Elcometer 456 Model E User manual

Operating Instructions
The New Elcometer 456
Coating Thickness Gauge
Product Manual
456 Dry Film Thickness Gauge
For more information: 1300 287 935 / [e-mail] / www.burwell.com.au
Copyright 2016 Burwell Technologies

Gauge Dimensions: 141 x 73 x 37mm (5.55 x 2.87 x 1.46").
Gauge Weight: Integral: 156g (5.5oz) including batteries;
Separate: 161g (5.68oz) including batteries.
Applicable patents: US6243 661; US5886522; US6762603; US7606671;
GB2306009; GB2367135; GB2342450, DE10131827
© Elcometer Limited 2012 - 2015. All rights reserved. No part of this document may be reproduced, transmitted,
transcribed, stored (in a retrieval system or otherwise) or translated into any language, in any form or by any
means (electronic, mechanical, magnetic, optical, manual or otherwise) without the prior written permission of
Elcometer Limited.
www.elcometer.com
TMA-0489 Issue 10
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Section
Page
1
GAUGE OVER
VIEW AND BOX CONTENTS...........................................................
4
2
GETTING ST
AR
TED.................................................................................................
5
3
T
AKING A
READING.................................................................................................
7
4
CALIBRA
TING THE GAUGE....................................................................................
8
5
THE DISPLA
Y...........................................................................................................
9
6
THE GAUGE FEA
TURES.........................................................................................
12
7
MEASUREMENT
MODES (ST)................................................................................
25
8
BA
TCHING (ST)........................................................................................................
26
9
DOWNLOADING DA
TA USING ELCOMASTER (BST)............................................
35
10
ELCOMASTER MOBILE
APPS (ST)........................................................................
55
1
1
CLOUD COMPUTING USING ELCOMASTER (ST)................................................
56
12
GETTING
THE MOST OUT OF ELCOMASTER......................................................
58
13
CALIBRA
TING THE ELCOMETER 456 (EBST).......................................................
60
14
CHANGING THE WELCOME SCREEN (BST).........................................................
64
15
GAUGE FIRMW
ARE UPDATES (BST)....................................................................
65
16
GAUGE ICONS & ERROR CODES (EBST).............................................................
66
17
GAUGE MENU STRUCTURES (EBST)...................................................................
70
18
ABOUT
IMO PSPC (ST)...........................................................................................
74
19
GAUGE
TECHNICAL SPECIFICATIONS (EBST)....................................................
75
20
PROBE
TECHNICAL SPECIFICATIONS (EBST).....................................................
76
21
GAUGE & PROBE
ACCESSORIES (EBST)............................................................
80
22
ADDITIONAL
REFERENCE INFORMATION...........................................................
82
23
LEGAL
NOTICES & REGULATORY INFORMATION..............................................
83
24
INDEX.......................................................................................................................
85
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CONTENTS
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WELCOME
Thank you for your purchase of this Elcometer 456 Coating
Thickness Gauge. Welcome to Elcometer.
Elcometer are world leaders in the design, manufacture and supply of
coatings inspection equipment. Our products cover all aspects of
coating inspection, from development through application to post
application inspection.
The Elcometer 456 Coating Thickness Gauge is a world beating
product. With the purchase of this gauge you now have access to the
worldwide service and support network of Elcometer.
For more information visit www.elcometer.com
ABOUT YOUR GAUGE
The Elcometer 456 Coating Thickness Gauge is a handheld gauge for
fast and accurate measurement of the thickness of coatings on metal
substrates.
The gauge is available in four models; Model E, B, S and T.
This manual describes the operation of all the Elcometer 456 models
and indicates, where necessary, which specific model(s) the feature is
available on in brackets after the feature.
All versions of the gauge feature an easy-to-use menu driven
graphical interface which guides the user through tasks such as
gauge configuration and calibration adjustment.
The gauge is available either with a built-in integral probe or as a
separate probe version. A wide range of probes is available to suit
requirements.
CONVENTIONS IN THESE INSTRUCTIONS
The Elcometer 456 is operated using a simple menu structure which
helps you get the most from your gauge.
