OptiSense PaintChecker Mobile User manual

PaintChecker Mobile
User Manual
EN Version 23.08

2 | PaintChecker Mobile
Table of Contents
1. Overview, Measuring Method and Models....................................................................................................................................4
1.1 How to use this manual ..............................................................................................................................................................4
1.2 Challenges for today's coating companies..........................................................................................................................4
1.3 The PaintChecker Mobile - Quick Reference ......................................................................................................................4
1.4 Copyright ©2023 OptiSense.....................................................................................................................................................4
1.5 The photothermal coating thickness measurement ........................................................................................................5
1.6 The model range............................................................................................................................................................................6
1.7 PaintChecker Mobile Delivery Contents ...............................................................................................................................7
1.8 Accessories.......................................................................................................................................................................................7
2. Safety and Responsibility ......................................................................................................................................................................8
2.1 Warning symbols and other guidelines ................................................................................................................................8
2.2 Correct use .......................................................................................................................................................................................8
2.3 Safety markings..............................................................................................................................................................................8
2.4 Intended use....................................................................................................................................................................................9
2.5 Unintended use ..............................................................................................................................................................................9
2.6 Danger from optical radiation..................................................................................................................................................9
2.7 Dangers due to invisible light radiation from the sensor ........................................................................................... 10
2.8 Risks caused by electricity.......................................................................................................................................................11
2.9 Fire hazards................................................................................................................................................................................... 11
2.10 Hazards when handling Li-ion batteries ......................................................................................................................... 11
2.11 Residual hazards....................................................................................................................................................................... 11
2.12 Responsibility of the operator............................................................................................................................................. 11
2.13 Requirements for personnel ................................................................................................................................................ 12
3. Setup and first steps ............................................................................................................................................................................ 13
3.1 Charging the batteries.............................................................................................................................................................. 13
3.2 Insert batteries............................................................................................................................................................................. 13
3.3 Connecting sensor and controller........................................................................................................................................ 14
3.4 Switching the device on and off ........................................................................................................................................... 14
4. Operation ................................................................................................................................................................................................. 15
4.1 Display............................................................................................................................................................................................. 15
4.2 Keys.................................................................................................................................................................................................. 15
4.3 Menu navigation......................................................................................................................................................................... 16
4.4 Instrument Settings ................................................................................................................................................................... 16
4.5 PC connection and OS Manager .......................................................................................................................................... 18
5. Measuring with the PaintChecker Mobile ................................................................................................................................... 19
5.1 Performing a measurement .................................................................................................................................................... 19
5.2 Measurement with spacer cap and tripod........................................................................................................................19
5.3 Measuring with OS Manager .................................................................................................................................................20
5.4 Measurement batches .............................................................................................................................................................. 20
5.5 Create a new batch .................................................................................................................................................................... 20
5.6 Recording a batch ...................................................................................................................................................................... 21
5.7 Evaluating a batch ...................................................................................................................................................................... 21
5.8 Appending to a batch............................................................................................................................................................... 21
5.9 Deleting a batch.......................................................................................................................................................................... 22
5.10 Setting limits .............................................................................................................................................................................. 22
5.11 Changing the application...................................................................................................................................................... 22
5.12 LARES® – Safety redefined.................................................................................................................................................. 23
6. Applications............................................................................................................................................................................................. 24
6.1 Creating a new application ..................................................................................................................................................... 24
6.2 Applications for measuring uncured coatings ................................................................................................................26

PaintChecker Mobile | 3
6.3 Editing an application ............................................................................................................................................................... 26
6.4 Deleting an application ............................................................................................................................................................26
6.5 Editing applications with OS Manager...............................................................................................................................26
7. Maintenance, error messages and best practice ...................................................................................................................... 27
7.1 Transport and storage............................................................................................................................................................... 27
7.2 Cleaning and Care......................................................................................................................................................................27
7.3 Periodic Check ............................................................................................................................................................................. 27
7.4 Services........................................................................................................................................................................................... 27
7.5 Error messages ............................................................................................................................................................................ 28
7.6 Disposal .......................................................................................................................................................................................... 28
7.7 Customer service and service hotline................................................................................................................................. 28
7.8 FAQ – Frequently asked questions.......................................................................................................................................29
7.9 Material Matrix - Best Practice .............................................................................................................................................. 30
8. Technical Data......................................................................................................................................................................................... 31

