ElektroPhysik MiniTest 440 Use and care manual

MiniTest 440
Technical Reference and Operating Manual
Advancing with Technology
ElektroPhysik
VERSION: 3.03

ElektroPhysik
Subject to change without notice
ElektroPhysik Dr. Steingroever GmbH & Co. KG
Pasteurstr.15
50735 Koln
Deutschland
Tel: [phone]
Fax: [phone]
Web: www.elektrophysik.com
Mail: info@elektrophysik .com
Disclaimer
Inherent in ultrasonic thickness
measurement is the possibility that the
instrument will use the second rather
than the first echo from the back
surface of the material being
measured. This may result in a
thickness reading that is TWICE what
it should be. Responsibility for proper
use of the instrument and recognition
of this phenomenon rests solely with
the user of the instrument

Contents
ElektroPhysik
Contents
1 General description....................................................................................E-1
2 Technical specification...............................................................................E-1
3 Measuring principle...................................................................................E-2
4 Complete set, spare parts and contents....................................................E-2
【4.1】Complete set ..............................................................................E-2
【4.2】Display.......................................................................................E-4
【4.3】Keypad.......................................................................................E-5
5 Preparation before measurement..........................................................E-6
【5.1】Preparation of the instrument.....................................................E-6
【5.2】Selection of the Probe................................................................E-6
【5.3】Treatment of the measured surface............................................E-7
6Function operation..................................................................................E-8
【6.1】Switch on ...................................................................................E-8
【6.2】Measurement..............................................................................E-8
【6.3】Calibration .................................................................................E-9
〖6.3.1〗Auto calibration ..............................................................E-9
〖6.3.2〗Velocity measurement...................................................E-11
【6.4】Menu display and operations ...................................................E-12
〖6.4.1〗Measuring mode............................................................E-13
〖6.4.2〗Sound velocity of the instrument ..................................E-14
〖6.4.3〗Database........................................................................E-16
〖6.4.4〗Measurement Unit.........................................................E-16
〖6.4.5〗Gain setting...................................................................E-18
〖6.4.6〗Switch off mode............................................................E-19
〖6.4.7〗Contrast.........................................................................E-19
〖6.4.8〗Language.......................................................................E-19
〖6.4.9〗Gauge data ....................................................................E-19
〖6.4.10〗Probe calibration.........................................................E-16
〖6.4.11〗Total reset....................................................................E-20
【6.5】Data..........................................................................................E-20

Contents
ElektroPhysik
【6.6】Data storage .............................................................................E-20
7 Measuring technology...........................................................................E-21
【7.1】Measuring methods................................................................E-21
【7.2】Pipeline measurement method ...............................................E-21
8 Maintenance and precautions.................................................................E-22
【8.1】Power check...........................................................................E-22
【8.2】Precautions...............................................................................E-22
〖8.2.1〗General precautions.....................................................E-22
〖8.2.2〗Precaution during the measuring.................................E-22
9 Standard delivery.....................................................................................E-23
Appendix......................................................................................................E-24

General description
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1 General description
Ultrasonic thickness gauge adopts micro-processor technology and the
ultrasonic measuring principle. It is used to measure the thickness or
sound velocity of metals and various other materials.
Before usage, please read the operation manual carefully to get to know
about the functions of the instrument and master the operations.
2 Technical specification
Display screen: 128×64 LCD dot matrix LCD display (with backlight)
Display digital: 4 digital
Measuring range: 0.65mm～500.0mm (Steel)
Display accuracy: 0.1mm (When the measured value is bigger than
100mm) ;
0.01mm (When the measured value is less than
100mm)
Accuracy: 0.65mm～9.99mm ±0.04mm
10.00mm～99.99mm ±(0.1%H+0.04) mm
100.0mm～500.0mm ±0.3%H
Sound velocity: 1000m/s～9999m/s
Data storage: 10 files including 5000 data
Measurement frequency: 2 times/sec in normal mode
10 times/sec in scan mode
Zero calibration: Auto
Auto switch off: 2 minutes, 5 minutes or shut down manually.
Power: 2 AA batteries, work 64 hours continuously.
Environment: Operating temperature: -20℃～50℃
Storage temperature: -25℃～60℃
Dimensions: 130mm（L）×73mm（W）×24mm（H）
Weight: 190g (Without battery)
Optional Probes:U5.0, U7.5, U10.0, U5HT, U2.0, U5.0E.

