OptiSense PaintChecker industrial User manual

Operation manual
PaintChecker industrial
PaintChecker industrial n-gauge
EN Version 3.1

2 | PaintChecker Industrial
1. Introduction................................................................................................................................................................................................4
1.1 Brief description .............................................................................................................................................................................4
1.2 Scope of Delivery...........................................................................................................................................................................4
1.3 General information on the operation manual..................................................................................................................4
1.4 Copyright ..........................................................................................................................................................................................4
1.5 Customer service ...........................................................................................................................................................................5
2. Safety Instructions ...................................................................................................................................................................................6
2.1 Symbol explanation of pictograms and signal words .....................................................................................................6
2.2 Proper use ........................................................................................................................................................................................6
2.3 Safety markings..............................................................................................................................................................................6
2.4 Risks caused by electricity..........................................................................................................................................................7
2.5 Dangers due to invisible light radiation from the sensor..............................................................................................7
2.6 Fire hazards......................................................................................................................................................................................8
2.7 Responsibility of the operator ..................................................................................................................................................9
2.8 Requirements for personnel......................................................................................................................................................9
3. Product Description ............................................................................................................................................................................. 10
3.1 Operating principle of photothermal coating thickness measurement................................................................10
3.2 LARES® – safety redefined.....................................................................................................................................................10
3.3 Features and area of application..........................................................................................................................................10
3.4 Model overview sensors ..........................................................................................................................................................11
3.5 Controller model overview......................................................................................................................................................13
3.6 Connections of the controller................................................................................................................................................14
3.7 Communication interfaces......................................................................................................................................................15
3.8 Accessories....................................................................................................................................................................................15
4. Installation ............................................................................................................................................................................................... 16
4.1 General notes on installation and set-up of the system .............................................................................................16
4.2 Mounting the controller...........................................................................................................................................................16
4.3 Mounting the sensor.................................................................................................................................................................17
5. Commissioning ...................................................................................................................................................................................... 18
5.1 General notes on commissioning.........................................................................................................................................18
5.2 Switching on the measuring system ...................................................................................................................................18
5.3 Aligning the sensor....................................................................................................................................................................18
5.4 Establishing Communication..................................................................................................................................................18
6. Calibration................................................................................................................................................................................................ 19
6.1 Introduction..................................................................................................................................................................................19
6.2 Included calibrations ................................................................................................................................................................. 19
6.3 User calibration ...........................................................................................................................................................................19
6.4 Reference samples and reference masters .......................................................................................................................19
7. Operation ................................................................................................................................................................................................. 21
7.1 Measuring procedure................................................................................................................................................................21
7.2 Self-test...........................................................................................................................................................................................21
8. Communication Protocols................................................................................................................................................................. 23
8.1 Introduction..................................................................................................................................................................................23
8.2 Modbus RTU.................................................................................................................................................................................23
8.3 Profinet ...........................................................................................................................................................................................23
8.4 OptiSense ASCII protokoll.......................................................................................................................................................23
8.5 Error codes ....................................................................................................................................................................................24
9. Maintenance ........................................................................................................................................................................................... 25
9.1 Spare parts ....................................................................................................................................................................................25
9.2 Replacing the sensor cable ..................................................................................................................................................... 25
Table of Content

