ElektroPhysik MiniTest 4500 User manual

ElektroPhysik
Operating instructions
Coating thickness gauges
MiniTest 2500 and MiniTest 4500

© ElektroPhysik MiniTest 2500 - MiniTest 4500 2 of 73
© ElektroPhysik
Version 1.0 14.06.2018
Gauge software Version: from 1.0.1
Sensor Software: from 1.0
Subject to technical change without notice.
ElektroPhysik
Dr. Steingroever GmbH & Co. KG
Pasteurstr. 15
50735 Cologne
Germany
Tel.: [phone]
Fax.: [phone]
Internet: http://www.elektrophysik.com/
Mail:: [e-mail]

Index
© ElektroPhysik MiniTest 2500 - MiniTest 4500 3 of 73
Index
1. Introduction...............................................................................................................................8
2. First steps..................................................................................................................................9
2.1 Inserting batteries and connecting the sensor .......................................................................9
2.2 Operation of the gauge........................................................................................................10
3. Description of the measuring system....................................................................................11
3.1 Gauge.................................................................................................................................11
3.1.1 General.......................................................................................................................11
3.1.2 Front view...................................................................................................................11
3.1.3 Operating keys............................................................................................................12
3.1.3 Interfaces....................................................................................................................12
3.1.4 Power supply ..............................................................................................................12
3.1.4.1 Batteries and rechargeable batteries........................................................................12
3.2 Sensors...............................................................................................................................13
3.2.1 Sensors of the MiniTest 1100 –2100 - 3100 - 4100 series..........................................13
3.2.1.1 Adaptation of sensor types F05, F1.6, F3, F1.6/90, F2/90, F10, F20, N.08 Cr,
N02, N1.6, N1.6/90, N2/90, CN02 and FN1.6, FN1.6P, FN 1.6/90, FN2/90.......................13
3.2.1.2 Adaptation of sensor types N10, N20 and N100.................................................14
4. Measuring, Storage and Data Processing in DIRECT or APPL-BATCH mode....................15
4.1 Switch on / start-up screen..................................................................................................15
4.2 Structure of the APPL-BATCH system...........................................................................17
4.3 Switching APPL-BATCH mode on / off..........................................................................18
4.4 Displaying the number of active APPL-BATCH..............................................................19
4.5 Selection of an APPL memory.......................................................................................19
4.6 Selection of a BATCH memory......................................................................................19
5. Measuring................................................................................................................................20
5.1 Important Notes on Coating Thickness measurement.........................................................20
5.1.1 Interpretation of readings ............................................................................................20
5.2 Basic settings......................................................................................................................20
5.3 Preparing measurement......................................................................................................21
5.3.1 Calibration...................................................................................................................21
5.4 Taking readings...................................................................................................................21
5.4.1 Taking readings without using the sensor stand..........................................................21
5.4.2 High-precision stand ...................................................................................................22
5.4.3 Duplex coating systems..............................................................................................22
5.5 Errors during measurement.................................................................................................22
5.6 Measurement on high temperatures using high-temp sensors ............................................22

Index
© ElektroPhysik MiniTest 2500 - MiniTest 4500 4 of 73
6. Calibration...............................................................................................................................24
6.1 General notes on calibration................................................................................................24
6.2 Calibration methods ............................................................................................................25
6.2.1 Factory pre-setting......................................................................................................25
6.2.2.1 Zero Calibration.....................................................................................................25
6.2.2.2 Two-point Calibration.............................................................................................25
6.2.2.3 Multi-point Calibration............................................................................................25
6.2.2.4 Two-point Calibration without zero.........................................................................26
6.2.2.5 Calibration through a coating (CTC) ......................................................................26
6.4.3.1 Calibration of FN-type sensors .............................................................................26
7. Calibration...............................................................................................................................27
7.1 Activate factory settings.................................................................................................27
7.2 Zero Calibration.............................................................................................................27
7.3 Two-point calibration (zero setting plus one calibration foil)...........................................28
7.3 Multi-point calibration (zero setting plus up to four calibration foils) ...............................29
7.5 Two-point calibration using two calibration foils without zero calibration........................30
7.6. Calibration Through the Coating....................................................................................33
7.7. Sensors N10 and N20 ...................................................................................................34
7.7.1 Standardization (Acquisition of Infinite Value) .............................................................34
7.7.2 Two-point calibration (zero setting plus one calibration foil) ...................................34
7.7.3 Elimination of dielectric interferences of the coating material.................................35
7.8 N100 Sensor .................................................................................................................35
7.8.1 Standardization (Acquisition of Infinite Value)........................................................35
7.8.2 Two-point calibration (zero setting plus one calibration foil) ...................................36
7.8.3 Elimination of dielectric interferences of the coating material.................................36
7.9 Sensor F20....................................................................................................................37
7.10 Sensor F50....................................................................................................................37
7.11 Tube sensors F1.6/90, F2/90, N1.6/90 and N2/90.........................................................38
7.12 Chrome Coatings on Copper.........................................................................................38
7.13 Sensor CN02.................................................................................................................38
7.14 Recalibration in an APPL memory line ..............................................................................38
7.15 Shot-blasted and rough surfaces..................................................................................40
7.15.1 General..................................................................................................................40
7.15.2 Method A (roughness Rz > 20µm).........................................................................40
7.15.3 Method B (roughness Rz < 20µm).........................................................................40
7.15.3 Method C Calibration with two calibration foils of different thickness......................40
8. Data Management ...................................................................................................................41
8.1 Batches...............................................................................................................................41

