WAGNER Layer Check LC 1000 User manual

P_03487
Layer Check
LC 1000
Non-contact layer thickness
measurement
Version 03/2018

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OPERATING MANUAL
VERSION 03/2018 ORDER NUMBER DOC 2395602 Layer Check
Table of Contents
1 ABOUT THESE INSTRUCTIONS 6
1.1 Preface 6
1.2 Warnings, Notices and Symbols in these Instructions 6
1.3 Languages 7
1.4 Abbreviations 7
1.5 Terminology for the Purpose of this Manual 7
2 CORRECT USE 8
2.1 Device Type 8
2.2 Type of Use 8
2.3 Field of Application 8
2.4 Misuse 8
2.5 Warranty Conditions 9
3 IDENTIFICATION 10
3.1 CE Identication 10
3.2 Type Plate 10
4 BASIC SAFETY INSTRUCTIONS 11
4.1 Safety Instructions for the Operator 11
4.1.1 Safe Handling of the Devices 11
4.1.2 Electrical Devices and Equipment 12
4.1.3 Personnel Qualications 12
4.2 Safety Instructions for the Personnel 13
4.2.1 Safe Handling of the Devices 13
4.2.2 Grounding the Unit 13
4.2.3 Maintenance and Repair 13
4.2.4 Protective and Monitoring Equipment 13
5 DESCRIPTION 14
5.1 Components 14
5.2 Mode of Operation 14
5.3 Protective and Monitoring Equipment 15
5.4 Included Items 15
5.5 Technical Data 16
5.6 Operating Elements and Dimensions 17

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6 ASSEMBLY AND COMMISSIONING 18
6.1 Training of Assembly/Commissioning Personnel 18
6.2 Storage Conditions 18
6.3 Transport Inspection 18
6.4 Assembly and Installation 18
6.4.1 Installation and Connecting to the Mains 19
6.4.2 Assembly of Additional Components (Example) 20
6.5 Software Environments 21
6.6 Connecting with the PC 21
6.7 Network and Administrator Settings 22
6.7.1 Conguring the Layer Check Network Access 22
6.7.2 Installing the Layer Check Desktop Client 24
6.7.3 Change Language 25
6.7.4 Administrator Settings 26
7 OPERATION 27
7.1 Training the Operating Personnel 27
7.2 Layer Check Use for Rough Surfaces 27
7.3 Measuring with the Desktop Client 28
7.3.1 Manual Measurement 29
7.3.2 Automated Measurement with External Sensor 30
7.3.3 Measurement Statistics 34
7.3.4 Warnings and Errors 35
7.3.5 System and Maintenance Information 36
7.3.6 Conguring Layout of Main Window 37
7.4 Web Client 38
7.4.1 Measuringinstruments 38
7.4.2 Monitor 39
7.4.3 Settings 40
7.5 Layer Check Applications 41
7.5.1 Creating New Layer Check Application 41
7.5.2 Reference Measurement 43
7.5.3 Calibration Report 49
7.6 Measuring Before Curing 53
7.6.1 Measuring Powder Lacquers Before Curing 53
7.6.2 Measuring Liquid Coatings before Curing/Drying 53
7.6.3 Creating Application for Measurements before Curing 54
7.7 Backing up and Transferring Layer Check Applications 54
7.7.1 Exporting Application 55
7.7.2 Importing Application 56
7.8 Importing Material File 57
7.9 Exporting Measurement Data 58

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8 REMOTE CONTROL 59
8.1 TCP/IP 59
8.1.1 General Format of Commands and Results 60
8.1.2 "MEASURE" Command 61
8.1.3 "GETCONFIGURATIONS" Command 62
8.1.4 "GETCONFIGIDS" Command 62
8.1.5 "GETTHICKNESSBOUNDS" Command 63
8.1.6 "STARTAUTOMATION" Command (automatic mode) 64
8.1.7 "STOPAUTOMATION" Command (automatic mode) 64
8.1.8 "TRIGGERAUTOMATIONSENSOR" Command (automatic mode) 64
8.1.9 "GETAUTOMATIONSTATE" Command (automatic mode) 64
8.1.10 "CREATESAMPLE" Command (automatic mode) 64
8.1.11 "GETNUMBEROFMEASUREMENTS" Command 64
8.1.12 "GETSERVICESTATUS" Command 65
8.1.13 "GETCOATMASTERSTATUS" Command 65
8.1.14 "GETOBJECTTEMPERATURE" Command 65
8.1.15 "GETLASTOBJECTTEMPERATURE" Command 65
8.2 HTTP 66
9 MAINTENANCE 67
9.1 Maintenance Personnel 67
9.2 Safety Instructions 67
9.3 Software Maintenance 68
9.3.1 Diagnosis 68
9.3.2 Restoring Software on the Layer Check 69
9.4 Measurement Window 70
9.5 Filter Pads 70
9.6 Blank Measurement 71
10 TROUBLESHOOTINGTROUBLESHOOTING 72
11 DISPOSAL 72
12 SPARE PARTS 73
12.1 How can Spare Parts be Ordered? 73
12.2 Filter Pad 73
13 EU DECLARATION OF CONFORMITY 74

