Coatmaster Flex User manual
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coatmaster Flex
User Manual
coatmaster.com
Version: 05-2023
coatmaster Flex
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© 2019-2023 coatmaster AG
Distribution and duplication of this document, and utilization and communication of its contents other
than for legitimate purposes, are not permitted without the express permission of coatmaster AG.
Violations will result in legal action.
All rights are reserved
Subject to technical
are not to be
in the event of patent grant or utility model registration (ISO 16016).
changes and printing errors, the values given are approximate and
understood as legally warranted characteristics. These values may
vary according to component tolerance.
Last update: 05/2023
coatmaster Flex
Table of contents
1. Technical Data ............................................................................................................................5
2. Customer Requirements and Device Specification..................................................................7
3. Applications.................................................................................................................................8
4. Functionality and Measuring Principle .....................................................................................9
5. Safety and Responsibility....................................................................................................... 10
5.1. Warning Symbols............................................................................................................................... 10
5.2. Signs and Icons ................................................................................................................................... 11
5.3. Improper Use...................................................................................................................................... 11
5.4. Product Safety.................................................................................................................................... 13
5.5. Compatibility with flame detectors ................................................................................................. 13
6. Delivery Scope......................................................................................................................... 14
7. Set-up ....................................................................................................................................... 15
7.1. Battery................................................................................................................................................. 15
7.1.1. Battery Charging ........................................................................................................................................15
7.1.2. Battery Installation......................................................................................................................................16
7.2. Navigation Panel ............................................................................................................................... 17
7.3. Turning the Power On/Off ............................................................................................................... 17
7.4. Language Selection ........................................................................................................................... 18
7.5. Wi-Fi Settings ..................................................................................................................................... 18
7.6. Activation............................................................................................................................................. 20
7.7. Operation with coatmaster® Local server ..................................................................................... 21
8. Operating Instructions ............................................................................................................. 23
8.1. System Settings................................................................................................................................... 23
8.1.1. Network Troubleshooter.............................................................................................................................23
8.1.2. Select license and server ...........................................................................................................................24
8.1.3. User Level.....................................................................................................................................................25
8.1.4. Measurement Unit .......................................................................................................................................26
8.1.5. Auto power off............................................................................................................................................26
8.1.6. Contact information ....................................................................................................................................26
8.1.7. Factory Reset...............................................................................................................................................27
8.1.8. Automation mode........................................................................................................................................27
8.2. Main Menu .......................................................................................................................................... 27
8.3. Block Menu .......................................................................................................................................... 30
8.3.1. Select a block..............................................................................................................................................30
8.3.2. Create a new block....................................................................................................................................30
8.3.3. Rename a block...........................................................................................................................................31
8.3.4. Remove a block...........................................................................................................................................31
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8.4. Application Menu ............................................................................................................................... 31
8.4.1. Delete an application.................................................................................................................................33
8.4.2. Favorite an application..............................................................................................................................34
8.4.3. Advanced calibration report.....................................................................................................................34
8.4.4. Calibration Menu ........................................................................................................................................35
8.4.5. Quick Application .......................................................................................................................................35
8.4.6. Manual Application ....................................................................................................................................36
8.4.7. Reference Measurements...........................................................................................................................37
8.4.8. Calibration Report......................................................................................................................................40
8.4.9. Rename application....................................................................................................................................41
8.4.10. Edit Materials Properties or Display Options.........................................................................................41
8.4.11. Materials Properties...................................................................................................................................42
8.4.12. Display Options...........................................................................................................................................42
8.4.13. Display Options (Bounds)...........................................................................................................................43
8.4.14. Setting Bounds.............................................................................................................................................44
8.4.15. Example of a Calibration Process............................................................................................................46
8.4.16. Offset calibration .......................................................................................................................................47
9. Measurement............................................................................................................................ 48
10. Data Transfer/Cloud .............................................................................................................. 49
10.1. Login ................................................................................................................................................ 49
10.1.1. Applications .................................................................................................................................................52
10.1.2. Monitor .........................................................................................................................................................52
10.1.3. Export ...........................................................................................................................................................53
10.1.4. Help ..............................................................................................................................................................54
11. Troubleshooting and Best Practice......................................................................................... 55
11.1. Error Messages .............................................................................................................................. 55
11.2. Error Codes..................................................................................................................................... 56
11.3. Frequently Asked Questions (FAQs)............................................................................................ 58
11.4. Hotline ............................................................................................................................................. 58
12. Storage and Transportation................................................................................................... 58
13. Maintenance and Repair........................................................................................................ 59
13.1. Replacement of the Inlet Filter ..................................................................................................... 60
13.2. Cleaning and Care........................................................................................................................ 60
13.3. Warranty........................................................................................................................................ 60
14. API-Interface Description........................................................................................................ 61
coatmaster Flex
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Foreword
Dear Customer,
with the purchase of a coatmaster® Flex, you have acquired a high-quality, precision product. In this
manual we provide you with some instructions to help you to work successfully and productively with
this device for many years. coatmaster AG has made every effort to manufacture a safe and high-
quality device that complies with all applicable regulations. Our strict quality control procedures
ensure high quality standards even for high volume production. Please apply your own controls and
treat the device with care. Should you have any questions regarding the use of the equipment, please
do not hesitate to contact us.