Index
© ElektroPhysik MiniTest 2500 - MiniTest 4500 5 of 73
8.1.1 General.......................................................................................................................41
8.2 Offset ..................................................................................................................................41
8.3 Block size............................................................................................................................41
8.4 Upper limit / Lower limit .................................................................................................41
8.5 Single values / Continuous measurement mode............................................................42
8.6 Measuring with statistics .....................................................................................................42
8.7 Taking a series of measurement with statistical calculation...........................................43
8.8 Deleting outliers or erratic readings ...............................................................................43
8.9 Storage capacity overflow..............................................................................................44
8.10 Display or print-out of a series of measurements...............................................................44
8.10.1 Single value statistics.............................................................................................44
8.10.2 Block value statistics..................................................................................................45
9. Deletion....................................................................................................................................46
9.1 Deleting the last reading................................................................................................46
9.2 Deleting statistical values ..............................................................................................46
9.4 Deleting a series of measurements including limits and statistics within an APPL-BATCH
memory.....................................................................................................................................46
9.5 Deleting limit values within an APPL-BATCH memory.........................................................46
9.6 Deleting all series of measurements incl. statistics, limits and calibration values of an
APPL memory...........................................................................................................................47
9.7 Total Reset....................................................................................................................47
10. Data output and transfer.......................................................................................................48
10.1 Printing data......................................................................................................................48
10.2 Data transfer to PC (terminal program)..............................................................................48
10.3 Read out data via a PC.....................................................................................................49
11. Further functions ..................................................................................................................50
11.1 Initialization .......................................................................................................................50
Initial functions and settings.................................................................................................50
11.1.1 Total Reset ........................................................................................................50
11.1.2 LCD Segment Test ............................................................................................50
11.2 Gauge configuration..........................................................................................................50
11.2.1 Blockgröße................................................................................................................50
11.2.2 Display illumination................................................................................................51
11.2.3 Keypad illumination................................................................................................51
11.2.4 Acoustic signal.......................................................................................................51
11.2.5 Time and date stamp.............................................................................................51
11.2.6 Time and date........................................................................................................51
11.2.7 Measuring unit: ‘metrical’ - Inch’ (imperial) .............................................................52
11.2.8 Automatic data transfer in continuous mode ..........................................................52

Index
© ElektroPhysik MiniTest 2500 - MiniTest 4500 6 of 73
11.2.9 Timestamp.............................................................................................................52
11.2.10 Setting of display colours for measurements......................................................52
11.2.11 Setting of display colours for readings above preset limits .................................53
11.2.12 Setting of display colours for readings below preset limits..................................53
11.2.13 Optional alarm output –Setting of signal length of the measuring value.............53
11.2.14 Optional alarm output –Setting of signal length for readings above limits..........53
11.2.15 Optional alarm output –Setting of signal length for readings below limits ..........53
11.2.16 Configuration of the optional foot switch.............................................................53
11.2.17 Pairing of a BLUETOOTH printer.......................................................................53
11.2.19 Format of logged measuring values...................................................................54
11.2.20 SENSOR INIT....................................................................................................54
11.2.21 „POWER SUPPLY“ Setting................................................................................54
11.2.22 „POWER OFF“ Switch off time...........................................................................55
11.2.23 SYSINFO...........................................................................................................55
11.2.24 Table of basic settings for MiniTest 4500................................................................56
11.2.25 Table of basic settings for MiniTest 2500................................................................57
12. Accessories...........................................................................................................................58
12.1 General.............................................................................................................................58
13. Care and maintenance..........................................................................................................59
13.1 Care..................................................................................................................................59
13.1.1 Using NiMH rechargeable batteries...........................................................................59
13.2 Maintenance......................................................................................................................60
14. Technical data.......................................................................................................................61
14.1 Gauge specification...........................................................................................................61
14.2 Sensor specifications ........................................................................................................62
14.3 Standard supply................................................................................................................65
14.3.3 Coating thickness gauge MiniTest 2500/ 4500 with interchangeable sensor.............65
14.3.4 Interchangeable sensors for MiniTest 2500/4500......................................................65
14.4 Accessories.......................................................................................................................66
15. Annexe...................................................................................................................................67
15.1 Error messages and trouble shooting................................................................................67
15.2 Statistical terms.................................................................................................................68
15.3 Safety notes......................................................................................................................69
15.4 Declaration of conformity according to EU directive...........................................................70
15.5 Return of used equipment.................................................................................................70
15.6 Service-Adressen..............................................................................................................71
16. Change history......................................................................................................................72
17. Index ......................................................................................................................................73