Complete set
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3 Measuring principle
The ultrasonic wave emitted from the probe transmitted through the
coupling agents and reach the measured work-piece. One part of then is
reflected on the work-piece surface and the probe receive the reflected
echo. By accurately measuring the ultrasonic travel time, the thickness
will be getting and displayed in figures.
4 Complete set, spare parts and contents
【4.1】Complete set
①Screen
②Keypad
③Battery compartment (back cover )
1
2
3
6
4
5

Display
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④Nameplate(back cover )
⑤Probe socket (identify pin)
⑥USB interface
【4.2】Display
①The measured data file groups and the storage data in each file group.
②Probe type
③Full battery Flat battery indicator
④Measuring mode
⑤Measurement icon and measuring unit
⑥The current selected gain method of the amplifier
⑦The current selected sound velocity
⑧The current measured data
①
②
③
⑤
⑥
④
⑧
⑦

Function
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【4.3】Keypad
①
Power ON/OFF.
Press this key to switch on or switch off the instrument.
②
Menu key.
Press this key to go to the operation menu.
③
Up and down key.
Achieve switch among the menu options in the menu
operation.
Press the up key to switch on or off the backlight.
④
In menu operation, press “OK”to confirm, and “ESC”to
exit.
In Measurement state, press “OK”to save the current data.
⑤
Shortcut key of calibration
Auto calibration, second calibration and sound velocity
measurement are available.
⑥
Shortcut key Data
Press this key to read the stored date.
Note: For the operation of each function key, it will give detailed
instruction in the function operation below.

Function
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5 Preparation before measurement
【5.1】Preparation of the instrument
For the newly purchased instrument, please check the instrument and its
accessory according to the standard delivery table in chapter 9. If you find
it is not the same as the table listed, please contact the manufacture in
time. If the instrument is damaged, please do not use it and contact the
manufacture as soon as possible.
【5.2】Selection of the Probe
Type
Frequency
Measuring range
Temperature
U5.0E
5.0MHz
E-E 3.0～25mm
P-E 1.0～200mm
<60℃
U5.0
5.0MHz
0.8mm～300mm
<60℃
U5HT
5.0MHz
3.0mm～100mm
<350℃
U7.5
7.5MHz
0.65mm～50mm
<60℃
U10.0
10.0MHz
0.65mm～20mm
<60℃
U2.0
2.0MHz
2.0mm～500mm
<60℃
Users can select the suitable probe according to the thickness of the
work-piece to be measured.
U5.0E: The probe can measure the thickness of work-piece through pass
the coating under the E-E mode; and it can be used as the
normal probe under the P-E mode.
U5.0: The probe is used common in many measurements, for example
when the measuring surface is flat or with huge curvature, or the
thickness of the work-piece to be measured is large than 50mm.
U5HT: Mainly used in the thickness measurement when the temperature
is less than 350℃
U7.5: Mainly used in the measurement of thin wall thickness and small

Function
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curvature surface.
U10.0: Mainly used in the measurement of thin wall thickness and small
curvature surface.
U2.0: Mainly used in the measurement of coarse particles such as cast
iron.
【5.3】Treatment of the measured surface
When the surface to be measured is too rough or rusty heavily, please
perform the treatment according to the following methods:
1. Clean the measured surface by grinding, polishing or filing, etc. or use
coupling agent with high viscosity for that.
2. Use coupling agents on the work-piece surface to be measured.
3. Take multiple measurements around the same testing point.
6 Function operation
【6.1】Switch on
Select the correct probe and insert it into the probe socket and then press
to switch on the instrument, the following screen displays:
If you did not insert the probe before switching on the instrument, the
screen will prompt you than “Please insert the probe”. At this moment
insert the probe into the socket and waiting to go to the measuring status.
Note: Please use the standard provided probe, otherwise the
instrument will does not work normally and displaying “Error”.

Measurement
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【6.2】Measurement
There are two ways to access to measurement status, which are:
1. Insert the standard probe and switch on the instrument to go to the
measuring status.
2. During menu operation, press “ESC”to return back to the measuring
status.
Note: From measuring screen, press “OK” to save the current
measured value.
【6.3】Calibration
It will cause error during the primary stage of usage and operating, this
caused by the following three aspects:
1. The probe itself or the temperature variation
2. System error caused by the match of the instrument and the probe.
3. Calculation error caused by the sound velocity set in the instrument is
different from that of the actual material. In order to eliminate the possible
error, the instrument provides three solutions to resolve it.
Press key, and then press or to select the options.

Auto calibration
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〖6.3.1〗Auto calibration
Using different probe, wear out probe and the environment temperature
will all cause measurement error, for these factors, the “Auto calibration”
function is available.
1. Press key, screen displays as following, ,
2. Select “Auto Calibration”, Press “OK”key.
Note: During calibration, ensure the clean of the probe surface
because the attached coupling agents and other dirt will influence the
calibration accuracy. When the measuring temperature changes greatly,
it is recommended to use this function to make sure the measurement is
accuracy.
〖6.3.2〗Velocity measurement
Because the work-piece is made from various materials and even the same
material with different content and processing technology, the sound
velocity will changed. And this change will cause the measuring error. If
the error is not enough to influence the measuring accuracy, it can be
neglected. Otherwise it is necessary to get the accurate sound velocity of
the work-piece to be measured. In this case, the function of velocity
measurement can be used, the usage is as follows:

Velocity
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1. Select or preset the sound velocity almost that of the material.
2. Select a measured sample whose thickness is nearly the same as the
work-piece to be measured and measure the actual thickness A by other
measuring methods (For example, Caliper).
3. Use the Minitest 440 to measure the sample and get a thickness B.
4. Press key, screen displays as following
5. Select “Vel. Meas.”, press “OK”key. Screen displays as following:
6. Press or key to adjust the sound velocity and make
the measured thickness value B is almost or the same with the thickness
value A. Press “OK”key to confirm.
7. Re-measure the sample's thickness and recheck the deviation between
the measured value and the actual value. If the two values are the same,
that sound velocity is the accurate value of the materials.
8. This new velocity will be stored in “Menu-Velocity-Vel. Custom”.