As an example, the Languages option is located within Setup which is
under the Menu softkey and is shown in these instructions as:
Menu/Setup/Language
3
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Packaging
The gauge is packed in cardboard packaging. Please ensure that this
packaging is disposed of in an environmentally sensitive manner.
Please Consult your Local Environmental Authority for further
guidance.
1 GAUGE OVERVIEW AND BOX CONTENTS
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Gauge Overview
1 LED Indicators - Red (left), Green (right)
2 Colour Screen
3 Multifunction Softkeys
4 On/Off Key
5 Internal Probe / Separate Probe Connection
6 USB Data Output Socket (below cover)
7 Battery Compartment (¼ turn open/close)
8 Wrist Strap Connection
Box Contents
§ Elcometer 456 Coating Thickness Gauge
§ Calibration Foils (Integral gauges)
§ Test Certificate
§ Wrist Harness
§ Protective Case (B, S & T models)
§ Transit Case (T model)
§ 1 x Screen Protector (S & T models)
§ 2 x AA Batteries
§
USB Cable & ElcoMaster™ Software
(S & T models)
§ User Guide
1
2
3
4
5
6
8
7
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2 GETTING STARTED
Fitting the batteries
Your gauge is supplied with batteries ready to fit. To insert or
replace the batteries:
1. Lift the latch at the back of the gauge and
+
rotate anticlockwise.
2. Remove the battery compartment cover.
3. Insert 2 batteries (type LR6/AA) taking care to
ensure correct battery polarity.
4. Replace battery compartment cover and rotate
the latch clockwise to close.
The battery condition is indicated by a symbol in the top right of the
display:
• Full symbol (orange) = batteries at full capacity
• Empty symbol (red, flashing) = batteries at lowest sustainable
level
To maximise battery life, ensure that Auto Screen Brightness is
selected, or the screen brightness is low via Menu/Setup/Screen
Settings/Screen Brightness and the Bluetooth is disabled (if you
are not using it) via Menu/Bluetooth and uncheck the Enable
Bluetooth radio button.
Connecting the probe (separate gauges only)
1. Rotate the probe plug to align the pins
2. Screw in the collar - clockwise
1
2
1
2
+
+
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Fitting the wrist harness
A wrist harness is supplied with each gauge. This can be fitted into the
right hand side of the gauge using the wrist strap connection. To fit the
harness, pass the harness loop through the wrist strap connection,
pass the main wrist harness through the loop and pull.
Switching the gauge on/off
ŸTo switch on, press on/off key for more than 0.5 seconds.
ŸTo switch off, press and hold on/off key until the screen blanks.
The gauge will switch off automatically after 5 minutes of inactivity.
To switch off this feature, press Menu/Setup and uncheck the Gauge
Auto Off radio button.
Selecting a language
When the gauge is switched on for the first time after dispatch from the
Elcometer factory the display will show the language selection screen:
1. Select your language using the éê softkeys
2. Follow the on screen menus
To access the language menu when in a foreign language:
1. Switch the gauge OFF
2. Press and hold the left softkey and switch the gauge ON
é
3. Select your language using the softkeys
ê
The language can also be changed via Menu/Setup/Language
Selecting units
The Elcometer 456 can display readings in both metric and imperial
measurement units (microns, millimetres, mils or inches).
The appropriate measurement unit can be changed via
Menu/Setup/Units
Adjusting the beep volume
Each time a measurement is taken, the gauge will beep. The beep
volume can be adjusted and can even be switched off via
Menu/Setup/Beep Volume
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3 TAKING A READING
1. Hold the gauge (integral) or the probe by its sleeve (separate gauge)
2. To take a reading, bring the probe down onto the surface whilst
holding it perpendicular
3. For subsequent readings, lift the probe off and then replace it onto
the coated surface
ü
DO
•
Hold the probe by the probe sleeve
•
Gently place the probe onto the surface
•
Allow the sleeve to make contact with the
surface - to improve accuracy
û
DO NOT
•
Drag the probe over the coated surface
•
Bang the probe down hard onto the surface
•
Allow the probe to hover over the surface as
this could result in a false reading
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4 CALIBRATING THE GAUGE
Calibration adjustment is the process of setting the gauge to known values
of thickness to ensure accuracy on different substrate types, shapes and
surface finishes.