Index
© ElektroPhysik MiniTest 2500 - MiniTest 4500 7 of 73

1. Introduction
© ElektroPhysik MiniTest 2500 - MiniTest 4500 8 of 73
1. Introduction
The new coating thickness gauges MiniTest 2500 and MiniTest 4500 combine high precision modern
measuring technique and a classic handling concept.
Coating thickness gauges MiniTest 2500 and MiniTest 4500 measure non-destructively according
to the magnetic induction or the eddy current principle depending on the sensor type connected to
the gauge. The gauges comply with the following standards:
DIN EN ISO 1461
DIN EN ISO 2064 DIN EN ISO 2178
DIN EN ISO 2360
DIN EN ISO 2808
DIN EN ISO 19840
ASTM B244
ASTM B499
ASTM D7091
ASTM E376-03
AS 3894.3-2002
SS 18 41 60
SSPC-PA 2
The portable gauge is used for quick and precise non-destructive coating thickness measurement in
the field of industrial corrosion protection and is used by manufacturers and end users of corrosion
protected products, by authorities and inspectors,in electroplating and paint shops as well as in
chemical industry, automotive production, ship building, aviation and tool and machine engineering.
MiniTest coating thickness gauges are equally qualified for use in a laboratory as well as in rough
industrial environments or construction sites thanks to their particularly rugged housing designed in
protection class IP65.
A broad selection of measuring sensors is available for the MiniTest 2500/4500 line of coating
thickness gauges allowing to handle standardapplications as well as more complexmeasuring tasks
as for example measurement in tubes or thick coatings up to 100mm coating thickness.
The intelligent MiniTest-sensors also cope with sophisticated applications such as measurement of
objects with unusual geometry or coatings with special material properties. This wide range of
applications is possible through memorization of corresponding key datawithin the sensor which are
automatically taken into account at each measurement
The scope of application is determined by the sensor connected to the gauge:
F-type sensors work according to the principle of magnetic induction and can measure non-
magnetic coatings such as paint, enamel, rubber, aluminum, chrome, copper, zinc etc applied on
iron and steel (including steel alloys and hardened magnetic steels).
N-type sensors work according to the eddy current principle and measure insulating coatings
such as paint, anodizing, ceramics etc. applied on all non-ferrous metals (for example aluminum,
copper, zinc die cast, brass etc.) including austenitic steels.
FN-type sensors combine both principles and identify the substrate underneath the coating thus
automatically switching to the correct measuring principle to measure on base material steel or
non-ferrous metal.
Modern data administration allows simple access to the internal data memory with maximum
storage capacity of up to 2 million measuring values. MiniTest 4500 features a data memory with
‘APPL-BATCH mode’allowing measurement and storage of readings in a user definable memory.
A total of up to 2,000,000 readings and more than 9,800 batches can be evaluated according to
different statistical principles. The option limit setting (LIMIT) offers to determine Cp and Cpk
values.
Both models feature a USB interface to connect to notebooks and PCs. MiniTest 4500 additionally
offers a Bluetooth interface for wireless data transfer to mobile devices like Smartphones and
printers directly on site..

