure 5: Battery charging).
If the battery becomes defective, liquid can escape. Avoid contact. If contact accidentally
occurs, flush with water. If liquid also comes into contact with the eyes, seek medical help.
Liquid ejected from the battery may cause irritation or burns.
If the battery becomes defective, escaping liquid may come into contact with adjacent components.
Check any affected parts. Clean such parts or replace them, if required.
7.1.2. Battery Installation
Push the fully charged battery into the
designated holder at the bottom of the device
until it snaps into place.
Ensure that the red tab
is completely engaged.
Figure 7:Battery installation
7.1. Battery
7.1.1. Battery Charging
First charge the 18V battery pack by sliding the battery pack into the battery charger (see Figure 5:
Battery inserted in charger). Use only the approved power charger.

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7.2. Navigation Panel
Figure 8: Input panel -keys and elements show an overview of the most important elements for navigating
the menus.
Figure 8: Input -panel keys and elements
ⒶOn/Off button
ⒷBack button (to go back
to the previous display or,
in the menu, one level up)
ⒸOK button
ⒹArrow keys
7.3. Turning the Power On/Off
After you have connected to the Flex server, and the charged battery is inserted, turn on the unit
by pressing the On/Off button Ⓐin the input panel (see Figure 8: Input panel -keys and
elements).
It takes about 20 seconds for the coatmaster® Flex to boot up. To see the time until the coatmaster® Flex
is fully operational, view the boot window on the coatmaster® Flex screen; the boot indicator scale is
shown in the display.
Figure 9: Turning off
To switch off the device, press the On/Off button Ⓐ, then
confirm the action by pressing the OK button Ⓒ.
CAUTION Do not remove the battery to turn off the device!
The device can be forced to shut down when the On/Off button is pressed for more than five
seconds. With this shortcut procedure, a ‘OK button Ⓒ’ confirmation is not necessary.

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7.4. Language Selection
After switching on the coatmaster® Flex, you will be directed to the language selection menu.
Figure 10: Language selection
The default language is English.
Available languages:
Bulgarian, Czech, German, Greek, English,
Spanish, Estonian,
Finnish, French, Hebrew,
Indonesian, Italian, Japanese, Korean, Polish,
Portuguese, Romanian, Russian, Slovenian,
Serbian, Thai, Turkish, Vietnamese, Indian,
Chinese
Move the cursor to your
preferred language,
using the up and down arrow keys Ⓓand the OK
button Ⓒto confirm.
You will then be taken to a 'Settings' menu.
7.5. Wi-Fi Settings
To use your coatmaster® Flex, you must set it up to connect to a Flex server by Wi-Fi connection. The Flex
server can either be a coatmaster® Cloud server (through internet connection) or a coatmaster® Local
server (no Internet required). To connect to the coatmaster® Cloud server, a connection to the Internet is
necessary. If no Internet access is possible, a coatmaster® Local server must be used.
The Wi-Fi connection setup must be conducted only once for the activation of the coatmaster® Flex (see
Figure 11). The login credentials are stored on the device, and afterwards the Flex will automatically try
to connect to previously stored Wi-Fi networks.
If no connection is stored, the Flex will automatically start the Wi-Fi network connection process. To connect
to a new Wi-Fi network, select the “Systems Settings” icon in the main display (see Figure 26), then select
“Network”.
When starting the coatmaster® Flex for the first
time, it will automatically connect to the
coatmaster® Local server, if available. If not, after
language selection, the device opens the Wi-Fi
network subme
nu so that you can select the
network you wish to connect to.
Choose your local Wi-Fi network in the list using
the up/down arrow keys Ⓓ
and the OK
button Ⓒto validate.
The coatmaster® Flex supports two Wi-Fi security
standards: WPA2 (only password required) and
WPA2-Enterprise (username
and password
required).

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Figure 11: Wi-Fi Settings
Figure 12: Password
The Wi-Fi symbol in the status line indicates the
strength of the Wi-Fi signal:
high medium low none
Select the desired Wi-Fi network, using the arrow
keys Ⓓto navigate the keyboard and press the
OK button Ⓒto confirm the characters (see Figure
8: Input panel -keys and elements).
Activate the option “wpa2-enterprise” if the
network requires this security level.
Activate the option “auto-connect” if you want to
store the network credentials on the coatmaster®
Flex for automatically connecting to this network if
it is available upon boot time.
During the connection period, the following
message in the status field appears:
When the Wi-
Fi connection is successfully
esta
blished, you must confirm using the OK
button Ⓒ

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If you have conducted a factory reset and need to re-activate your coatmaster® Flex, the Wi-
Fi network you were connected to before,resetting will be saved and the coatmaster® Flex will
automatically connect to it.
Connection to the internet may be provided by mobile phone hotspots. Internet availability of
course depends on mobile connection stability. Use an Android phone to connect to the
coatmaster® Flex to the Internet. Usage of iOS devices may lead to connection errors.
7.6. Activation
When starting the device for the first time, or
after a factory reset, with the device connected
to the Internet (either with the provided local
server or via the selection of a Wi-Fi network),
the license code and the activation key must be
entered to unlock your device. These details will
have been provided separately by your
purchasing point
. If you are not prompted to
enter the activation code and the coatmaster®
Flex is working, we have already activated the
device for you and no further action is required.
Before entering the license code and activation
key, make sure to select the correct server from
the drop-down menu as follows:
Location
Server to select
Europe
Europe
Americas
US
China
China
Asia (excl. China)
Europe
Local server
Local server
License: hkeqex
Key: oxjzbe
Custom servers
Custom, enter the IP
address.
Figure 13: Activating menu –select server

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If you are prompted to enter the activation key, the cursor moves to the License code field.
When the OK button Ⓒis pressed, a submenu with a keyboard opens. Here the code can be entered,
using the arrow keys Ⓓto navigate the keyboard in conjunction with the OK button Ⓒ(see Figure 8:
Input panel -keys and elements) to validate a character and move to the next one.
To save the license code, use the arrow keys Ⓓto move the cursor down to the ‘Enter’ field, then press
the OK button Ⓒ . You can interrupt the operation at any time by moving the cursor to the ‘Cancel’ key
and confirming with the OK button
Ⓒ .
After saving the license code, the submenu for the activation key will be opened.
Proceed in a similar way to enter and save the activation key.
After the activation key is saved, you will be automatically redirected to the main menu
(see Figure 26: Main display).
Your coatmaster® Flex is now registered with the Flex server. Before you can start measuring, you need
to select the appropriate user level and the units in which you want to measure (metric or imperial) (see
section 8.1.4).
7.7. Operation with coatmaster® Local server
The coatmaster® Local server may be used in cases where no Internet access is available. It provides a
solution for operating the Flex in a local environment, using a small computer (the local server) which
provides its own Wi-Fi network.
Scope of delivery:
•Local server computer (no keyboard, no mouse, no display)
•External power supply
•2 x Wi-Fi antenna
•230V power cord
Figure 14: Enter license code
Figure 15:
Licence code