The calibration of the gauge can be adjusted using several different
methods for use in accordance with National and International Standards
and the calibration adjustment method chosen depends on the condition
of the substrate to be measured.
1. Press the Cal softkey
2. For alternative calibration methods,
select Cal/Cal Method
3. Select Calibrate and follow the on-screen
instructions
4. When prompted place the probe on the
centre of the foil(s) or on the uncoated
metal substrate
Foils can also be stacked to increase the thickness value.
The calibration method is indicated on the screen by a symbol - see
Multiple Calibration Methods on page 18.
Not all calibration methods are available for all gauge types. For a
comprehensive guide to each calibration method and the calibration
adjustment process see Multiple Calibration Methods on page 18.
When using an FNF probe it must be calibrated in both the ferrous mode
and in the non-ferrous mode to ensure accuracy of reading.
When using an Ultra/Scan probe in Scan Mode or Auto Repeat Mode
(see Measurement Modes on page 25), it must be calibrated using either
the Smooth or Rough/2 Point calibration method - see Multiple
Calibration Methods on page 18.
For more information on calibrating the Elcometer 456, see page 60.
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5 THE DISPLAY
The Elcometer 456 gauge has a colour display:
• White characters: All measurement and statistical values.
• Orange characters: All menu items, statistical parameters and
symbols.
• Red: A measurement value which is outside set limits; a limit symbol
when the limit value has been exceeded (Model S & T).
• - - - indicates reading outside range of probe.
If you see the Cal softkey flashing, the gauge should be calibrated.
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Model
a
Green LED
EBST
b
Battery Life Indicator
EBST
c
Bluetooth On
ST
d
Substrate Type - F, N, FNF
EBST
e
Calibration Method
BST
f
Reading Outside Calibration Warning On
T
g
Upper Limit On
ST
h
Units of Measurement - µm, mils, mm, inch
EBST
i
Batch Type - normal, counted average, IMO
ST
j
Menu Softkey
EBST
k
Display Softkey
BST
l
Red LED - Reading outside limit/ IMO Fail
ST
m
Batch Name (when in batching)
T
Date & Time (when not in batching)
ST
n
User Selectable Statistics - 4 rows
BST
o
Reading Value
EBST
p
Calibration Softkey
EBST
q
Batch / Data Softkey
BST
r
Bar Graph - highest, lowest & average reading
BST
s
Lower Limit On
ST
t
Measurement Mode - Standard, Auto Repeat, Scan
T
u
Softkeys
EBST
v
Run Chart - last 20 readings
ST
w
Upper & Lower Limits On
ST
For a complete list of icons, see “Gauge Icons” on page 66 - 68
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Reading display size (BST)
The character size of the measurement value on
the display increases or decreases depending on
the number of statistics that are displayed; or if a
graph is displayed on the measurement screen .
To maximise the reading size, either:
Ÿreduce the number of statistical values that
are displayed via Display/Statistics/Select
Statistics, or
Ÿdisplay the reading only by checking the
Display/Readings Only radio button.
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6 THE GAUGE FEATURES
The Elcometer 456 coating thickness gauge has a number of easy to use
features and functions to help the user be more efficient. These include:
Fast reading rate (EBST)
The Elcometer 456 is capable of taking greater than 70 accurate,
repeatable and reproducible measurements every minute.
Easy to use menu structure in more than 30 languages (EBST)
Designed to be intuitive, the Elcometer 456 menus and calibration
instructions are available in multiple languages via
Menu/Setup/Language.
Bright colour screen (EBST)
Each gauge is supplied with a scratch and solvent resistant 2.4"
(60mm) TFT colour screen which clearly displays the reading. The
screen brightness can be adjusted manually (EBST) - via
Menu/Setup/Screen Settings/Screen Brightness/Manual or
automatically (BST) using the gauge’s ambient light sensor which can
be switched on via Menu/Setup/Screen Settings/Screen
Brightness/Auto.