2. First steps
© ElektroPhysik MiniTest 2500 - MiniTest 4500 9 of 73
2. First steps
This section addresses first time users of a MiniTest coating thickness gauge introducing the basic
functions of the gauge and demonstrating how to take readings.
2.1 Inserting batteries and connecting the sensor
a) Withdraw the gauge and the batteries from the storage case.
b) Untighten the screws of the battery compartment on the back of the gauge using for example a
coin and open the battery compartment.
c) Insert the batteries from the supply schedule observing correct polarity (see illustration).
d) Close the battery compartment and fix the lid with the screws.

2. First steps
© ElektroPhysik MiniTest 2500 - MiniTest 4500 10 of 73
2.2 Operation of the gauge
Press the red ON-OFF key to switch the gauge on.
a) The gauge is now switched to measuring mode (see illustration.) and is ready to measure. The
display shows the measurement screen without measuring value.
b) Upon initial operation the measuring series is set to „Direct Mode“and factory calibration is
preset (For more detailed information on „Calibration” refer to chapter 6).
c) The factory pre-setting is recommended for quick and easy measurement and if a medium
measuring accuracy is sufficient. For a detailed description of different calibration methods refer
to chapter 6.2.
d) To take readings, place the sensor in right angle onto the measuring object. The coating
thickness will be displayed on the screen after a short while (less thana second). Remove sensor
and take next reading.
Status bar
Display Illumination
Battery-
level
Activated measuring
principle: Fe
Time
Number of
readings
Measuring
unit
current
reading
Sensor is lifted
from surface

3. Description of the measuring system
© ElektroPhysik MiniTest 2500 - MiniTest 4500 11 of 73
3. Description of the measuring system
3.1 Gauge
3.1.1 General
A large optionally backlit display allows easy reading of measuring values and statistical data.
The colour of the backlit display is user definable thus offering for example quick marking of a
reading within limits in green and outside limits in red.
The housing is made of an impact-proof and scratch-resisting material and conforms to protection
class IP 65.
3.1.2 Front view
1. USB-Interface
2. Battery charge level
3. Note: Selected APPL-Batch group
4. Offset note: Offset is activate
5. Limit note: Limits are active
6. Note: Reading is within, above or below preset limits
7. Note: Statistical value (here: Mean value)
8. Note: Readings are blocked
9. Note: Number of readings
10. Zero key to calibrate zero without calibration standard/
Double assignment Recording of infinite value when
working with sensor types N10, N20, N100
11. Calibration key for calibration with precision standards /
Double assignment Calibration through a coating (CTC)
12. Key to select measuring principle Ferrous, Non-Ferrous
or Auto FN when using FN sensors /
Double assignment Switch to continuous mode
13. Activation key for DIRECT- or APPL-BATCH Mode
14. Key to access a subgroup (BATCH) within an
APPLICATION /
Double assignment Activate / Deactivate Bluetooth
Interface
15. Key to enter limit values /
Double assignment Key to enter an Offsets
16. Arrow keys for navigation in settings, e.g. calibration and
limit values, key lock
17. Key to confirm an action /
Double assignment ESCAPE or QUIT function
18. Arrow keys for navigation in settings, e.g. calibration and
limit values, key lock
19. Delete key
20. ON/OFF switch and initial functions
21. Key to visualize statistical values and transfer measuring
and statistical values to printer, PC or APP Miniview
22. Measuring unit: Automatically selected according to
preselection of the sensor connected: µm, mm or mils,
inches
23. Current reading
24. Active calibration method is displayed; here ZERO
25. Active measuring principle N-Fe (when measuring on
non-ferrous metal) or FERROUS (when measuring on
steel
26. Display of time
27. Sensor plug
28. Note: Bluetooth active/paired
29. Optional socket: 1. To connect an external trigger (e.g.
footswitch), 2. To trigger a signal confirming the
measuring value (optical or acoustical), RS 232 Interface
30. Note: PC connection via USB active
31. Note: Keypad locked
2
3
4
5
7
8
22
6
6
9
15
14
16
17
18
19
21
20
10
11
12
13
23
24
25
1
26
27
29
28
30
31

