ElektroPhysik 85-809-0023 User manual

PAINT BORER 518 USB 1

Layer Thickness Measuring

NOTICE
Please read and precisely follow this operating manual before commissioning the

instrument.

Operating Manual

Instrument

PAINT BORER

Model 518 USB

Country of origin: Germany

Status: X/2016

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TABLE OF CONTENTS
Page

1 General information 4

1.1 Incoming goods inspection 4

1.2 Proper and intended usage 4

1.3 Storage and operations 4

1.4 Safety information 4

1.5 Copyright protection 4

1.6 Address of the manufacturer 4

2 Device specifications 5

2.1 Designation and type 5

2.2 Included in the delivery 5

2.2.1 Base unit 5

2.2.2 Additional accessories (must be ordered optionally) 5

2.2.3 Replacement parts 5

2.3 Technical specifications 6

2.3.1 Base unit 6

2.3.2 Wedge cut drill 6

3 Commissioning – Operations – Handling 7

3.1 Commissioning / driver and software installation 9

3.1.1 Minimum system requirements 9

3.1.2 Camera driver 9

3.1.3 Software installation 9

3.2 Commissioning and calibration 10

3.3 Power supply 14

3.

4 Lig

3.3 Setting the image focus 15

3.4 Slider mechanism 16

3.5 Wedge cut drill 16

4 Program functions 17

4.1 Menu and screen components 17

4.2 Information about the sample 19

4.3 Selection of drill and image color 20

4.3.1 Drill selection 20

4.3.2 Image color 20

4.4 Composition of the sample (layer composition) 21

5 Layer thickness measurement 23

5.1 Preparing the test samples 23

5.2 Drilling into the sample 23

5.3 Carrying out the measurement (via software) 24

5.3.1 Grab image 24

5.3.2 Selecting the circles 25

5.3.3 Tracing the circles 25

5.3.4 Display of measured values 26

6 Inserting a customer logo 27

hting and auxiliary lighting 14

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7 Logs 29
8 Special measuring problems 31

8.1 Delamination 31

9 Maintenance and care 32

Declaration of Conformity (page 33)

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1 General information

1.1 Incoming goods inspection

Check the delivery for completeness. Report any transport-related damages directly to
the supplier or the responsible insurance agent.

1.2 Proper and intended usage

The PAINT BORER 518 USB is used to measure the thickness of organic coatings on
substrates using the wedge cut method.

Erichsen GmbH & Co. KG is not liable for damages caused by improper use.

1.3 Storage and operations

Refer to section 2.3.1 for the permissible temperature ranges.

1.4 Safety information

The generally applicable laws and regulations concerning accident prevention and
environmental protection are applicable.

1.5 Copyright protection

The copyright of this operating manual is kept by
ERICHSEN GmbH & Co. KG, D-58675 Hemer, Germany.
This manual is intended only for the operator and their staff. It contain regulations and
instructions that may not be fully or partially reproduced, distributed or otherwise
communicated.
Violation of these rights could result in a criminal prosecution.

1.6 Address of the manufacturer

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2 Device specifications

2.1 Designation and type

The layer thickness measuring instrument TNO PAINT BORER Model 518 USB:

(order number 2348.01.31) featuring a high-resolution digital microscope with in tegrated
light

2.2 Included in the delivery

2.2.1 Base unit

1 No.5 drill, for layer thicknesses up to 300 microns
1 felt-tip marker, black
1 felt-tip marker, silver
1 screwdriver
1 rechargeable battery (9 V)
1 power supply (100 – 240) VAC / (47 – 63) Hz
1 software
1 calibration template
1 operating manual
1 plastic case

2.2.2 Additional accessories (must be ordered optionally)

Drill No.2 for layer thickness to 200 microns (order number 910927241)
Drill No.4 for layer thickness to 500 microns (order number 910927741)
Drill No.3 for layer thickness to 1000 microns (order number 910927841)
Drill No.1 for layer thickness to 2000 microns (order number 910927141)

2.2.3 Replacement parts

Drill No.5 for layer thickness to 300 microns (order number 910928241)

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Drill

No. 2 1)

No. 5 2)

No. 4 1)

No. 3 1)

No. 1 1)

Measurement
range

up to 200

microns

up to 300

microns

up to 500

microns

up to 1000

microns

up to 2000

microns

Scale factor (f)

2 microns /

div.