PaintChecker Industrial | 3
9.3 Replacement of Controller......................................................................................................................................................25
9.4 Replacing a Sensor.....................................................................................................................................................................26
9.5 Transport and storage...............................................................................................................................................................26
9.6 Cleaning and maintenance .....................................................................................................................................................26
9.7 Transport and storage...............................................................................................................................................................26
10. Technical Data ...................................................................................................................................................................................... 27
10.1 System specifications..............................................................................................................................................................27
10.2 Measurement system control protocol ........................................................................................................................... 32
Fig. 1: PaintChecker industrial n-gauge with various laser and LED sensors 4
Fig. 2: Operating principle of photothermal coating thickness measurement 10
Fig. 3: Tube LLP3.5, LHP3.5, LHP10 11
Fig. 4: Dimensional drawing Industrial Angle sensors LLP1.6, LHP1.66 12
Fig. 5: Dimensional drawing Industrial Cube sensors LEDB3.3, LEDR3.3 12
Fig. 6: Description of the controller 13
Fig. 7: Dimensions | Controller industrial 14
Fig. 8: Controller industrial n-gauge HP 14
Fig. 9: Power supply industrial n-gauge HP 14
Fig. 10: Installation dimensions 16
Fig. 11: Connector assignment 16
Fig. 12: Incorrect distance to the measured part 17
Fig. 13: Correct distance to the measured part 17
Fig. 14: Correct distance to the measured part 18
Fig. 15: Reference Master 20
Fig. 16: Dimensional drawing of a reference sample 20
Fig. 17: Dimensional drawing of a reference sample 20
Fig. 18: Typical application of a Reference Master 20
Fig. 19: Typical measurement sequence 21
Fig. 20: System configuration 25
Fig. 21: Disposal 26
Fig. 22: Circuit diagram 29
Fig. 23: Connector locations 31
Table of Figures
Table of Tables
Table 1: Application examples ASCII protocol................................................................................................................................ 23
Table 2: Error bits........................................................................................................................................................................................ 24
Table 3: Sensor cable connector........................................................................................................................................................... 25
Table 4: Sensor specifications................................................................................................................................................................ 27
Table 5: Controller specifications ......................................................................................................................................................... 28
Table 6: Pin assignment X14 .................................................................................................................................................................. 30
Table 7: Pin assignment X15 / X15.1................................................................................................................................................... 30
Table 8: Pin assignment X16 / X16.1................................................................................................................................................... 30
Table 9: Pin assignment X17 .................................................................................................................................................................. 30
Table 10: Input signals.............................................................................................................................................................................. 32
Table 11: Output signals.......................................................................................................................................................................... 35

4 | PaintChecker Industrial
1. Introduction
1.1 Brief description
The PaintChecker industrial systems are photo-
thermal measuring systems according to DIN EN
15042-2:2006. They are used for non-contact and
non-destructive coating thickness measurement.
They are suitable for moist and dry organic coatings
such as solvent-based and water-soluble paints and
varnishes, powder paints and varnishes on various
substrates, metals, extruded rubber and ceramics.
A PaintChecker industrial measuring system consists
of a controller and sensor(s). Depending on the con-
troller, it can be equipped with up to eight sensors.
The sensors are connected to the controller via
cables. These in turn can be connected to a higher-
level PLC controller via various interfaces.
The OS Manager software provided with the system
can be used to perform measurements and statistic-
ally evaluate the measured values.
1.2 Scope of Delivery
The scope of delivery of the measuring system is spe-
cified in the documents Data Sheet Controller indus-
trial and Data Sheet Sensors industrial.
1.3 General information on the operation manual
This operation manual enables the safe and efficient
use of the measuring system. The manual is part of
the delivery, must be kept near the measuring system
at all times and must be accessible to the staff.
The staff must have carefully read and understood
this manual before using the system. A basic pre-
requisite for safe working with the system is compli-
ance with all safety and work instructions given in this
operation manual. In addition, the local safety re-
quirements as well as the general safety regulations
in the area of application of the measuring system
also apply.
Illustrations in this operation manual are for general
understanding only and may differ from the actual
design.
1.4 Copyright
This operation manual is protected by copyright.
Passing on the operation manual to third parties, all
types of duplication, including excerpts, and the use
and/or passing on of its contents are prohibited
without the written permission of OptiSense GmbH &
Co. KG (hereinafter referred to as the "manufac-
turer"), except for internal purposes.
Fig. 1: PaintChecker industrial n-gauge with various laser and LED sensors

PaintChecker Industrial | 5
Violations will result in liability for damages. The
manufacturer reserves the right to assert further
rights. The manufacturer retains the copyright.
© OptiSense GmbH & Co. KG | Annabergstraße 120 |
45721 Haltern am See | GERMANY©
1.5 Customer service
The OptiSense customer service is available for tech-
nical questions::
OptiSense GmbH & Co. KG
Annabergstraße 120
45721 Haltern am See
GERMANY
Tel. [phone]
[email protected]
www.optisense.com