3. Description of the measuring system
© ElektroPhysik MiniTest 2500 - MiniTest 4500 12 of 73
3.1.3 Operating keys
MiniTest 2500 and MiniTest 4500 are equipped with a generous keypad. One key pressure is
sufficient to access functions like calibration, limit setting, and display of statistics.
The ON-OFF-key serves to switch the gauge on or off. Switching the gauge on by simultaneously
pressing the ON-OFF key and the keys + Clear, a total reset is carried out and the gauge returns
factory settings (For more detailed information on initial functions refer to section 11.1).
All keys have a double assignment. Simple pressure of a key will access the functions shown in
major writing like ‘Zero’and ‘Stats’(Statistics). Functions shown in minor grey writing like ‘ ’ and
‘Send’are accessed by keeping the key depressed for approximately 0.5 seconds.
- ‘OK’confirms settings and selects menu points.
- ‘ ’ quits an action or a menu.
- ‘ ’ or ‘ ’ modify settings and navigate within initial functions.
- ‘Clear’deletes the last reading, the statistics, an application ‘Appl’, a series of measurements
‘Batch’or limit and offset values.
- ‘ ’ opens the table of initial functions
- ‘ ’ activates and deactivates display and keypad illumination
- ‘ ’ locks the keypad with a password
- ‘ ’ activates and deactivates the Bluetooth Interface (only MiniTest 4500).
3.1.3 Interfaces
The model MiniTest 4500 is equipped with a USB and Bluetooth interface. MiniTest 2500 is only
equipped with a USB interface.
3.1.4 Power supply
3.1.4.1 Batteries and rechargeable batteries
Coating thickness gauges MiniTest 2500 and 4500 are powered by three alkaline-manganese-
batteries 1.5V, type AA / LR6 (included in standard supply); alternatively, the gauge can be operated
on rechargeable NiMH batteries type AA / HR6. Please use only the battery types recommended
by ElektroPhysik (see section 13.1 Accessories).
When working with rechargeable batteries, the settings of the gauge must be adapted to
rechargeable batteries (section 13.1.1). An external charger is required to recharge the batteries
(Accessories).
For more detailed information on the use of batteries and rechargeable batteries, refer to section
13.1.1.
Note:
- Remove batteries or rechargeable batteries from the instrument if not in use for extended
periods.
- The battery symbol indicates 5 different battery states. l.
- When reaching the lowest battery state, the battery level symbol will start to flash. In this
state, voltage is insufficient for powering the display backlight and keypad illumination. The
symbol is no longer displayed.

3. Description of the measuring system
© ElektroPhysik MiniTest 2500 - MiniTest 4500 13 of 73
- If batteries are completely discharged, the messages „E06“and „Low Batt“appear and the
gauge switches off.
- Insert fresh batteries within one minute immediately after removing the used ones. If you
wait for longer than one minute, time settings may be lost. However, readings and
calibration values will remain in memory.
- For field use, replacement batteries should always be at hand
- Erratic readings due to low battery do not occur as the gauge switches off automatically or
does not switch on at all if batteries are too low.
- Used or defective batteries or rechargeable batteries may contain hazardous substances
and must be disposed of according to the legal provisions of your country.
3.2 Sensors
Select a sensor suitable for your measuring task, plug to the gauge and screw on.
Important: Whenever a sensor is connected or removed, the gauge must be switched off.
All sensor systems (except sensor type CN02 and customized designs) are spring-mounted in the
handling sleeve. This construction ensures stable positioning of the sensor with a constant contact
pressure. The V-groove at the top of the handling sleeve allows reliable measurement on objects
of cylindrical shape.
Hold the sensor at the handling sleeve and place on the object to be measured.
Note: Sensors are equipped with a hard, wear-proof sensor pole. However, sliding sensors across
rough and hard surfaces, for example shot blasted surfaces, should be avoided.
3.2.1 Sensors of the MiniTest 1100 –2100 - 3100 - 4100 series
All sensors of the predecessor series are compatible with coating thickness gauges MiniTest 2500
and MiniTest 4500. However, it is required to perform a one-time adaptation of the sensor to the
measurement electronics.
3.2.1.1Adaptation of sensor types F05, F1.6, F3, F1.6/90, F2/90, F10, F20, N.08 Cr, N02, N1.6,
N1.6/90, N2/90, CN02 and FN1.6, FN1.6P, FN 1.6/90, FN2/90
Upon initial connection of the sensor to the gauge, the MiniTest 2500 or 4500 will display “INF”
flashing as well as “SET” and “SENSOR IN AIR” when switched on.
Hold the sensor in a sufficient distance to any metal and press the OK key.
‘INF’ and ‘WAIT’ will continue to flash on the display and a counter will count down from 30 to 0.
Keep the sensor away from any metal until the counter has reached ‘0’.
Once the ‘INF’ adaptation is completed, ‘ZERO”, ‘NFe” and ‘ALUMINIUM-PLATE’ will flash on the
display when an N-type or FN-type sensor is connected to the gauge.
Place the sensor on the aluminum zero standard.
‘ZERO’ and ‘ALUMINIUM-PLATE’ will continue to flash on the display and a counter will count
down from 30 to 0. Do not remove the sensor from the standard until the counter has counted
down to ‘0’.
Once the aforesaid adaptation is completed, ‘ZERO”, ‘Fe” and ‘STEEL-PLATE’ will flash on the
display when an F-type or FN-type sensor is connected to the.
Place the sensor on the steel zero standard.

