MICRO-EPSILON FSC1/7 User manual

Operating Instructions
FSC1/7, FSC1000

MICRO-EPSILON
MESSTECHNIK
GmbH & Co. KG
Koenigbacher Str. 15
94496 Ortenburg/Germany
Phone [phone]
Fax [phone]
email [email protected]
www.micro-epsilon.com
Layer thickness measuring device for insulators on metal and
carbon fiber-reinforced plastics (CFRP)

FSC1/7, FSC1000
Contents
1. Safety ................................................................................................ 5
1.1 Symbols Used ................................................................................................... 5
1.2 Warnings............................................................................................................ 5
1.3 Notes on CE Marking ........................................................................................ 6
1.4 Notes regarding FCC Approval ......................................................................... 6
1.5 Intended Use ..................................................................................................... 7
1.6 Proper Environment........................................................................................... 7
2. Overview ........................................................................................... 8
2.1 Structure, Functional Principle .......................................................................... 8
2.2 FSC1/7 and FSC1000 Technical Data............................................................... 9
3. Delivery ........................................................................................... 10
3.1 Unpacking, Included in Delivery...................................................................... 10
3.2 Storage ............................................................................................................ 10
4. Initial Operation.............................................................................. 11
4.1 Dimensional Drawings..................................................................................... 11
4.2 Insert and Replace Battery Pack ..................................................................... 12
4.3 Connecting the Sensor.................................................................................... 13
5. FSC1/7 and FSC1000 Operation.................................................... 14
5.1 Switch-on Phase, Warm-up............................................................................. 14
5.2 General Controller Operation .......................................................................... 14
5.3 Measuring Program Start ................................................................................ 15
5.4 Setup, Parameters ........................................................................................... 16
5.5 Adjustment of the Measuring System ............................................................. 18
5.5.1 General ........................................................................................... 18
5.5.2 Load Adjustment Table................................................................... 19
5.5.3 Managing Adjustment Tables......................................................... 19
5.5.4 Performing an Adjustment.............................................................. 20
5.5.5 Removing a Calibration Point......................................................... 25
5.5.6 Checking Calibration Points........................................................... 26
5.5.7 Number of Calibration Points Exceeded........................................ 27
5.5.8 Checking Calibration Point Temperature ....................................... 28
5.5.9 Incorrect Distance Between Calibration Points.............................. 28

FSC1/7, FSC1000
5.6 Performing a Measurement, Single Value....................................................... 29
5.7 Performing a Series of Measurements, Statistics ........................................... 32
5.8 Measurement Data .......................................................................................... 34
5.8.1 General Info .................................................................................... 34
5.8.2 Displaying Measurement Data ....................................................... 34
5.8.3 Managing Measurement Data........................................................ 35
5.8.4 Saving/Exporting Measurement Data ............................................ 36
5.9 Ending the Measuring Program, Switching off the Controller ........................ 37
6. Liability for Material Defects.......................................................... 38
7. Cleaning, Service, Repair .............................................................. 38
8. Decommissioning, Disposal .......................................................... 39
9. License agreement, software ........................................................ 40
Appendix......................................................................................... 41

Page 5
Safety
FSC1/7, FSC1000
1. Safety
System operation assumes knowledge of the operating instructions.
1.1 Symbols Used
The following symbols are used in these operating instructions.
Indicates a hazardous situation which, if not avoided, may result in minor or moderate injuries.
Indicates a situation that may result in property damage if not avoided.
Indicates a user action.
iIndicates a tip for users.
Measurement Indicates hardware or a software button/menu.
1.2 Warnings
This product contains nickel metal hydride (NiMh) accumulators. Rechargeable accumulators are not ordinary
waste. Dispose of used accumulators in accordance with national laws and regulations.
Damaged accumulators may leak, contact with skin can cause burns.
> Use suitable protective gloves if necessary.
Improper charging or replacement of the accumulator may cause the battery to explode.
> Use the charger supplied by Micro-Epsilon for charging.
Only replace the accumulators with accumulators of the same type.
Avoid shocks and impacts to the sensor.
> Damage to or destruction of the sensor
Avoid exposure of sensor and controller to splashes of water.
> Damage to or destruction of the sensor/controller