3 microns /

div.

5 microns /

div.

10 microns /

div.

20 microns /

div.

Cutting angle ( D )

5.7°

8.5°

14.0°

26.7°

45°

tan D

0.10

0.15

0.25

0.50

1.0

Geometry

double-edged

single-edged

Head diameter

5 mm

Material

Hard metal

2.3 Technical specifications

2.3.1 Base unit

Dimensions (L x W x H) 155 mm x 55 mm x 110 mm
Weight excluding packaging: approx 850 g
Drill speed: approx. 180 rpm

Min. sample dimensions: 150 mm x 25 mm
Power supply (alternative)

- 9 volt battery 6F22

- 9 volt battery 6LR61

- Power supply (100 – 240) VAC / (47 – 63) Hz
18 VDC / 0.8 A

Temperature range

- During storage: -10 °C to +70 °C

- During measuring: -10 °C to +40 °C

Image sensor microscope: 2 mega-pixels (5 mega-pixels interpolated)
Lighting: eight white LEDs, adjustable

PC interface: USB 2.0 or 3.0
Magnification: 50x
Image format: PNG
Operating system: Windows2000/XP/Vista/7/8/10

Menu language: English, German

2.3.2 Wedge cut drill

Table: Characteristics of the wedge cut drill

1)

Available as an accessory

2

) Included in the delivery

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Drill

Digital microscope

Adjustment for the image
sharpness (the sharpness is
pre-set)

Knurled ring for adjusting
t

3 Commissioning – Operations – Handling

he lighting brightness

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Battery compart m e n t

Button (additional lighting)

Power supply

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3.1 Commissioning / driver and software installation

3.1.1 Minimum system requirements

x PC laptop or tablet with WIN7, VISTA, WIN8, WIN8.1 or WIN10
x Unused USB-2 port or USB-2 hub
x 4 GB of free space
x Graphics: 1280 x 800

3.1.2 Camera driver

x Connect the PC to the internet.
x Connect the camera to a free USB-2 port.

The driver will be automatically downloaded and installed from the internet; follow the
instructions from your operating system if necessary.

Install the software after the message Device can be used is displayed.

3.1.3 Software installation

We have deliberately omitted an installer program to simplify file access and to minimize
OS dependencies.

x Copy the Erichsen file (from the supplied USB flash drive) onto the C: drive or another

Windows partition.

x Open the Erichsen folder.
x Open the 518 folder.
x Open the bin141 folder.
x Select the 518.exe, right click and select "Send to -> Desktop (Create Shortcut)".
x Repeat this procedure with the folder Protocols in the same directory.

The software program can be started directly from the desktop and the data can be
viewed by double-clicking on it.

If there is a network/software administrator at your company, contact him or her
for help.

The software runs directly from the included USB flash drive.
The space for logs is limited to the size of the USB flash drive.

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3.2 Commissioning and calibration

The calibration is only required for the initial commissioning and after the optical focusing.

x Start the program (main screen)

x Click on the Grab image button (= live image)

x Align the standard plate with the calibration circle in the middle.

The image must appear sharp; focus the sharpness before the calibration!

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x Click on the Grab image button again.

The image is now stored for calibration.

x Click on the Configuration button. The configuration window opens.

x Click on the Calibration button ; the button will now be colored red.

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x Use the mouse pointer and the left mouse button to

trace the edge of the calibration circle in the main
window.

correct wrong wrong

If the first attempt is not successful, you may retrace the circle with the left mouse button
until it is correct.

x Click on the calibration button again. The calibration is finished.
x Close the configuration window.
x The calibration can be checked to see if it was successful from the control monitor.

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x The calibration value should be maintained between 5.0 and 6.0 microns.
x For the vertical measurement of the drilled hole diameter, the resolution of the USB

camera is approximately 5.5 microns per pixel. (This can vary from 5 to 6 microns,
depending on the focus adjustment of the lens.)

x The calibration of the USB microscope results in an average achievable resolution for

depth measurements of:
Drill 1 (0 – 2000 microns): 5.5 microns

Drill 2 (0 – 200 microns): 0.55 microns
Drill 3 (0 – 1000 microns): 2.75 microns
Drill 4 (0 – 500 microns): 1.375 microns
Drill 5 (0 – 300 microns): 0.825 microns

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The charging socket for connecting the AC adapter is located on the rear of
the PAINT BORER. The charging time is 14 hours. Measurements may be

Do not connect the charger while you are operating the instrument with the
battery!