Battery or USB Powered (EBST)
Each gauge can be powered either using 2 x AA lithium, alkaline or
rechargeable batteries or by connecting the Elcometer 456 to your PC
via a USB cable.
Two year gauge warranty (EBST)
The Elcometer 456 gauge is supplied with a 1 year warranty against
manufacturing defects. To extend this warranty to 2 years, simply
register your gauge via the elcometer.com website.
Emergency light mode (BST)
If all the lighting fails during an inspection in dark environments, the gauge
is fitted with an emergency light feature - once selected
(Menu/Emergency Light), the display turns bright white. To switch off this
function either press and hold the Esc softkey or power off the gauge.
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Automatic rotating display (BST)
Using the internal accelerometer, the gauge
will automatically rotate the display to allow
you to easily read the thickness value in any
orientation - 0°, 90°, 180° & 270°.
This function can be switched off by un-checking
Menu/Setup/Screen Settings/Auto Display
Rotation
Gauge firmware updates (BST)
Using Elcometer’s free data management software, ElcoMaster™,
users can receive prompts when there is a gauge firmware update
available for their model version.
When the Elcometer 456 is connected (via USB), to any computer
with an internet connection and with ElcoMaster™ installed,
ElcoMaster™ highlights the availability of a firmware update,
identifies to the user the new features and guides the user through the
gauge firmware update process.
Caution, before upgrading your gauge firmware, ensure that you have
downloaded all inspection readings from the gauge. For more
information regarding ElcoMaster™ see page 35 Downloading Data.
Bluetooth™ (ST) and USB Data output (BST)
Elcometer 456 gauges have the ability to transfer data via USB (BST)
to a computer or wirelessly via Bluetooth™ (ST) technology to PC’s,
PDA’s or mobile phones which are Bluetooth™ enabled using
ElcoMaster™ or ElcoMaster™ Mobile Apps respectively.
Bluetooth™ data output can be switched on via
Menu/Bluetooth/Enable Bluetooth. For more information
regarding ElcoMaster™ see page 35 Downloading Data.
ElcoMaster™ Data output (BST)
Users can download data from any Elcometer gauge directly into
ElcoMaster™ by connecting the gauge to the PC and following the on
screen prompts.
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Symbol / icon
Model
Description
η BST The number of readings taken
x
BST
Mean (average)
σ
BST
Standard deviation
Hi BST Highest reading taken
Lo
BST
Lowest reading taken
cv% BST Coefficient of variation; The COV is defined as the ratio of
the standard deviation to the mean and is a normalised
measure of dispersion - when comparing batches with
widely different means, one should use the coefficient of
variation for comparison instead of standard deviation (σ).
Once the data has been transferred to the computer, the user can
produce professional reports in seconds. Data can also be transferred
®
into programs, such as Excel , in a similar manner.
For more information regarding ElcoMaster™ see page 35
Downloading Data.
Counted Average (BST)
Users can define the number of individual gauge readings to be taken
within a spot or measurement area using the Counted Average
function. The gauge stores the average of the individual readings into
memory. The individual readings within the counted average are not
saved. Select Display/Statistics/Counted Average.
Counted Average is also available when in Batching (ST) - see
BatchTypes on page 32.
On Screen Statistics (BST)
User selectable statistical and general measurement information can
be displayed on the gauge. The information to be displayed can be
selected and managed by selecting the Display softkey.
ŸUp to 8 statistics can be selected to be displayed on the reading
screen via Display/Statistics/Select Statistics
ŸEnsure that Display/Readings & Selected Stats is also checked.
ŸTo view all statistics select Display/Statistics/View All
The following statistical and general information can be displayed on
your gauge:
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Symbol / icon Model
Description
EIV
BST
Elcometer index value; Used to assess a coating’s
overall quality. Ideal for use in the automotive refinishing
industry. USA patent number US7606671.