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1 ABOUT THESE INSTRUCTIONS
1.1 PREFACE
The operating manual contains information about safely operating, installing, maintaining,
cleaning and repairing the device. The operating manual is part of the device and must be
available to the operating and service personnel.
The device may only be operated by trained personnel and in compliance with this
operating manual. Operating and service personnel should be instructed according to the
safety instructions.
This equipment can be dangerous if it is not operated according to the instructions in this
operating manual.
1.2 WARNINGS, NOTICES AND SYMBOLS IN THESE INSTRUCTIONS
Warning instructions in this manual highlight particular dangers to users and to the
device and state measures for avoiding the hazard. These warning instructions fall into the
following categories:
DANGER Immediate risk of danger.
Non-observance will result in death or serious injury.
WARNING Potential risk.
Non-observance may result in death or serious injury.
CAUTION Potentially hazardous situation.
Non-observance may result in minor injury.
NOTICE Potentially hazardous situation.
Non-observance may result in damage to property.
Notice Provides information about particular characteristics and how
to proceed.
Explanation of warning notice:
LEVEL OF DANGER
This notice warns you of a hazard!
Possible consequences of not observing the warning notice.
The measures for preventing the hazard and its consequences.

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1.3 LANGUAGES
The Layer Check LC 1000 operating manual is available in the following languages:
Language Order no. Language Order no. Language Order no.
German 2395601 English 2395602 Spanish 2395605
French 2395604 Italian 2395606 Chinese 2395607
Additional languages on request or at: www.wagner-group.com
1.4 ABBREVIATIONS
Order no. Order number
Spare part
Position
Marking in the spare parts lists
Number of pieces
LAN Local area network
SNR Signal to noise ratio
IR Infrared
1.5 TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL
Personnel qualications
Trained person Is instructed in the tasks assigned to him/her, the potential risks
associated with improper behavior as well as the necessary
protective devices and measures.
Electrically trained
person
Is instructed by an electrician about the tasks assigned to him/her,
the potential risks associated with improper behavior as well as
the necessary protective devices and measures.
Electrician Can assess the work assigned to him/her and detect possible
hazards based on his/her technical training, knowledge and
experience in relevant provisions.
Skilled person in
accordance with
TRBS 1203
(2010/Revision 2012)
A person, who, based on his/her technical training, experience
and recent vocational experience, has sucient technical
knowledge in the areas of explosion protection, protection
from pressure hazards and electric hazards (if applicable) and
is familiar with the relevant and generally accepted rules of
technology so that he/she can inspect and assess the status of
devices and coating systems based on workplace safety.

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2 CORRECT USE
2.1 DEVICE TYPE
Non-contact layer thickness measuring device: Layer Check LC 1000
2.2 TYPE OF USE
The thickness measuring device is suited to the non-contact measurement of layer thicknesses
for the following coatings: powder lacquers before and after curing, adhesives and liquid
coatings before and after drying and ceramic coatings on all materials.
–Powder coatings on metallic base
–Adhesive coatings on metallic base
–Polymer coatings on metallic base
–Liquid coating on metallic base
–Liquid coating (when wet) on non-metallic base
–Thermal spray coatings
WAGNER explicitly prohibits any other use!
The device may only be operated under the following conditions:
Do not deactivate safety xtures.
Use only WAGNER original spare parts and accessories.
The operating personnel must be trained on the basis of this operating manual.
Follow the instructions in the operating manual.
Observe service intervals.
2.3 FIELD OF APPLICATION
The device is not suitable for use in potentially explosive areas.
(See Chapter 3.1"CE Identication".)
2.4 MISUSE
Misuse can lead to physical injury and/or property damage!
Special attention must be paid that:
Do not operate the device in environments where liquids may enter the housing.