Page 6
Safety
FSC1/7, FSC1000
Avoid exposure of sensor to aggressive media (detergents, cooling emulsions).
> Damage to or destruction of the sensor
Avoid bending, clamping and tensile stress of the sensor cable.
> Damage or destruction of the sensor cable
Avoid grinding the measuring area.
> Damage of the sensor
1.3 Notes on CE Marking
The following apply to the FSC1/7 and FSC1000:
EU Directive 2014/30/EU | EU Directive 2014/35/EU | EU Directive 2011/65/EU
Products which carry the CE mark satisfy the requirements of the EU directives cited and the European harmonized standards (EN)
listed therein. The measuring system is designed for use in industrial environments and meets the requirements. The EU Declaration
of Conformity is available to the responsible authorities according to EU Directive, article 10.
1.4 Notes regarding FCC Approval
The FSC1/7 and FSC1000 are registered under the FCC identifier: 2AMBGMEMW02, equipment class
- Part 15 Class B Computing Device Peripherals and
- Part 15 Class C Low Power Communication Device Transmitter
with the US Federal Communications Commission (FCC).
This device complies with part 15 of the FCC Rules. Operation is subject to the following two conditions:
(1) This device may not cause harmful interference, and (2) this device must accept any interference received, including interference
that may cause undesired operation.
If sensor and/or controller are modified, the FCC approval becomes void.
This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to part 15 of the FCC Rules.
These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment
generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause
harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installa-
tion.

Page 7
Safety
FSC1/7, FSC1000
If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment
off and on, the user is encouraged to try to correct the interference by one or more of the following measures:
- Reorient or relocate the receiving antenna
- Increase the separation between the equipment and receiver
- Connect the equipment into an outlet on a circuit different from that to which the receiver is connected
- Consult the dealer or an experienced radio/TV technician for help
1.5 Intended Use
- The FSC1/7 and FSC1000 are designed for use in industrial and laboratory applications. They are used to measure the thickness
of paint and other electrically insulating layers on substrates such as carbon fiber-reinforced plastics (CFRP), CFRP with metallic
lightning protection and metals.
- The system must only be operated within the limits specified in the technical data, see Chap. 2.2
- The system must be used in such a way that no persons are endangered or machines and other material goods are damaged in
the event of malfunction or total failure of the measuring system.
- Take additional precautions for safety and damage prevention in case of safety-related applications.
- The system is designed for battery operation; operating with a charger connected is not permitted.
1.6 Proper Environment
- Protection class: IP 40
- Temperature range
Operation: +10 ... +40 °C (+50 ... +104 °F)
Storage: 0 ... +45 °C (+32 ... +113 °F)
- Humidity: 20 ... 80 % (non-condensing)
- Ambient pressure: Atmospheric pressure

Page 8
Overview
FSC1/7, FSC1000
2. Overview
2.1 Structure, Functional Principle
The FSC1/7 and the FSC1000 are suitable for thickness measurements of insulating layers on
- CFRP,
- CFRP with lightning protection,
- metals
- and conductive or weakly conducting materials.
The device includes a sensor (handheld module) and a controller (control and display module).
The system operates
- based on microwaves, no coupling medium is required,
- on a non-destructive basis, without affecting coating or substrate.
One measurement takes less than 1 second.
Fig. 1 Sensor Fig. 2 Controller

Page 9
Overview
FSC1/7, FSC1000
2.2 FSC1/7 and FSC1000 Technical Data
Model FSC1/7 FSC1000
Measuring range 500 µm 1000 µm
Resolution Static 1 µm 1 µm
Display 1 µm or 0.01 mils 1 µm or 0.01 mils
Repeatability £2 µm £4 µm
Linearity 1 £±3 µm £±5 µm 2
Duration single measurement < 1 sec.
Frequency range 24 … 24.25 GHz (ISM band)
Supply voltage NiMh battery 6 V, 4500 mAh
Battery life approx. 8 hours 3
Min. target thickness Coating none
Substrate depending on material and its conductivity 4, > 1 µm
Min. target size 20 mm diameter
Target material (substrate) electrically conductive and poorly conductive materials such as CFRP 4,
CFRP with lightning protection, metals
Coupling medium not required
Active measuring area approx. 15 mm diameter
Interface USB
Temperature Storage -0 ... +45 °C (+32 ... +113 °F)
Operation +10 ... +40 °C (+50 ... +104 °F)
1) Adjustment based on calibration points, distance max. 150 µm; not taking into account the film tolerance
2) From 500 µm: also depends on the dielectric constant, typically <±3 %.
3) With approx. 1,000 measurements, new and charged battery
4) With CFRP woven materials at least one layer; with CFRP laid materials at least two layers with different angles