NDFT ST Nominal dry film thickness;
The target or specified dry
film coating thickness value.
IMO PSPC
ST
International Maritime Organisation’s Performance
Standard for Protective Coatings clearly defines
the
acceptance criteria for a coating. The Elcometer
456
can be quickly set up to display these parameters:
% > NST The percentage of readings greater than or equal to
the
Nominal Dry Film Thickness Value.
90
%
100
ST
The percentage of readings between 0.9 x NDFT and
the NDFT.
90:10 ST Displays either pass (ü) or fail (X)
To pass the IMO PSPC 90/10 rule:
ŸAt least 90% of all dry film thickness readings shall
be greater than or equal to the NDFT value, and
Ÿnone of the remaining measurements shall be
below
0.9 x NDFT
X!
ST
If all the measurements taken at any point are greater
than 0.9 x NDFT, but less than 90% of the readings
are
greater than or equal to the NDFT, were the
inspection
to stop, then the IMO PSPC condition would be a
fail.
Statistically, however, were more measurements to
be
taken which were all greater than or equal to the NDFT
,
then there would come a time when the IMO
PSPC
condition returns to a pass. This is depicted by
the
“failing” icon - X!. For more information on the
IMO
PSPC see About IMO PSPC on page 74.
ST
Low Limit
ST
High Limit
ST Number of readings below the low limit
ST
Number of readings above the high limit
User definable warning limits can be set. Once
the
reading exceeds the limit the gauge notifies the user
by
turning the reading and relevant limit icon red,
flashing
the red LED, and sounding the alarm beep. For
more
information see Limits on page 23.
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Analogue Bar Graph (BST)
By selecting Display/Readings & Bar Graph
the user can view an analogue representation
of the current thickness value together with
the highest (Hi), lowest (Lo) and average (x)
reading. The graph is updated automatically
when each reading is taken.
The values on the top left and right of the bar
signify the measurement range using the
thin calibration foil value less 10% and the
thick calibration foil value plus 10%. If
calibrated using the factory calibration, the
probe scale range ±10% is used. If limits are
set, the limit values ±10% are used and the
relevant limit icon is displayed above the bar
in the appropriate position.
With Limits: The current measurement is
displayed as a white or red bar; white if
within set limits, and red if outside set limits.
If below the lower limit, the left arrow head
is also filled red and if above the upper limit,
the right arrow head is filled red.
If the next measurement taken is within set limits, the left or right arrow
outline will remain red to signify that the previous reading was outside
set limits.
Without Limits: The current measurement is displayed as a white bar.
If outside the measurement range, the left or white arrow head is also
filled white.
If the next measurement taken is within range, the left or right arrow
outline will remain white to signify that the previous reading was
outside range.
4 Users can choose to show Readings & Selected Stats (ST) - see On Screen
Statistics on page 14, Readings & Run Chart (ST) - see Run Chart on page 17,
Readings & Bar Graph (BST) or Readings Only (BST). Readings & Run Chart is
only available when in Batching, it is not available in Standard (Immediate) Mode.
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Run Chart (ST)
By selecting Display/Readings & Run Chart the user can view a line
trend graph of the last 20 measurements. The graph is updated
automatically when each reading is taken.
Up to five horizontal axes are displayed representing different values /
statistics as follows:
ŸHighest reading in the batch “ ”
ŸLowest reading in the batch “ ”
(for batches of more than one reading)
ŸMean of readings in the batch “ ”
(for batches of more than one reading)
ŸHigh limit for the batch “ ” (when enabled)
ŸLow limit for the batch “ ” (when enabled)
The readings are displayed as white or red points; white if a reading is
within limits (or no limits have been set), and red if outside set limits.
When in Scan Mode (T) - see Measurement Modes on page 25, the
Analogue Bar Graph is displayed on screen whilst scanning. This is
replaced by the Run Chart when the scan is completed.
The highest and lowest reading for each
scan is displayed on the run chart above and
below the average value together with either
a white or red vertical line; white if within set
limits, and red if outside set limits.