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2.5 WARRANTY CONDITIONS
The warranty conditions form part of the manufacturer's general terms and conditions.
The software is installed on the embedded PC integrated in the Layer Check. Any system
modications and modications to the embedded PC may impair or damage the Layer Check
and are therefore prohibited. This includes, e.g.,
– Installation of further software
– Software updates
WAGNER assumes no liability for the loss of data on the embedded PC.We would recommend
regularly backing up data on the embedded PC:
–Saving application data: see Chapter 7.7
–Saving measuring data: see Chapter 7.9

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3 IDENTIFICATION
3.1 CE IDENTIFICATION
The device may not be used in potentially explosive areas.
3.2 TYPE PLATE
J. Wagner GmbH
D-88677 Markdorf
Made in Switzerland
Type: Layer Check LC 1000
Voltage: 220–240 VAC 50/60 Hz
Current max: 10 A
Art. No.: 2364012
Serial No. :
P_03642
3
4
5
6
2
1
Designation
1Manufacturer and CE symbol
2Device Type
3 Input voltage
4 Maximum input current
5 Article number
6 Serial number

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4 BASIC SAFETY INSTRUCTIONS
4.1 SAFETY INSTRUCTIONS FOR THE OPERATOR
Keep this operating manual at hand near the device at all times.
Always follow local regulations concerning occupational safety and accident prevention.
The operator shall inform the seller without delay of any safety-related events which
may arise when operating the device or its accessories.
Legal requirements, such as local, state and federal legislation, applicable to the
device or its accessories, must be strictly observed.
4.1.1 SAFE HANDLING OF THE DEVICES
Integrated light source!
Direct visual contact may result in visual impairments.
Never look directly into the light source.
When using the Layer Check in the process environment, we would recommend
building an optical screen around the light source. The screen will absorb the light
pulse so it has no impact outside the measurement area. Items such as blackened
plates are suitable for the screen.
False alarm from incompatible re alarms!
The light pulse from the LayerCheck may trigger re alarm systems.
Only use compatible re alarms with dual UV/IR sensors in locations where the Layer Check
is used.

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4.1.2 ELECTRICAL DEVICES AND EQUIPMENT
Electric shock hazard!
Danger to life from electric shock.
Prepare device in accordance with the local safety requirements with regard to the
operating mode and ambient inuences.
The Layer Check housing must not be opened. Exception: Unscrewing the rear cover
to clean and/or change the lter mats (see Chapter 9.5).
Only have device maintained by the WAGNER Service Department.
Exception: Filter mat (see Chapter 9.5).
Operatedevicein accordancewith thesafetyregulationsand electrotechnicalregulations.
If water escapes from the Layer Check, you must immediately switch it o with
the mains switch, disconnect the mains plug and contact the WAGNER Service
Department.If water escapes from the Layer Check, you must immediately switch
it o with the mains switch, disconnect the mains plug and contact the WAGNER
Service Department.
Must be repaired immediately in the event of problems.
Decommission if it poses a hazard or is damaged.
Must be de-energized before work is commenced. Inform personnel about planned work.
Observe electrical safety regulations.
Ground all devices to a common grounding point.
Only operate the device with a properly installed socket with a protective ground wire
connection.
In order to interrupt the power supply in an emergency by disconnecting the mains
plug, no devices or other objects may be blocking access to the mains plug.
Keep liquids away from electrical devices.
4.1.3 PERSONNEL QUALIFICATIONS
Hazard due to incorrect use of device!
Risk of death due to untrained personnel.
Ensure that the operating personnel has been instructed by the operator in accordance
with the operating manual and the operating instructions. The device may only be
operated by trained sta. Refer to the operating instructions for information about
the required personnel qualications.
Ensure that the operating sta have read and understood the operating manual.
The device may only be used by people who have the training or professional
experience to enable them to understand the risks which may arise when operating
the device.

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4.2 SAFETY INSTRUCTIONS FOR THE PERSONNEL
Always follow the information in this manual, particularly the safety instructions and
the warning instructions.
Always follow local regulations concerning occupational safety and accident prevention.
4.2.1 SAFE HANDLING OF THE DEVICES
Integrated light source!
Direct visual contact may result in visual impairments.
Never look directly into the light source.
4.2.2 GROUNDING THE UNIT
Electric shock!
Danger to life.
Before use check that grounding is correct.
Immediately replace any defective cables.
4.2.3 MAINTENANCE AND REPAIR
Hazard due to improper maintenance and repair!
Danger to life and equipment damage.
Only a WAGNER service center may carry out repairs and replace parts.
Exception: Filter mat.
Do not change or modify the device; if change is necessary, contact WAGNER.
Only repair and replace parts that are listed in the 12 chapter that are assigned to
the unit.
Do not use any defective components.
Before all work on the device and in the event of work interruptions:
– Shut down power supply.
Observe the operating and service manual for all work.
4.2.4 PROTECTIVE AND MONITORING EQUIPMENT
Hazard due to removal of protective and monitoring equipment!
Danger to life and equipment damage.
Protective and monitoring equipment must not be removed, modied or rendered
unusable.
Regularly check for perfect functioning.
If defects are detected on protective and monitoring equipment, the device must not
be operated until these defects are remedied.