6 | PaintChecker Industrial
2. Safety Instructions
2.1 Symbol explanation of pictograms and
signal words
Safety instructions are indicated by hazard picto-
grams in this operation manual. These pictograms
convey information about the type of danger. The
signal words indicate the extent of the danger. A dis-
tinction is made between two levels of danger:
Danger is the signal word for the serious danger cat-
egories and Caution is the signal word for the less
serious danger categories.
DANGER! This combination of symbol and
signal word indicates a serious
danger. The symbol shows the dan-
ger in case of incorrect use
DANGER! The combination of symbol and
signal word indicates a serious
danger category. This symbol in-
dicates a fire hazard.
DANGER! The combination of symbol and
signal word indicates a serious
danger category. The symbol stands
for risks caused by electricity.
CAUTION! The combination of symbol and
signal word indicates a less serious
danger category. The symbol indi-
cates the corresponding hazard.
TIPS AND RECOMMENDATIONS
This symbol highlights tips and re-
commendations as well as informa-
tion for efficient and error-free op-
eration.
DANGER! The combination of symbol and
signal word indicates a serious
danger category. The symbol shows
the danger in case of laser radi-
ation.
2.2 Proper use
The PaintChecker industrial photothermal measuring
system is used to determine the thickness of wet and
dry organic coatings for quality assurance and pro-
duction-related testing. Proper use includes ob-
serving all information contained in this manual. Any
use outside or beyond proper use is considered im-
proper use.
Danger in case of improper use
• The light beam of the sensor must never be
directed at easily flammable materials.
• The sensor must never be used in explosive areas.
• The sensor must never be used to illuminate,
or dry other objects.
• The sensor must never be used for medical
purposes.
• The sensor must never be immersed in liquids.
• The light beam of the sensor must never be
directed at people.
• Incorrect measurement parameters may result in
damage to the object being measured
2.3 Safety markings
2.3.1 Safety labelling in the working area
The following symbols and information signs are loc-
ated in the working area. They refer to the immediate
environment in which they are placed.
• All safety, warning and operating instructions
must be kept in a legible condition at all times.
• Damaged signs or stickers must be replaced
immediately.
Danger!
Improper use of the PaintChecker indus-
trial system can lead to dangerous situ-
ations.
Caution!
Danger with illegible signage! Over time,
stickers and signs can become dirty or
otherwise unrecognisable, so that haz-
ards cannot be recognised and neces-
sary operating instructions cannot be
followed. This creates a risk of injury

PaintChecker Industrial | 7
2.3.2 Safety marking on the measuring system
Depending on the type and current level of the laser
power supply used and the working distance of the
sensor, the laser safety class varies.
Warning sign 7
Danger group 3
Position: over status LEDs of
the controller
Warning sign 6
Hazard group 1
Position: over status LEDs of
the controller
Warning sign 5
Laser class 3R
Position: over status LEDs of
the controller
Warning sign 4
Laser class 1M
Position: over status LEDs of
the controller
Warning sign 3
Position: Near the light source (lens of the
sensor)
Warning sign 2
Position: Near the light source (lens of the
sensor)
Warning sign 1
Position: Near the light source (lens of the
sensor)
2.4 Risks caused by electricity
Danger to life due to electric current
• Work on the electronics of the measuring system
may only be carried out by OptiSense or by
personnel trained by OptiSense.
• If the insulation is damaged, the power supply
must be switched off immediately and the repair
must be arranged.
• Fuses must never be bypassed or deactivated.
When replacing a fuse, attention must be paid to
the correct rating.
• Voltage-carrying parts must be protected from
moisture. Otherwise a short circuit may occur.
• Protective covers must never be opened by the
user except for installation. In the event of faults,
the system must be returned immediately to
OptiSense GmbH & Co. KG.
• The main plug must be disconnected before
cleaning or maintenance work or when
troubleshooting.
• The mains cable must be laid in such a way that it
cannot be run over, kinked or pinched, come into
contact with liquids, heat or the laser itself, or be
damaged in any other way.
• The mains socket must always be easily access-
ible.
2.5 Dangers due to invisible light radiation
from the sensor
The description of the dangers of the radiation used
here depends on the equipment. The risk class ap-
plicable to the PaintChecker is indicated on the warn-
ing label of the controller. The limits for radiation
Danger!
When touching live parts, there is an im-
mediate risk of death due to electric
shock. Damage to the insulation or indi-
vidual components can be life-threaten-
ing.
Electrical information sign
Position: Right on controller housing
Caution!
The accident prevention regulations of
DGUV regulation 11 as well as the regula-
tions of the occupational health and
safety ordinance on artificial optical radi-
ation (OStrV) must be observed.