Page 10
Delivery
FSC1/7, FSC1000
Model FSC1/7 FSC1000
Humidity 20 … 80 % r.H. (non-condensing)
Protection class (DIN EN 60529) IP40 (sensor and controller)
Control and display elements
3.2” resistive LCD touch display, membrane keypad
statistical functions with recording and data export : Min., Max., counter, mean value
and standard deviation
dynamic tilt prevention (can be activated, configurable)
3. Delivery
3.1 Unpacking, Included in Delivery
1 Sensor including hand strap
1 Controller including shoulder strap
1 Exchangeable battery
1 Charger
1 Sensor cable with push-pull latching mechanism
1 Box with calibration foils
1 Operating instructions and test certificate
1 Carry case
Carefully remove the components of the measuring system from the packaging and ensure that the goods are forwarded in such
a way that no damage can occur.
Check the delivery for completeness and shipping damage immediately after unpacking.
If there is damage or parts are missing, immediately contact the manufacturer or supplier.
3.2 Storage
Temperature range storage: 0 ... 45 °C (+32 ... +113 °F)

Page 11
Initial Operation
FSC1/7, FSC1000
4. Initial Operation
4.1 Dimensional Drawings
123 (4.84)
48 (1.89)
54 (2.13) 68 (2.68)
Fig. 3 Sensor dimensions, in mm (inches)
Active measuring surface sensor
128 (5.04) 43 (1.96)
230
(9.06)
238
(9.37)
Fig. 4 Controller dimensions, in mm (inches)

Page 12
Initial Operation
FSC1/7, FSC1000
4.2 Insert and Replace Battery Pack
Connect the NiMh battery to the controller with the contacts on the upper side, see Fig. 5.
iCharge the battery before initial operation. The battery must not be charged during measure-
ments.
Switch the controller off as defined before replacing the battery.
Replacing the battery: Press the latching mechanism on the battery together and pull it out.
Charging the battery: Connect the battery to the charger. The LED of the charger signalizes the
charging process.
Fig. 5 Controller with battery
The state of charge of the battery is displayed on the controller screen, see Fig. 6. The display will light up green with a state of charge
from 20% to 100% and red for less than 20%. The controller will display a warning message when the remaining capacity is 10%. The
controller will switch off automatically when the status display reaches 0%.
The status display for the battery becomes visible approximately one minute after the controller is switched on.
Fig. 6 Battery state of charge

Page 13
Initial Operation
FSC1/7, FSC1000
4.3 Connecting the Sensor
The sensor cable is equipped with an ODU mini-snap (Push-Pull) connector. To release the plug, the ribbed metal sleeve must be
pulled back to unlock it. Do not turn the plug to unlock it, the cable as well as the controller may be damaged.
Before switching on, connect the sensor, sensor cable and controller.
Fig. 7 Measuring system consisting of sensor, sensor cable and controller

Page 14
FSC1/7 and FSC1000 Operation
FSC1/7, FSC1000
5. FSC1/7 and FSC1000 Operation
5.1 Switch-on Phase, Warm-up
To prevent temperature and/or drift effects, which can lead to incorrect measurement results, proceed as follows:
Switch on the controller. Press the On button for 1 sec.
The ON LED in the upper right corner will light up.
Connect the sensor with sensor cable to the Sensor connection on the upper side of the
controller.
iBefore operation, the measuring system requires sufficient time to adapt to the ambient
temperature.
LED On
USB
Sensor
On button
5.2 General Controller Operation
The controller can be operated using the touchscreen or the keyboard. The touchscreen is
“resistive,” which means that it can also be operated when wearing gloves or with a round
stylus.
iDo not use any sharp objects on the touch screen and the keyboard in order to avoid
damage.
Keyboard: Use the arrow keys to navigate the menu.
ENTER key: Activates the next menu
ESC key: Return to the previous menu.
The numeric field is used to enter, for example, a comment for a measurement or the name
for an adjustment. Multiple characters have been assigned to the keys. Accordingly, a key
must be pressed a certain number of times to get a specific letter or number.
Fig. 8 Controller Keyboard

Page 15
FSC1/7 and FSC1000 Operation
FSC1/7, FSC1000
5.3 Measuring Program Start
After switching-on, the controller displays the start page, see Fig. 9.
Fig. 9 Controller start screen Fig. 10 No sensor connection
The connection to the sensor is established when the sensor’s serial number is displayed at the bottom of the screen, see Fig. 9. The
device is ready for operation.
If a connection to the sensor cannot be established, this is reported, see Fig. 10.
If the connection to the sensor is interrupted, e.g. because the sensor cable is removed, this will be displayed, see Fig. 10. Press OK
and connect the sensor cable with the controller to continue the measurements.
The state of charge of the battery is displayed after a few seconds.