We recommend removing the battery if you are always using the PAINT

then the battery may be left inserted. However, the charger should not be

Caution

3.3 Power supply

The PAINT BORER 518 USB can be operated in th e f ield – wh en it is discon nected f rom
the mains power suppl y. A 9-vo lt NiCd rechar geable batter y (IEC No. 6F22) can be used
as the internal voltage source. Alternatively, a 9 -volt non-rechargeable battery (alkaline
type IEC No. 6LR61) may be used.

The 9-volt battery is delivered in a separate package; it must be inserted in the black
plastic compartment on the right side of the instrument before you start using the
instrument.

taken during the charging phase even when the battery is not installed.

BORER with the mains power supply. Otherwise, the battery can be over­charged.

If you are using the instrument in the field (with the battery) sporadically,
permanently connected.

3.4 Lighting and auxiliary lighting

The lighting intensity can be adjusted using the knurled dial on the digital microscope.
Turn the dial to adjust the lighting intensity from 0 to 100%.
In this way you can adjust the illumination for the particular sample.
We recommend using a medium setting
both directions (lighter or darker) if needed.

When working with certain coatings, it may be helpful to also use indirect lighting.
For additional
used.

sample illumination, a white light emitting diode (LED) with diffuse light is

so that the lighting intensity can be adjusted in

The green button at the rear of the instrument can be pressed to activate the side lighting.
When switched on, the LED can be adjusted to three brightness levels.

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Briefly press the button to turn on the LED. The mid-level brightness will be set
automatically after the LED is turned on.

The three levels of brightness can be switched on consecutively by repeatedly pressing
the button.
Press and hold the button to turn the LED off. The LED will also turn off automatically
after 60 seconds.

Example:
Grey plastic coating

without additional lighting with additional lighting

White top coating

without additional lighting with additional lighting

Colored coatings or multi-colored coating systems provide a higher contrast so that side
lighting is not necessary.

3.3 Setting the image focus

The image focus is pre-set.
If you still need to adjust the focus, the adjusting dial can be turned slightly to the left or

right to make adjustments.

! You will then need to carry out a calibration!

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3.4 Slider mechanism

The slider is a key functional element of the PAINT BORER. It holds the drill apparatus
and the measuring microscope. The slider can be moved along a lengthwise guide so
that either the drill or the microscope is in the end position above the test point.

The slider is in the drill position when it is slid all the way to the left
By pressing down gently from above on the spring-loaded drill unit, it will lower and
simultaneously switch on the motor.

The right
microscope.

end stop position of the slider is the measurement position of the digital

(left end stop).

3.5 Wedge cut drill

(Refer to the table in section 2.3.2.)

The basic configuration of the P AINT BORER 518 USB includes a boring tool for the
measurement range of 300 microns (the No.5 drill). Additional drills are available as
accessories: for up to 200 microns (drill number 2), 500 microns (drill number 4), 1000
microns (drill number 1) and 2000 microns (drill number 3).

Drill number 1 has a single-edge cutting profile. Drills numbered 2, 3, 4 and 5 have a two­edge cutting profile so that they can make proper conical bores at very shallow incidence
angles (5.7°, 8.5°, 14° or 26.7°).

All drills are made of solid hard metal (carbide) which is extremely wear-resistant but also
extremely brittle. Therefore, the drills should not be exposed to excessive shock
(especially when working on hard substrates).

In order to change the drill bit, loosen the clamping screw in the drill chuck (using the
screwdriver included with the delivery) and pull out the drill bit. Insert the new drill bit so
that it snaps into the coupling. Then tighten the clamping screw.

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4 Program functions

1. Double click on to open the program.

2. The Main screen is shown below.

4.1 Menu and screen components

Quit: Exits the program.
Green: Connection to the camera is established.

Red: there is no connection.

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Configuration: Opens the window for calibration and for language selection.

Load language: Opens the window for selecting the language.
Select the desired *.lan (language) file and load it by clicking on Load.
The selected language will be activated after the program is restarted.
Calibration: Refer to page ... for instructions.

Load image: Loads a previously saved image.
The image can be edited as a newly captured image.