8 | PaintChecker Industrial
duration given here have been determined in part by
an expert in laser technology and are not generally
applicable to other devices of this safety class.
Incoherent radiation of risk group 1 (RG1)
Radiation in the IR-A range. There is a low risk here.
Damage to the retina can be largely ruled out. Even
prolonged but time-limited exposure to the light
source does not cause any damage.
Irradiation of the skin near the exit aperture of the
sensor can cause damage to the skin in the focus. The
laser radiation itself is not visible.
Source: LED (Cube-LEDR)
Mode: pulsed
λ: 950 nm +- 19 nm
Eₑ: 20.1 kW/m²
Incoherent radiation of risk group 3 (RG3)
Radiation in the UV-B range. Poses a risk in case of
short exposure within the safety distance. Protective
measures are essential here. When an individual
threshold dose (minimum erythema dose) is ex-
ceeded, so-called sunburn (UV erythema) occurs. The
maximum permissible irradiation of the skin is 64
seconds per day.
If the cornea is irradiated for more than 120 seconds
within a period of 1000 seconds, impairment accord-
ing to the criteria of EN 62471:2008 is to be expected.
Source: LED (Cube-LEDB)
Mode: pulsed
λ: 365 nm +- 9 nm
Eₑ: 5.4 kW/m²
LARES
A health hazard due to invisible light radi-
ation of class 1 can be excluded when used
correctly (see LARES®). The radiation is
accessible in this system, but so weak that
any damage can be excluded. This is important be-
cause the light radiation is in the non-visible wave-
length range.
Coherent radiation of class 1M
Radiation in the IR-B spectrum. Radiation of this class
can be dangerous if an optical instrument (magnify-
ing glass, microscope, etc.) is in front of the eye.
Glasses are not regarded as an optical instrument in
this case.
Irradiation of the skin near the exit aperture of the
sensor can cause burns in the focus. The laser radi-
ation itself is not visible.
Source: Laser diode (Tube LLP, Angle LLP)
Mode: pulsed
λ: 1480 nm
Pmax: < 5 mW (Laser 16 mm)
Pmax: < 7 mW (Laser 35 mm)
Coherent radiation of class 3R
Radiation in the IR-B spectrum. Radiation of this class
can be dangerous to the eye when looking directly
into the laser beam. Therefore, direct irradiation of
the eye should be avoided. The risk of injury increases
with the duration of exposure.
Class 3R lasers should only be used when direct view-
ing into the beam is unlikely.
• The laser beam must never be directed at the
eyes or skin.
• The light beam must never be viewed with optical
instruments such as magnifying glasses or
microscopes.
• The system may only be switched on after the
light beam exit aperture of the measuring head
has been inspected for external damage.
• The system must be switched off immediately
after the measurement and secured against being
switched on again.
• If the sensor is damaged, the system must no
longer be used. The sensor must be returned
immediately to OptiSense GmbH & Co. KG
2.6 Fire hazards
• The sensor must not be used in a potentially ex-
plosive atmosphere.
• The light beam of the sensor must not be direc-
ted onto easily flammable materials.
• Suitable extinguishing equipment (fire blanket,
fire extinguisher) must be kept available.
• In the event of fire, work with the system must be
Danger!
Irradiation of the skin near the exit aper-
ture on the measuring head can cause
burns in the focus. The laser radiation it-
self is not visible.
Danger!
The light beam can easily set fire to
flammable materials, liquids or gases,
causing serious or even fatal injuries.