3. Description of the measuring system
© ElektroPhysik MiniTest 2500 - MiniTest 4500 14 of 73
‘ZERO’ and ‘STEEL-PLATE’ will continue to flash on the display and a counter will count down
from 30 to 0. Do not remove the sensor from the standard until the counter has counted down to
‘0’.
‘SAVE’ and ‘OK’ will flash on the display.
Press ‘OK’ in order to complete the adaptation of the sensor. Gauge and sensor are now ready to
measure.
Adaptation of a sensor to the series MiniTest 2500 / 4500 does not affect the use of the same
sensor with a gauge from the series MiniTest 1100 / 2100 / 3100 / 4100.
The adaptation procedure can be repeated at any time in point 20 of the initial settings.
Note: Sensor type F 20 requires a multi-point calibration according to section 7.4 in order to
adhere to the tolerances. Sensor type F 50 is only supported by the MiniTest 2500 / 4500 series
beginning from software version 1.1.
3.2.1.2Adaptation of sensor types N10, N20 and N100.
To adapt the sensor to the gauge, the zero standard and the three precision standards from the
calibration set supplied with the sensor is required.
When a sensor from the MiniTest 1100-4100 series is connected to a MiniTest 2500 or 4500 for
the first time, the gauge will display ‘INF”, ‘SET’ and ‘ON COATING WITHOUT SUBSTRATE‘ after
being switched on.
Place the sensor on the three precision standards stacked on top of each other and hold the
sensor and the precision standards in the air keeping a sufficient distance to any metal objects or
place the three standards on a polystyrene plate. Press the OK key. This procedure eliminates
dielectric influences oft he coating material as described in section 7.7.3.
‘INF’ and ‘WAIT’ will continue to flash on the display and a counter will count down from 30 to 0.
Keep the sensor away from any metal until the counter has reached ‘0’.
Once the ‘INF’ adaptation is completed, ‘ZERO”, ‘NFe” and ‘ALUMINIUM-PLATE’ will flash on the
display when an N-type or FN-type sensor is connected to the gauge.
Place the sensor on the aluminum zero standard.
‘ZERO’ and ‘ALUMINIUM-PLATE’ will continue to flash on the display and a counter will count
down from 30 to 0. Do not remove the sensor from the standard until the counter has counted
down to ‘0’.
‘SAVE’ and ‘OK’ will flash on the display.
Press ‘OK’ in order to complete the adaptation of the sensor. Gauge and sensor are now ready to
measure.
Adaptation of a sensor to the series MiniTest 2500 / 4500 does not affect the use of the same
sensor with a gauge from the series MiniTest 1100 / 2100 / 3100 / 4100.
The adaptation procedure can be repeated at any time in point 20 of the initial settings.
Hold the sensor in a distance to any metal and press ‘OK’.
Precision standards
Polystyrene plate

4. Measuring, Storage and Data Processing in DIRECT or APPL-BATCH mode
© ElektroPhysik MiniTest 2500 - MiniTest 4500 15 of 73
4. Measuring, Storage and Data Processing in DIRECT or
APPL-BATCH mode
The following section describes:
the DIRECT mode
the APPL-BATCH mode
the structure of APPL-BATCH memory system
How to change from DIRECTto APPL-BATCH mode
How to select a scertain memory in APPL-BATCH mode
How to enter calibration values and limits
Special features of the APPL-BATCH memory system.
APPL = Application memory
BATCH = Memory for series of measurement
4.1 Switch on / start-up screen
Being switched on the unit will display the measurement mode of the last active series of
measurements („Batch“).
The model MiniTest 4500 offers two different working modes: ‘DIRECT mode’ and ‘APPL-
BATCH mode’.
‘DIRECT mode’ is intended for quick occasional readings. Readings as well as the 6
statistical values (8 if limits have been set) can be shown on the display and printed by
pressing STATS’. The statistical analysis function can evaluate up to 9,999 readings.
In ‘APPL-BATCH mode’ a maximum of 10,000 single readings and approx. 500 separate
series of measurements can be stored in data memory individually. Single readings,
statistical values and the related histogram can be printed directly or at a later point.
Important note:
Working in APPL-BATCH mode (e. g. calibrating, measuring setting of limits etc.) is only possible,
when the display shows „APPL BATCH“. Otherwise, activate the APPL-BATCH memory using the
keys APPL and BATCH. Also refer to Section 3.4 and 3.5.
Status line
Display Illumination
Battery-
level
Active measuring
principle: Fe
Time
Number of
readings
Measuring
unit
Current
reading