Grab image: Click on the Grab Image button once: a video image of the

measurement appears in the main window.

This enables you to position and process holes for which no image processing was
carried out.

Establishing the initial connection to the camera can take up to five seconds.
By default after the drilling is completed, the microscope is inserted and does not need to

be positioned.

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The Grab image button is now colored red.

When the button is pressed again, the image is stored for processing and can be

measured.
"Measurement" is discussed separatel y on page 23 in sec tion 5.3.

Save button: the measurement is saved and the log file is created.

4.2 Information about the sample

Measurement date and time: cannot be changed; the time setting is taken from the
system

Sample: can be edited
Material: can be edited
Comment: can be edited

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It is very important to choose the proper drill for the measurement.
If the wrong drill is selected for the measurement, the incorrect angle will result
in a false measurement result.

4.3 Selection of drill and image color

4.3.1 Drill selection

You can select one of the five standard drills
(for example:drill number 5 is included in the deliver y).

4.3.2 Image color

There are four modes available for displaying the image and image contrast
optimally.

False colors: There are 13 different variations that can be
chosen from the list of numbers .

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4.4 Composition of the sample (layer composition)

A measurement of the layer structure is possible for up to six layers:

You can activate (with ) or deactivate the selection, depending on the layer
compositions.

You should only select the layers that are actually present in your sample!
Substrate: The coated substrate can be specified here.
Name: Identification fields for the individual layers (shown here as an

example).

The fields can be edited and may be assigned any name (e.g. the

technical designation for a coating).
Layer: The number of layers, starting with the first layer.
Layer thickness [μm]: Displays the thickness of each layer in microns.
Circle 1 to Circle 7: Selection button for tracing the measured circles (whereby circle 1

is always the drill tip in the substrate).

X deletes a selected circle; a circle can then be re-traced.

deletes all circles.

N

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5 Layer thickness measurement

5.1 Preparing the test samples

First, select a flat section on the sample such that the PAINT BORER's rubber side skids
can safely stand on the base. The minimum sample dimensions are 150 x 25 mm.

Apply a contrast marking to the area being tested. This should cover an area with a
minimum diameter of 6 mm. This marking should facilitate the microscopic analysis by
emphasizing the color contrast between the sample surface and the drilled layer.

Use the included black felt-tip marker for marking the contrast on bright samples. Use the
sliver felt-tip marker for marking darker layers (apply thinly and let it harden well).

5.2 Drilling into the sample

Insert and secure the cutting tool for the desired measuring range in the drill's tool holder.
If the layer thickness is unknown, initially carry out a trial drilling with large drilling angle

and then select the optimum drill.
If you are working with a multi-layer system, you can work with different drills. You can

first drill with a large angle to dete rmine the total layer thickness and to cover the entire
layer profile visually. Then use another drill to measure the top layer separately (use a
smaller angle for higher accuracy).

Move the PAINT BORER's slider all the way to the left (left end stop). Then set the
measuring instrument onto the sample so that the drill tip is positioned over the middle of
the contrast mark.

Start the drill process by pressing gently on the drill mechanism. This touch- regu la ted
press start can be adapted to the particular coating system and, if necessary, optimized
through preliminary testing.

The substrate must always be drilled into. The drill heads of the cutting tools are
dimensioned so that the drilling depth into the base material can be a quarter of the
respective measuring range without restricting it.

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5.3 Carrying out the measurement (via software)

After drilling the sample, move the PAINT BORER's slide all the way to the right (so that
microscope is above the drilled hole). Use the additional lighting if needed.

Open the program and click on the Grab image button.

5.3.1 Grab image

Grab image is now displayed in red. All other buttons are greyed out and disabled.
A live image of a two-layer structure consisting of a primer and top coat is shown here.

If the image and the drilled depth are okay and the substrate can be clearly seen, click on
the Grab image button again.

The image is now ready for measuring.

- Select the image's color scheme (in this case, "grey" provides the best contrast).

- Select the top coat and primer ( ).

(Only circles 1 – 3 can now be selected.)

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5.3.2 Selecting the circles

(Always start with circle 1.)
Circle 1 is always the inner substrate circle.

Circle 2

is, in this case, the primer.

Circle 3

is, in this case, the top coat.