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5 DESCRIPTION
5.1 COMPONENTS
P_03487
LC 1000 operating elements
See Chapter 5.6.
5.2 MODE OF OPERATION
The Layer Check operates on the principle of the
thermal layer check. A light pulse heats the surface
of the coating. After it has been briey heated by
a few degrees Celsius, the surface is cooled by
dissipating heat into the lower parts of the coating
and base. The manner in which the surface cools
depends on the physical properties of the coating and
base. If the coating has a lower thermal conductivity
than the base, the thinner the coating is, the faster
the surface temperature then subsides.
P_03495
IR sensor IR radiation
Flash lamp
Heat input in
pulses
Base
Coatings

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5.3 PROTECTIVE AND MONITORING EQUIPMENT
WARNING
Protective and monitoring equipment!
Risk of injury and damage to the device.
Protective and monitoring equipment must not be removed, modied or rendered
unusable.
Regularly check for perfect functioning.
If defects are detected on protective and monitoring equipment, the system must
not be operated until these defects are remedied.
Optical screen
When using the Layer Check in the process environment, we would recommend building
an optical screen around the light source. The screen will absorb the light pulse so it has
no impact outside the measurement area. Items such as blackened plates are suitable for
the screen.
5.4 INCLUDED ITEMS
Designation Order no.
Layer Check LC 1000:
– Layer Check measuring device
– Mains cable
--
The scope of delivery includes:
Service log book Layer Check LC 1000 --
Declaration of Conformity. For details, see Chapter 13 2395608
Operating manual for Layer Check, in German 2395601
Operating manual in the local language see Chapter 1.3
The delivery note shows the exact scope of delivery.
Note:
The Layer Check LC 1000 is available with monitor/PC, light barrier and lifting carriage (option):
Layer Check LC 1000 Standalone
(with lifting carriage)
Set
(without lifting carriage)
Designation Order no. Order no.
Layer Check LC 1000 2388371 2392757
Consists of:
– Layer Check measuring device ✓ ✓
– Mains cable ✓ ✓
– Layer Check gateway (PC) ✓ ✓
– Connection kit ✓ ✓
– Grounding cable ✓ ✓
– 15.6" IP65 display + support arm + USB ✓ ✓
– Lifting carriage ✓
– Light barrier ✓ ✓

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5.5 TECHNICAL DATA
Description LC 1000
Power supply 1000 J
Measuring distance* 5–30 cm; 2.0–11.8 inch
Measuring point** Ø 2–20 mm; 0.08–0.8 inch
Measuring range:
Powder lacquer not cured 1–500 µm
Powder lacquer cured 1–1000 µm
Powder lacquer started to gel 1–1000 µm
Liquid coating 1–1000 µm
Duration of measurement 20–2000 ms
Frequency with which measurement is repeated 0.5 Hz
Relative measurement object movement 50 m/min
Angle tolerance ±70°
Power connection IEC 320-C14
Rated voltage 230 V AC, 50 Hz
Maximum power consumption 2000 W
Operating temperature 5–35 °C; 41–95 °F
Relative humidity < 80 %
Dimensions 374 × 490 × 196 mm
14.7 × 19.3 × 7.7 inch
Weight 16.8 kg; 37 lb
Mount Guide rail
Interfaces
Ethernet
External sensor
WLAN optional
* depending on coating and substrate
** depending on distance / focal width

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5.6 OPERATING ELEMENTS AND DIMENSIONS
Front side Prole
P_03488
A
B
C
D
E
F
G
H
Measurement mm inch
A 374 14.72
B Ø 120 Ø 4.72
C Ø 47 Ø 1.85
D 102 4.02
Measurement mm inch
E 295 11.61
F 196 7.72
G 471 18.54
H 380 14.96
P_03480
2
1
3
4
5
Rear side
Function
1 On/o switch
2 Power connection
3 USB connection for WiFi
4 Ethernet connection
5 Sensor connection