4 | PaintChecker Mobile
1. Overview, Measuring Method and Models
1.1 How to use this manual
Thank you very much for purchasing the Paint-
Checker Mobile. The device is based on the outstand-
ing technology and high standards of OptiSense and
offers maximum precision mobile coating thickness
measurement.
This manual has been specially designed to guide
you step by step through the features and options of
your PaintChecker Mobile.
Please read the following section first!
• Before using your PaintChecker Mobile, read the
entire manual and all safety instructions to ensure
safe and proper operation
• The instructions in this manual refer to your
device at default settings
• The pictures and images used in this manual may
differ from the actual product
• The content of this user manual is subject to
change without notice. The latest version of this
manual can be found on the OptiSense website at
www.OptiSense.com
• The available functions may differ depending on
the particular device and software
• Keep this manual for future reference.
1.2 Challenges for today's coating companies
The challenges on coating companies are growing:
More individual products, smaller batch sizes and
more frequent colour changes. Added to this are the
growing documentation requirements and more and
more orders where the coating thickness is function-
ally relevant.
The PaintChecker mobile helps you to meet all these
requirements by checking coating thickness at an
early stage in the process – even before baking –
without contacting the part.
The mobile handheld device is particularly suitable
for random sample measurement as well as for coat-
ing inspection of large components or small batches.
1.3 The PaintChecker Mobile - Quick Reference
The OptiSense PaintChecker Mobile models support
accurate measurement of wet, powdery and solid
coatings on various substrates without contacting
the surface. The compact, lightweight, handheld
devices are designed for continuous, fatigue-free use
in the laboratory and on the production line.
The PaintChecker systems use the photothermal
measuring process to determine the thickness of
coatings on a wide variety of substrates.
As with other non-destructive coating thickness
measurement methods, e.g. ultrasonic, eddy current
or induction, photothermal coating thickness is not
measured directly, but calculated from measurement
signals. It is therefore important to consider the indi-
vidual thermal properties of coating material and
substrate.
The measurement is carried out without contact from
a distance of several centimetres. This means that wet
and sticky coatings can be measured just as easily as
soft and sensitive surfaces. A contamination of the
part or the carry-over of coating material is thereby
excluded in principle.
1.4 Copyright ©2023 OptiSense
All rights reserved: All brand names and trademarks
mentioned in this user manual are the property of
their respective owners. The use of brand names and
trademarks is for descriptive purposes only.

PaintChecker Mobile | 5
1.5 The photothermal coating thickness
measurement
1.5.1 Key technology for coating thickness checking
The photothermal coating thickness measurement is
a contactless measurement method for paints,
powder coatings and glazes on metallic and non-
metallic substrates. The different thermal properties
of coating and substrate are used to determine the
coating thickness.
The surface of the coating is warmed 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 coating thickness.
Fig. 1: The photothermal measuring method 1
1.5.2 Reproducible measurement results even with
most demanding coatings
Thick, heavy coatings need more energy to heat up
and cool down more slowly than thin, light coatings.
During the measuring process, it is therefore import-
ant, as in photography, that the strength of the light
source and the measuring time are optimally adjus-
ted to the respective situation, in order to obtain ac-
curate and reproducible measurement results.
In the case of powder coatings and paintwork, there
is also the fact that the user often does not want to
know the thickness of the powder or wet film that has
just been applied, but the later, final thickness after
baking or drying. For this purpose, the PaintChecker
Mobile takes the expected shrinkage of the coating
material during curing into account.
Thanks to the precise measuring spot, the method is
also suitable for the smallest components. The coat-
ing thickness can even be determined on bending
edges, corners and curved surfaces, where conven-
tional measurement technology reaches its limits.
Disturbances caused by rough surfaces or material
grains are compensated for by optical averaging, so
that even pastes and powders can be checked before
baking.
Fig. 2: The photothermal measuring method 2