Page 16
FSC1/7 and FSC1000 Operation
FSC1/7, FSC1000
5.4 Setup, Parameters
In the Setup menu, see Fig. 11, settings can be configured via the pull-down menus.
Measurement unit µm / mils
Buzzer output On / Off An audible signal indicates successful/unsuccessful measurement.
Date/Time Time in the format hh:mm:ss
Date in the format YYYY-MM-DD
Trigger Button / Key 1 / Both
Settings for triggering the measurement. Button: Start measurement by pressing
the button on the sensor. Key: Start measurement by pressing keys 1, 2 or 3 on
the controller. Both: Start measurement by pressing the button on the sensor or
keys 1 to 3.
Measure count 1 / 2 / 3 / 4 / 5
These settings parameterize the dynamic tilt prevention. Measure count sets the
number of sequential individual measurements. The delay between two mea-
surements is 100 ms. The mean value from this automatic series of measure-
ments is displayed.
Max Delta defines the maximum permissible difference between the smallest
and the largest measured value in the sequential measurements.
Max delta 5 / 7.5 / 10 / 12.5 µm
Style Dark contrast / Bright contrast Display

Page 17
FSC1/7 and FSC1000 Operation
FSC1/7, FSC1000
Gray highlighted fields
allow for a selection.
Fig. 11 Setup menu

Page 18
FSC1/7 and FSC1000 Operation
FSC1/7, FSC1000
5.5 Adjustment of the Measuring System
5.5.1 General
The Cal (calibration) menu makes it possible to load, manage and create adjustments.
Fig. 12 Cal (calibration) menu
Load Calibration Select, show and start existing adjustment table.
Manage Calibrations Manage, delete existing adjustment tables.
New Calibration Create new adjustment table. The measuring system can be calibrated on various substrate materials. Poten-
tial substrate materials are, for example, metals, CFRP or CFRP with lightning protection.
ESC Back to measuring mode
An adjustment for any metal can be used for all metals.
iCreate a separate adjustment table for every further substrate (CFRP, CFRP with lightning protection) in order to avoid inaccurate
measurements.

Page 19
FSC1/7 and FSC1000 Operation
FSC1/7, FSC1000
5.5.2 Load Adjustment Table
Switch to the Load Calibration menu.
Fig. 13 Adjustment table selection Fig. 14 Adjustment table details
Select the desired file and confirm with the Load button.
Once an adjustment is loaded, a window will appear with the basic information regarding the adjustment, see Fig. 14. After the Ok
button is pressed, the window will close and the measuring mode will be activated.
5.5.3 Managing Adjustment Tables
You can manage existing data sets in the Manage Calibration
submenu.
Possible options:
- Del Deletes the selected data set
- Load Loads the selected data set
- ESC Back to measuring mode
Fig. 15 Manage Calibration menu for loading or deleting

Page 20
FSC1/7 and FSC1000 Operation
FSC1/7, FSC1000
5.5.4 Performing an Adjustment
iOnly use undamaged calibration foils. Contamination, bends or damage within the black circle will lead to incorrect results.
Only use the foil within the black circle for the adjustment.1
Foils are also available with a certificate.
It is not possible to certify, or recertify, the foils after the fact.
Only use the area
within the black
circle to adjust for
the foil.1
Set the sensor vertically onto the substrate, do not
tilt it.
Switch to the New Calibration menu.
The adjustment can be started when Ready is displayed in the status win-
dow.
Fig. 16 Adjustment ready
You must select at least two calibration points for an adjustment,
e.g. 0 µm (= without calibration foil, measurement directly on the substrate)
and 100 µm.
Place the first calibration foil on the substrate, place the sensor on top,
avoid vibrations/tilting and trigger the measurement.
Calibration foil 1
Substrate
1) Influences due to film tolerances are not considered with the adjustment.