The highest, average and lowest reading
values for the last scan are also displayed
under the run chart.
4 Users can choose to show Readings & Selected Stats (ST) - see On Screen
Statistics on page 14, Readings & Run Chart (ST), Readings & Bar Graph (BST) -
see Analogue Bar Graph on page 16 or Readings Only (BST). Readings & Run
Chart is only available when in Batching, it is not available in Standard (Immediate)
Mode.
Time and date (ST)
Once the appropriate time and date has been set (Menu/Setup/Time and
Date), the user can display the time and date at the top of the Elcometer
456 display via Menu/Setup/Time and Date/Display Time and Date.
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ŸThe time format can be set to either the 12 hour or 24 hour clock via
Menu/Setup/Time and Date/Set Format/Set Time Format
ŸThe date format can be set to either dd/mm/yyyy, mm/dd/yyyy or
yyyy/mm/dd via Menu/Setup/Time and Date/Set Format/Set
Date Format
Please note that the time and date is replaced by the batch name
when the gauge is in Batch mode.
When a batch is created, re-opened (or when the gauge is switched
on whilst in batch mode) and when each reading is taken, the time and
date details are stored within the batch - allowing the user to have an
accurate record of when the measurements were taken. The time and
date stamp for each reading is displayed on ElcoMaster™.
Multiple calibration methods (EBST)
Calibration adjustment is the process of setting the gauge to known
values of thickness to ensure accuracy on different substrate types,
shapes and surface finishes and is often referred to as simply the
“calibration”.
The calibration of the gauge can be adjusted using several different
methods for use in accordance with National and International
Standards and the calibration adjustment method chosen depends on
the condition of the substrate to be measured.
The calibration method is indicated on the screen by a symbol.
When using an FNF probe it must be calibrated in both the ferrous
mode and in the non-ferrous mode to ensure accuracy of reading.
When using an Ultra/Scan probe in Scan Mode or Auto Repeat
Mode (see Measurement Modes on page 25), it must be calibrated
using either the Smooth or Rough/2 Point calibration method.
When switching between the Scale 1 and Scale 2 functions of the
scale 2 probes (Menu/Setup/Probe) the Elcometer 456 should be re-
calibrated to ensure accuracy across the appropriate measurement
range.
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Method
Description Icon Model
Zero
A simple method for calibrating on smooth
substrates. Simply place the probe on th
e
uncoated metal and the gauge will adjust
the
calibration accordingly. Also known as the
single
point calibration method.
BST
Smooth This is a more accurate method of calibrating
the
gauge than the Zero method as it requires
the
user to calibrate the gauge using a foil and
the
un-coated substrate.
The gauge’s on-screen calibration
instructions
will guide the user through the calibration
routine.
When selecting the foil value, the user
should
choose a thickness that is close to but
greater
than the expected dry film thickness value.
BST
Rough /
2 Point
Ideal for calibrating the gauge on both
profiled
metal substrates (when the uncoated surface
is
accessable) and substrates where there
are
significant differences in the magnetic (F)
or
electrical (N) properties of the substrate.
For
example cast iron, high carbon steel or
some
non-magnetic stainless steel alloys.
The calibration requires 2 foil values - one
above
the expected dry film thickness, and one below.
The gauge will guide the user through th
e
process with on screen instructions.
EBST
Zero Offset
This is the ISO 19840 method for coatings on
steel surfaces roughened by blast cleaning
or
when the substrate profile is unknown, or
not
accessible. The calibration uses the smoot
h
surface technique, and a correction value
(zero
offset) is applied to each reading to account
for
the effect of the roughened surface; the value
of
the offset depends on the initial surface
profile
and is described in ISO 19840 as follows:
ST
Profile according to
ISO 8503-1
Correction Offset
*
Value µm (mils )
Fine
10 (0.4)
Medium
25 (1.0)
Coarse
40 (1.6)
* mils values are calculated and for reference
as ISO 19840 indicates metric units only
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456 Dry Film Thickness Gauge
20 of 89For more information / 1300 287 935 [e-mail] / www.burwell.com.au