6 | PaintChecker Mobile
1.6 The model range
OptiSense is the world's leading provider of photo-
thermal measuring systems for coating thicknesses
on a wide variety of substrates.
A common feature of all mobile handheld devices is
their ability to measure a still soft powder layer on
substrates such as metal, wood, glass or plastic, re-
gardless of colour and type. With a simple measure-
ment the very cost-intensive rework of under- or
overcoating can be avoided.
The sensor head is detached from the control unit
and connected with a flexible cable. The lightweight,
ergonomically designed sensor can be carried com-
fortably in a holster and guided precisely and effort-
lessly to the component without touching or dam-
aging the sensitive coating.
LED sensors feature a larger measuring spot making
them ideal for freehand measurements on rough sur-
faces.
1.6.1 PaintChecker Mobile Gun-B
Fig. 3: PaintChecker Mobile Gun-B
The mobile OptiSense Gun-B is designed for contact-
less testing of freshly applied powder coatings prior
to burn-in.
1.6.2 PaintChecker Mobile Gun-R
The Gun-R model is particularly suitable for compon-
ents made of plastic or rubber.
Fig. 4: PaintChecker Mobile Gun-R
1.6.3 PaintChecker Mobile Laser Pen
Fig. 5: PaintChecker Mobile Laser Pen
The OptiSense mobile laser models are mainly used
for smooth coatings on metallic substrates. With their
tiny measuring spot the slim laser sensors are partic-
ularly suitable for coating thickness testing on delic-
ate small parts, corners and edges. A special version
with an extra short working distance allows you to
measure in very confined spaces or on coatings con-
taining high amounts of metal.
All OptiSense mobile models are eye-safe thanks to
the patented LARES® technology.

PaintChecker Mobile | 7
1.7 PaintChecker Mobile Delivery Contents
Your new PaintChecker Mobile is delivered in a sturdy
carrying case. Included in the scope of delivery are:
Fig. 6: PaintChecker Mobile Delivery Contents
Please note:
• The items supplied with the device have been
designed for this unit and may not be compatible
with other products.
• Other accessories may not be compatible with
your device.
❶Sensor with connection cable
❷Gray glass reference
❸Controller
❹Charger
❺USB power supply
❻Two sets of 4 rechargeable batteries
❼Shoulder strap
❽USB data cable
❾USB drive with user manual, OS Manager
software, etc.
❾
❽❼
❻
❺
❹
❸
❷
❶
1.8 Accessories
The following accessories are available for all models:
• Spacer caps
• Tripod
• Cable 2.3 m
• Calibration certificate
Use only accessories approved by OptiSense. Using
non-approved accessories may cause malfunction of
the device.

8 | PaintChecker Mobile
2. Safety and Responsibility
2.1 Warning symbols and other guidelines
This section provides you with all relevant informa-
tion for proper personal protection and for safe as
well as efficient operation. Read these instructions
carefully before operating the device. Please observe
any additional company- or country-specific direct-
ives and regulations that may apply.
For your safety, it is important that you read and fully
understand the following list of warning symbols and
their definitions! Safety instructions are indicated by
symbols and signal words. The symbol provides in-
formation about the type of hazard while the signal
word indicate it’s extend.
DANGER!
Warning of an imminent threat
that would cause death or serious
injury
DANGER!
Warning of a serious threat from
laser radiation
DANGER!
Warning of a serious threat due to
fire hazard
DANGER!
Warning of a serious electrical
voltage hazard.
ATTENTION!
Attention to a less serious hazard
category. The symbol shows an
exclamation mark.
2.2 Correct 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 incorrect 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, heat
or dry other object
• 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 signs are located in the
work 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
TIPS
This symbol highlights hints
and recommendations as well as
information for efficient and
trouble free operation
DANGER! Incorrect use of the PaintChecker
Mobile can lead to dangerous
situations