PaintChecker Industrial | 9
stopped immediately. The danger zone must be
left until the all-clear signal is given and the fire
department must be alerted.
2.7 Responsibility of the operator
The operator is the person who operates the measur-
ing system for commercial or business purposes or
who allows a third party to use the system and who
takes legal responsibility for the product and the pro-
tection of users, personnel or third parties.
The system is intended to be used for commercial
purposes. The operator of the system is therefore
subject to the legal requirements for occupational
health and safety.
In addition to the safety instructions in this manual,
the regulations for occupational health and safety
and environmental protection that apply to the sys-
tem's area of use must be observed. In particular, the
following applies:
• The operator must inform himself about the
applicable occupational safety regulations and
carry out a hazard analysis in order to determine
additional risks resulting from the special working
conditions at the place of use of the measuring
system. These must be implemented in the form
of work instructions for the users of the
measurement system.
• Throughout the period of use of the measuring
system, the operator shall verify that his work
instructions are up to date with the current
harmonised regulations and shall adapt them if
necessary.
• The operator must clearly define and specify who
is responsible for commissioning, operation and
cleaning.
• The operator must ensure that all employees
who handle the measuring system have read and
understood this manual.
The operator remains responsible for ensuring that
the measuring system is free from technical faults at
all times. The operator must have all safety devices
checked regularly for functionality and completeness.
2.8 Requirements for personnel
• There is a risk of injury if the personnel is not suf-
ficiently qualified.
• All tasks must be carried out by qualified person-
nel only.
• Keep unqualified personnel away from the danger
zone.
Danger!
If unqualified personnel carry out work
with the measuring system or are in the
danger zone of the measuring system,
risks arise which can lead to serious in-
juries and considerable damage to
property.

10 | PaintChecker Industrial
3. Product Description
3.1 Operating principle of photothermal coating
thickness measurement
Non-contact, fast and efficient: Photothermal coating
thickness measurement is a contactless method for
lacquers, powder coatings and glazes on metallic and
non-metallic substrates. The different thermal prop-
erties of the coating and the substrate are used to
determine the coating thickness.
The surface of the coating is heated up by a few de-
grees with a short, intense light pulse and then cools
down again by dissipating the heat into deeper areas.
The thinner the coating, the faster the temperature
drops. The temperature curve over time is recorded
with a highly sensitive infrared sensor and converted
into the coating thickness.
The light pulse can be generated in different ways.
Compared to xenon flash lamps, LEDs and diode
lasers offer all the advantages of semiconductor
technology here, such as long service life, high effi-
ciency and absolute vibration resistance.
Fig. 2: Operating principle of photothermal coating
thickness measurement
Due to the tiny measuring spot, the method is also
suitable for the smallest components. The coating
thickness can even be determined at bending edges,
corners and curved surfaces where conventional
measurement technology reaches its limits. Disturb-
ances caused by rough surfaces or material grain are
compensated by optical averaging, so that even
pastes and powders can be checked before curing.
The measurement is carried out without contact from
a distance of several centimetres. This means that wet
and sticky layers can be measured just as easily as
soft and sensitive surfaces. Contamination of the
component or carry-over of coating material is ex-
cluded in principle.
3.2 LARES® – safety redefined
LARES® stands for LAser Radiation Eye
Safety technology and is the intelligent
answer to the continuously increasing re-
quirements in the area of personal and
eye protection. Especially when working directly with
lasers, these safety requirements always have the
highest priority. By using the new LARES® techno-
logy in the manufacturing and process industry,
people, machines and the environment are reliably
protected. The handling and application of the
devices can be carried out without the user having to
be trained and instructed in a way that requires doc-
umentation. Thanks to LARES® technology, the
devices can be used directly and without any restric-
tions in almost all areas of application.
The LARES® logo on the corresponding
OptiSense products make the safe laser
technology immediately recognisable. All
devices with the LARES® logo are safe for
the eye – even during prolonged irradiation.
3.3 Features and area of application
The PaintChecker industrial is a photothermal coating
thickness measurement system for automated oper-
ation in production. It builds on OptiSense's many
years of experience in the manufacture of reliable
and durable coating thickness measurement systems
for production-accompanying component testing as
well as the production of small and thus flexibly ap-
plicable sensors.
The underlying photothermal measuring method is
standardised according to DIN EN 15042-2 and is
suitable for the examination of moist, powdery and
dry coatings on various substrates such as metal, rub-
ber and ceramics. The PaintChecker industrial meas-
uring system is designed for customer integration
into automatic coating systems and consists of the
following components:
• 1-8 sensors (depending on controller variant)
• controller
The PaintChecker industrial systems can be flexibly
integrated into the production line. There, they de-
tect process deviations immediately after coating and
thus help to avoid returns and unnecessary material
waste. The measurements can be carried out both in
stop-and-go operation on the stationary object and
directly on the moving part when using active motion
compensation.