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6 ASSEMBLY AND COMMISSIONING
6.1 TRAINING OF ASSEMBLY/COMMISSIONING PERSONNEL
The assembly and commissioning personnel must have the technical skills to safely
commission the device.
When assembling, commissioning and carrying out all work, read and follow the operating
manuals and safety regulations for the additionally required system components.
A skilled person must check to ensure that the device is in a reliable state after it is installed
and commissioned.
6.2 STORAGE CONDITIONS
Under certain circumstances, there will be information on the packages relating to storage
and putting back into storage, which is more exacting than the requirements stated here.
Observe this information accordingly.
Store packages under the following conditions:
– Do not keep outdoors.
– Store in a dry location free of dust.
– Do not subject packages to aggressive substances.
– Protect from sunlight.
– Avoid mechanical impact and vibrations.
– Storage temperature: 5–35 °C; 41–95 °F
Before switching on, wait until the device has reached room temperature.
– Relative humidity: max. 80 %
If storing for more than 3 months:
– Regularly check the general condition of all parts and the packaging.
– If necessary, refresh or renew the anti-corrosion protection.
– Start up Layer Check at least every six months.
6.3 TRANSPORT INSPECTION
Upon receipt, immediately check that the delivery is complete and has not incurred damage
during transport. If any damage incurred during transport can be seen externally, proceed
as follows:
– Do not accept delivery or only do so with reservations.
–Note the extent of damage on the transport documents or on the shipping company's
delivery note.
– Initiate the complaints process.
Raise a complaint about any damage as soon as it is detected. Claims for compensation for
damages can only be made within the claim periods.
6.4 ASSEMBLY AND INSTALLATION
Check the Layer Check's components against the delivery note. Keep original packaging
for future use. Read the operating manual.

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6.4.1 INSTALLATION AND CONNECTING TO THE MAINS
– Install the device on a clean, sturdy, at and horizontal surface.
– Do not place any objects on or under the device.
– The device must be located at a distance of at least 20cm; 7.9inch from the nearest
object or wall to ensure sucient cooling.
– Use the mains cable supplied to connect the device to the mains.
WARNING
Electric shock!
Danger to life.
Before use check that grounding is correct.
Immediately replace any defective cables.
CAUTION
Integrated light source!
Direct visual contact may result in visual impairments.
Never look directly into the light source.
When using the Layer Check in the process environment, we would recommend
building an optical screen around the light source. The screen will absorb the light
pulse so it has no impact outside the measurement area. Items such as blackened
plates are suitable for the screen.
Note:
In order to interrupt the power supply in an emergency by disconnecting the mains
plug, no devices or other objects may be blocking access to the mains plug.
NOTICE
False alarm from incompatible re alarms!
The light pulse from the LayerCheck may trigger re alarm systems.
Only use compatible re alarms with dual UV/IR sensors
(e.g., those from STS Brandschutzsysteme GmbH) in locations where the Layer Check is used.
NOTICE
90°
P_03643
90°
P_03644
Devices installed at too great an inclination!
Device overheats.
If the device is installed vertically tilted, do not
exceed an angle of 90°. If the device is installed
horizontally tilted, do not exceed an angle of 90°.

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NOTICE
Fingerprints and dirt on the lens!
Measurement errors and device faults.
Never touch the lens directly.
Clean lens and measurement window according to Chapter9.4.
6.4.2 ASSEMBLY OF ADDITIONAL COMPONENTS EXAMPLE
6.4.2.1 ASSEMBLY ON LIFTING CARRIAGE
Follow the instructions in the lifting carriage operating manual at all times!
P_03640
E
A
B
C
D
F
G
1. Position lifting carriage somewhere level, solid and smooth.
2. Secure lifting carriage's wheels.
3. Use hand crank (E) to move retaining xture (C) of lifting carriage (G) to a suitable
height.
4. Position measuring device (A) on retaining xture (C). Do not touch lens (B)!
5. Use 4 screws and washers to screw
underside of measuring device (A) onto
retaining xture (C).
P_03638
P_03639
6. Plug Ethernet cable into measuring device (A).
7. Plug light barrier cable into measuring device (A) (connection for external sensor).
8. Plug mains cable into measuring device (A).
6.4.2.2 MONITOR ASSEMBLY
Follow the instructions in the monitor operating manual at all
times!
P_03641
D
H
Switch o voltage supply.
1. Fit monitor holder (H) on lifting carriage (G). The long tube section
must be at the top.
2. Fit monitor (D) on monitor holder (H).
3. Install monitor (D) according to monitor operating manual.
6.4.2.3 GATEWAY ASSEMBLY
Follow the instructions in the gateway (embedded PC) operating manual at all times!
Switch o voltage supply.
1. Install gateway according to gateway operating manual.
2. Connect gateway with monitor.