PaintChecker Mobile | 9
2.3.2 Safety marking on the measuring system
Position Warning Label 1-4: Near the light source
(Sensor lens)
Position Warning Label 5-7: Back of the controller on
the battery compartment
2.4 Intended use
The PaintChecker Mobile from OptiSense is a port-
able hand-held device intended solely for measuring
the thickness of coatings.
The device is to be operated only by persons who
have read and understood this manual. Intended use
also means that the user reads and understands this
manual, in particular the safety section.
ATTENTION! Danger with illegible signage! Over
time, stickers and signs can become
dirty or otherwise unrecognisable, so
that hazards cannot be recognised
and necessary operating instructions
cannot be followed. This creates a risk
of injury
Warning Label 1 | General warning sign
Warning Label 2 | Laser Radiation & ESD
Warning Label 3 | IR radiation
Warning Label 4 | UV radiation
Warning Label 5 |
Class 1 Laser
Warning Label 6 |
Risk Group 3 UV
Warning Label 7 |
Risk Group 3 IR
Guidelines to avoid damage to the device:
• Do not expose the PaintChecker Mobile to
extreme temperatures. Keep it away from high
humidity or moisture
• Do not place the device in locations where it is
exposed to corrosive gases or salty air.
• Keep the PaintChecker in a locked cabinet and
give it only to people who have read and
understood the manual
• Do not use harsh cleaners, abrasives or solvents
to clean the device. Use only a clean, dry cloth
• Observe the technical specifications. To operate
the PaintChecker Mobile as intended, use only
accessories tested by OptiSense
By proper disposal of electrical equipment, you will
help to conserve valuable resources and avoid poten-
tial negative impacts on health and the environment,
which could otherwise be caused by inappropriate
waste disposal (see also Directive 2012/19/EU on
remanufacturing and recycling). Accessories and
packaging should also be recycled in an environ-
mentally friendly manner.
2.5 Unintended use
Any operation that does not comply with the tech-
nical specifications is considered unintended use. The
operator is solely liable for any damage caused by
unintended use. The following is prohibited
• Operating the device in environments where
liquids can enter the device
• Unauthorised alterations, additions or
modifications to the device
• Opening the device, except for changing the
batteries
• Removing safety marks, stickers, or labels. Keep
all safety marks, stickers and labels in a legible
condition
• OptiSense does not accept any liability for
damages resulting from unintended use. In this
case, warranty claims are void.
2.6 Danger from optical radiation
WARNING! The PaintChecker Mobile uses short,
intense light pulses (partly in the non-
visible range) for measurement.
Please observe the following safety
instructions:

10 | PaintChecker Mobile
• Do not point the sensor at easily flammable
material
• In order to completely exclude irradiation, a
distance cap can be used and contacting
measurements can be taken
• Do not put a damaged sensor into operation
• The device is not approved for operation in
potentially explosive atmospheres (ATEX)
2.7 Dangers due to invisible light radiation from
the sensor
The PaintChecker Gun-B emits UV radiation!
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
duration given here have been determined in part by
an expert in laser technology and are not generally
applicable to devices of this safety class.
Coherent radiation of laser class 1
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 do not constitute an optical instrument in this
case.
ATTENTION! The accident prevention regulations of
DGUV regulation 11 as well as the reg-
ulations of the occupational health
and safety ordinance on artificial op-
tical radiation (OStrV) must be ob-
served
Irradiation of the skin near the exit aperture on the
measuring head can cause burns in the focus. The
laser radiation itself is not visible
Incoherent IR radiation of risk group 3 (RG3)
Radiation in the IR-A range: There is a low risk here.
Damage to the retina can be largely ruled out. Even
when looking into the light source for a longer period
of time, no damage occurs. Irradiation of the skin in
the vicinity of the exit aperture on the measuring
head can cause damage to the skin in the focus. The
laser radiation itself is not visible.
Radiation in the UV-B range poses a risk with short
exposure within the safety distance. Protective meas-
ures are essential here. When an individual threshold
dose (minimum erythema dose) is exceeded, the 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 1,000 seconds with the PaintChecker Gun-B,
an impairment according to the criteria of the EN
62471:2008 standard is to be expected.
Source: Laser diode (Pen-1.6, Pen-3.5)
Mode of operation: pulsed
λ: 1480 nm
Emax: 750 mJ (laser 16 mm)
Emax: 750 mJ (laser 35 mm)
Source: LED (Gun-R)
Mode of operation: pulsed
λ: 950 nm +- 19 nm
Emax: 750 mJ
Source: LED (Gun-B)
Mode of operation: pulsed
λ: 365 nm +- 9 nm
Emax: 750 mJ
LARES A health hazard due to invisible light
radiation of class 1 is excluded when
used correctly (see 3.2.4 LARES®). The
radiation is accessible in this system, but
so weak that any damage can be
excluded. This is important because the
light radiation is in the non-visible
wavelength range