5.3.3 Tracing the circles

x Select the Circle 1 (which is now dark) and move the cursor to the edge of the substrate

borehole. Press and hold the left mouse button in this position. Press down on the
mouse button as you draw the circle and align it accurately; then release the mouse
button.

x Select the Circle 2. Draw a circle on the outer edge of the primer and position it.
x Click on the Circle 3. Draw a circle on the outer edge of the top coat and position it.
x Click with the right

button to finish after the last circle. All circles and circle buttons

should now be red.

If the positioning is not successful, then select the circle button corresponding to the

"unsuccessful" circle button again. Then delete the circle ( ) or draw and position
a new circle. This process is almost always successful after a little practice.

Click on to delete all circles simultaneously.

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5.3.4 Display of measured values

Circle 1 Circle 2 Circle 3

The measured layer thickness is displayed immediately.
This procedure is the same when processing a multi-layer coating structure; only

the number of circles (number of layers) changes.
When the measurement is okay, click on the Save button to save and to create

the log file.

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6 Inserting a customer logo

A custom logo can be added to the log.
The logo must be a PNG image with a max. size of 70 KB and max. dimensions of 450 x

160.
The image should be copied into the folder "Erichsen/518/bin-141/" with the name
Customer.png. (Make sure this is the exact name of the logo file!)

If different logos are used, we recommend renaming the logos and leaving them in the
same directory.

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7 Logs

The log files are created automatically when the measurement is saved (when the Save
button is clicked on).
A day folder and an hour folder are created automatically in the "Protocols" folder.

Day folder

Hour folder

The hour folders contain all logs from measurements that have been carried out and
saved within that hour.

PDF PNG Raw image (if saved)
All information about the sample and an image of the real test are listed separately in the

PDF document.
The PNG file is a screen shot of the measurement.
The second PNG file is a raw image of the sample and can be reloaded for another

measurement.

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PDF document

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8 Special measuring problems

8.1 Delamination

Brittle coating materials or coatin gs with poor a dhesi o n to the base material often result in
boreholes where the boundar y between the coating and the s ubstrate is not circular but
rather irregularly bounded.

Several holes should then be drilled in the sample. Take as many measurements as
possible at each hole. The largest measured value for the layer thickness is then a good
approximation of the true t hickness.

There are some additional steps that may be helpful when working with poorly adhering
coatings:

• The delamination issue is especially acute when the drill bit just penetrates the

boundary
between the coating and substrate.
Therefore, it is better to drill as deeply as possible into the substrate.

• Always drill intermittently. Do not drill in a single stroke. Blow away the residue chips

between the individual drilling strokes. This interrupted drilling method is especially
important for tough substrate materials (e.g. certain types of plastic), because these
tend to form large chips.

• The mechanical properties of soft plastic substrates are not favourable for drilling. Such

materials can be drilled better if they are cooled (in a freezer or with a cold spray).
When using cold spray, protect the coating surface with aluminium foil against the
harmful solvent.

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9 Maintenance and care

• The PAINT BORER 518 USB requires no maintenance.

• When used in wet conditions outdoors, this measuring instrument should be completely

and immediately dried off in order to avoid corrosion and malfunctions.

• The hard-metal (carbide) drill bits should be regularly checked for wear (using a 10x
magnifying glass) and replaced if necessary.

We reserve the right to make technical changes.

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EC Declaration of Conformity
EC Declaration of Conformity

Wir/We ERICHSEN GmbH & Co. KG, Am Iserbach 14, 58675 Hemer, Germany

erklären in alleiniger Verantwortung, dass das nachfolgend aufgeführte Produkt

declare under our sole responsibility that the product described below

Schichtdickenmessgerät PAINT BORER
PAINT BORER layer thickness measuring instrument

Modell / Model: 518 USB

- konform ist mit den Bestimmungen folgender Richtlinien:

- complies with the provisions of the following directives:

EMV-Richtlinie (2014/30/EU) – EMC Directive
Niederspannungsrichtlinie (2014/35/EU) – Low Voltage Directive

Angewandte Normen:

Applied Standards:

DIN EN 61000-6-2 (VDE 0839-6-2):2006-03

Bevollmächtigter für die Zusammenstellung der technischen Unterlagen:

Agent for the compilation of technical documents:

Bettina Betzinger-Rabe (Technical documentation)

Hemer, 21/03/2016

..........................................

ppa. Stefan Schneider
Technischer Leiter/Technical Director

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