Menu
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【6.4】Menu display and operations
Press to enter the menu screen and press or to
select the options.
Press “OK”to go to the selected option item.
Press “ESC” to exit and go to measuring status.
〖6.4.1〗Measurement
There are two kinds of measuring modes provided, P-E mode and E-E
mode. When the P-E mode is selected, all probes are available. When E-E
mode is selected, the probe U5.0E is available only for measuring the
thickness through pass the coating.

P-E mode
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《6.4.1.1》P-E mode
Under the P-E mode, there are five measuring modes provided, users can
select different measuring modes according to their requirements and
measuring environments.
Press key, select “measurement”, the instrument displays:
1. Standard: display the current value, satisfied with the normal
measuring needs.
2. Minimum: Among one measurement，display the minimum value of
the current measured point. It is suitable for testing the curvature surface
or needs to get the minimum value which is widely used in the thickness
measurement of pipeline.
Note: it is not recommended to use this function when measuring cast
iron or alloy materials.
3. Difference: display the accurate differential value between the
measured value and reference value set by the users, suitable for
quality check to identifying the qualified products whose thickness is in
the admissive error.
4. Limitation: set the upper and lower limit, when the measured thickness
exceeds the preset limit, it will display and give alarm. This measurement
mode is more widely used than differential mode.

E-E mode
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5. Scan: This mode is recommended to measure the high temperature
work-piece
《6.4.1.2》E-E mode
The Echo-to-Echo option allows you to make measurements between two
consecutive back wall echoes. Therefore, a good usage of the
Echo-to-Echo option is for measuring through coatings to measure only
the true metal thickness.
Note: The probe U5.0E is available for this function only.
〖6.4.2〗Sound velocity
Sound velocity plays an important role in measurement. Different material
is of different sound velocity. When the sound velocity is incorrect, it will
cause wrong measured results. There are two ways to select the material's
sound velocity, which are “Materials selection”and “velocity custom”.
1. Press key, select “Velocity”, the screen will display as
follows:
2. Press or to select the options. Press “OK”to confirm.

Materials
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《6.4.2.1》Materials selection
If the material and its sound velocity are known, users can select a sound
velocity which is almost that of the standard material. The “material
options”gives the sound velocity of 9 different materials which can be
select by yourself.
Note: the 9 values are just the theriotic values, if users want to get
accuret measuremnts , please refer to the sound velictiy function and get
he more accurate sound velocity.
The 9 materials are: aluminum, titanium, steel, stainless steel, glass,
copper, brass, polystyrene and nylon.
《6.4.2.2》Velocity Custom
When the sound velocity of 9 materials is not satisfied with the
requirements of the users, there is a sound velocity tabe which give the
sound velocity of various materials in the appendix. Use this table to set
the correct sound velocity.
Note: For more accurate measurements, please refer to 〖6.3.2〗
the function of sound velocity measuring to get more accurate sound
velocity.

Database
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〖6.4.3〗Database
The instrument provides 10 file groups storage space. 500 group data can
be stored in each file group, so the total storage space is 5000 groups data.
In each group data concludes following contents, such as the measured
data, probe type, sound velocity and the selected measuring mode.
In the database, users can set or delete any file in the 10 file groups.
《6.4.3.1》Memory setting
In this function, users can select a file name 01-10 according to your
actual needs. Once the file is selected, it will become the current file
which used to save the measured data.
1. Press key, select “Database”- Memory set”.
2. Select the file name, press “OK”to confirm.
The figure below shows the file is selected but there is no data in it.
The figure below shows the file is selected and there are storage data in it.
Note: If some file is selected and has storage data in it, but the
users change the probe or measuring mode and want to save measured
data to the file again, the instruments will prompt users to select another
file. The set file is not available.

Gain setting
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《6.4.3.2》Memory delete
When the users confirm to delete the used file, this function can be used to
manage the files.
1. Press key, select “Database”- Memory del”.
2. Select the file you want to delete and press “OK”to confirm.
Note: When delete some files, all storage measured data in the file
will be deleted. So users should confirm the invalid data before deleting
files or backup the files in your PC.
〖6.4.4〗Measurement Unit
Users can select the displayed accuracy and the measuring unit. When
selecting the high accuracy, the workpiece surface to be measured should
be smooth, for the purpose of get a accurate value.
1. Press key, select “Measuring unit”
2. Select the unit you want and press “OK”to confirm.
Note: when probe U5HT ad U2.0 is selected, it is recommended to
use 0.1 mm and 0.01in.