4. Measuring, Storage and Data Processing in DIRECT or APPL-BATCH mode
© ElektroPhysik MiniTest 2500 - MiniTest 4500 16 of 73
Status after Switch on
Press ON key while holding the probe in the air. The gauge automatically resumes the mode
selected previously (either ‘DIRECT-’ or ‘APPL-BATCH’).
If start-up proceeds in ‘APPL-BATCH mode’, the gauge will select the ‘APPL-BATCH’memory
previously selected and the last ready (if available) will be displayed.
Calibration values and statistics are stored in memory.
Measurement can start directly in ‘DIRECT mode’ or be continued in ‘APPL-BATCH’ mode
provided the gauge works with a valid calibration.
If all data have been deleted, only the measuring unit, e.g. < µm > along with the measuring mode
FERROUS or NONFERROUS will be shown depending on the sensor connected to the gauge.
Note:
If you switch from ‘DIRECT’ mode to ‘APPL-BATCH’ mode, all statistical data will be kept in
memory.
The statistical data will not be stored if you change the probe.
When pressing the APPL-BATCH key, the pair of numbers of the last active APPL-BATCH
memory will be shown on the display.
The gauges switches off automatically according to the selected switch-off-time after the last
measurement (see also section 11.1 initial settings).

4. Measuring, Storage and Data Processing in DIRECT or APPL-BATCH mode
© ElektroPhysik MiniTest 2500 - MiniTest 4500 17 of 73
4.2 Structure of the APPL-BATCH system
MiniTest 2500 and MiniTest 4500 generally group reading in series of measurements in one
memory batch. MiniTest 2500 features one fixed memory (DIRECT) whereas MiniTest 4500
features one DIRECT memory and 99 application memories (APPL) combined with memories for
series of measurements (BATCH).
New readings are always added to the active memory and stored. The gauge will preserve the
active memory when switched off and automatically resume this memory when switched on again
not requiring any further settings. The following actions are possible:
- Continue to measure in active memory
- Set up a new series of measurement (BATCH) within an application memory (APPL)
- Set up of a new application memory (APPL) with corresponding series of measurement
(BATCH)
- Selection of an existing series of measurement (BATCH) within an application memory
(APPL)
- Selection of an existing application memory (APPL) with corresponding series of
measurement (BATCH))
Perform one of the above mentioned actions in order to specify the active series of measurement
(BATCH) for measurements hereinafter.
The application memories (APPL) with their corresponding batch memories (BATCH) allow to
store calibration settings for different applications in an application memory (APPL). The batch
memory (BATCH) stores single readings of a series of measurement along with their statistical
analysis (see illustration: APPL-BATCH memory).
BATCH memory columns
APPL
(application) memory
lines
1
2
3
...
97
98
99
1
1
2
3
97
98
99
2
1
2
3
97
98
3
1
2
3
97
98
.
.
.

4. Measuring, Storage and Data Processing in DIRECT or APPL-BATCH mode
© ElektroPhysik MiniTest 2500 - MiniTest 4500 18 of 73
97
1
1
1
97
98
98
1
1
1
97
98
99
1
1
1
97
98
99
Illustration: APPL-BATCH memory
With MiniTest 4500 99 application memories (APPL-memory lines) –subdivided in 99 BATCH-
memory columns each, i.e. 9,801 memories in total, are available.
Several million readings can be logged to the memory.
APPL memory line
(for saving calibration values only)
Each of the 99 application memory lines can be allotted a calibration and an OFFSET setting for
one probe. A selection of calibrations are thus instantly available for different tasks, e.g. for
measuring coating thickness on flat or curved surfaces or for taking measurements using a range
of probe types. Once a calibration has been entered into an APPL memory line it remains there
and can be activated at any time simply by entering the corresponding APPL number. After this,
readings can start immediately within a selected group (BATCH) of particular application memory
BATCH-(Group) Memory
(for storing limits and readings)
Each of the application memories (APPL memory lines) is subdivided into BATCH memories. Each
BATCH memory can store a series of readings using one calibration and also evaluate them in
statistical form. In addition, a set of two tolerance limits (LO and HI) can be stored in each BATCH
memory. The BATCH subdivisions provide for individual assessment of the coatings of a number
of product samples measured with one probe and based on the same calibration.
4.3 Switching APPL-BATCH mode on / off
When the gauge is switched on it will resume the previously selected mode, i.e. either APPL-
BATCH or DIRECT mode.
In order to switch from DIRECT to APPL-BATCH mode, press ‘APPL’. The last APPL-BATCH
number will appear, e.g. < 2 : 1 >.
Either continue taking readings in this APPL-BATCH memory or select a different memory (see
section 4.5). Confirm your choice by pressing ‘APPL’again. Readings can be taken as soon as
“APPL-BATCH”appears on display.

4. Measuring, Storage and Data Processing in DIRECT or APPL-BATCH mode
© ElektroPhysik MiniTest 2500 - MiniTest 4500 19 of 73
To switch from APPL-BATCH mode to DIRECT mode, press and hold the APPL key while the
gauge is switched on. DIRECT mode is activated and the gauge is ready to measure.
4.4 Displaying the number of active APPL-BATCH
If the gauge is switched on and is already functioning in APPL-BATCH mode, a reading will
normally be displayed.
Press either APPL or BATCH to display the two-number memory in current use, e.g.<2 : 1>. Press
the same key again to confirm your choice. Readings can be taken as soon as APPL-BATCH
appears on the display.
4.5 Selection of an APPL memory
1. Press the APPL key in order to display the two-number designation of the active APPL-BATCH
memory. Use the arrow keys to select a new APPL memory.
2. If you hold down the key you can quickly scroll through the memory showing a running display
of numbers already occupied until a free APPL address is found. The number of this memory
will then appear on screen, e.g. < 5 : 1>. Free memories can be distinguished by a flashing
APPL number.
Note:
An APPL memory can be activated directly by connecting the sensor that served to create the
APPL memory originally. If another sensor even of the same sensor type is connected, the
message “LOC“will be displayed along with sensor type and serial number.
This also happens if the probe which has been used for APPL-memory creation has been
repaired.
To delete or select APPL-memories please refer to section 9.6
3. The calibration valid for your selected APPLmemory is shown on display, e.g. one-point or
twopoint calibration. If the standard calibration is valid, there will be no indication on the
display.
Either maintain the currently valid calibration or recalibrate according to one of the methods
described in section 7.1 to 7.13.
4. All following readings will be stored in the selected APPL-BATCH memory.
4.6 Selection of a BATCH memory
1. Select an APPL memory line if this has not been done.
2. Press BATCH. The number of the previously selected number will now appear, e.g. <3 : 2>.
If, for example, APPL memory line number 3 has not yet been used, the gauge automatically
selects the first BATCH memory, e.g. <3 : 1 >. A free BATCH is indicated by flashing numbers
on the display.
3. If required, use the arrow keys to select a new BATCH no. Keep the key pressed down for
quickly scrolling through the memory until a free BATCH number is found. The number will
then be displayed, e.g. <3 : 8>. Press BATCH to confirm.

5. Measuring
© ElektroPhysik MiniTest 2500 - MiniTest 4500 20 of 73
5. Measuring
5.1 Important Notes on Coating Thickness measurement
Make sure the operator has been properly instructed regarding the use of coating thickness
gauges and has basic knowledge of the specific requirements for measurement of the application.
The operator should have basic knowledge of the following:
Appropriate selection of a measuring device suitable for his application
Fundamentals on the electro-magnetic measuring principle
Influences through magnetic fields and the surrounding fields
Influence through the surface properties of the object to be tested (roughness, shape and
build-ups on the surface)
Statistical evaluation of measuring series
5.1.1 Interpretation of readings
The information obtained from the coating thickness measurement only refers to those parts of the
test object that have been covered by the sensor. For that reason, conclusions may not be drawn
on parts of the measuring object that have not been covered by the sensor during measurement.
In general, such conclusions are only admissible if comprehensive experience and approved
methods of statistical data acquisition are available.
5.2 Basic settings
Before taking readings, it is necessary to adjust a few settings:
Fix the data format for data storage before the first use of the gauge.
Either comma or point are available. This setting is important for later transfer of data to a
spreadsheet calculation for example Microsoft Excel (see section 10.2)
If required or necessary, the following settings can also be performed at initial set-up:
Definition of block statistics (see section 8.3)
Limit setting (see section 8.4)
Offset setting (see section 8.2)
All readings will be stored to the active APPL-BATCH memory.
Note:
Limits can still be set after readings have been taken.