We wish you success and ‘a perfect coating’.
The Founders Prof. Dr. Nils A. Reinke and Andor Bariska
coatmaster AG
1. Technical Data
Characteristics Tolerance/ Description
Measuring distance range 20 -150 mm
Measurement angle / tolerance ±70°
Measuring point size 2 mm2 at 75 mm distance
Measuring range thickness 10 - 500 µm (depending on coating type)
Standard deviation Typical < 2% of the thickness
Measuring time Typical 300 ms (depending on setting for coating thickness)
Storage conditions -10 - 50°C max. 80% humidity (non-condensing)
Power supply Bosch GAL 18V-40
2x Bosch ProCore 18V, 4 Ah
Number of measurements Up to 1.300 measurements per battery charge (4 Ah)
Operating conditions Temperature: 0 - 35°C, Rel. humidity: 10% -75%
Weight (without battery) 1.3 kg
Dimensions 374 x 91 x 203 mm
IP protection type IP50
Table 1: Technical data
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2. Customer Requirements and Device Specification
Measuring the coating thickness early in the process is the key to documenting and controlling coating
processes, saving coating material, improving coating quality, and reducing production time and scrap.
Coating processes are highly sensitive to changes in environmental conditions; therefore, it is crucial
to have access to a thickness gauge that is easy to operate and works well in an aggressive (dust, high
temperature) industrial environment.
The patented measurement process used by the coatmaster® Flex is non-contact (as opposed to
systems based on magnetic induction or ultrasound) and non-destructive. It can be applied on wet,
powder, and cured coatings, regardless of the coating material, thickness, or color (including white).
In contrast to magnetic induction-based systems, the Flex device permits measurement of coating
thickness early in the process, i.e., directly after the application of the coating material, before drying
or curing. This allows:
•Savings of 10% - 30% coating material
•Reducing time for color changes
•Accelerating training of new personnel
•Avoiding cost intensive rejects & reworks
•Documenting coating processes
•Reducing environmental impact
•Establishing industry 4.0 standards
•Online-connection to ERP-System
coatmaster® Flex is the most advanced measurement gauge for non-contact thickness measurements.
It outperforms any other photothermal, LED/laser-based, and ultrasound systems on the market in all
industrial relevant aspects. It requires minimal calibration and is insensitive to the angle and distance
of measurement. Its superior reliability, user-friendliness, safe usage, cost-effectiveness, precision, and
accuracy is highly appreciated by major coating-line manufacturers, large paint manufacturers,
renowned experts and most importantly by coaters around the globe.
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3. Applications
The coatmaster® Flex is a flexible and robust handheld device for non-contact measurement of
coatings.
The coatmaster® Flex is unique and versatile and can be used in a wide variety of industries and
industrial sectors:
•Automotive
•Rail
•Aerospace
•Building Industry
•Furniture
•Profiles
•Wind Power
•Pipelines
•Medical/Technical
The coatmaster® Flex is particularly suitable for the following applications:
Powder paints
Due to control of coating thickness measurement with Flex, up to 30% of powder
quantity can be saved. Measurement early in the process prior to curing also saves
time and reduces rework rates.
Wet paints
Precise measurements are possible even before drying. The measuring equipment
capability is guaranteed. This saves material and time and ensures quality.
Functional coatings
Thickness measurement of functional coatings (i.e., e-coats, adhesives, anti-
corrosive coatings) in wet and dried state. Highly accurate measurement even on
rough surfaces and for soft coatings.
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4. Functionality and Measuring Principle
The coatmaster® works according to the principle of advanced thermal optics (ATO). The surface of the
coating is heated with a light pulse. After brief heating by a few degrees, the surface is cooled by heat
conduction to deeper areas of the coating and the substrate. The cooling process on the surface
depends on the thermal properties of the coating and the substrate. The thinner the coating, the faster
the surface temperature decreases, provided it has a lower thermal conductivity than the substrate.
The thickness and thermal properties of the coating are derived from the dynamics of the surface
temperature.
Figure 1: Illustration of the measuring principle
①Flash lamp
②Pulsed heat input
③Coatings
④Substrate
⑤IR radiation
⑥IR sensor
Generally, coatings have a very irregular surface. Powder coatings prior to curing have an even rougher
surface but can nevertheless be measured with the coatmaster® Flex. The properties of this roughness
are influenced by various factors, such as pre-treatment, the type and roughness of the substrate, the
type of coating (e.g., particle size, distribution, and chemical composition), and the exact conditions
(temperature distribution, baking time) during curing. The diagram below shows a microscopic sketch
of this roughness. The ATO automatically compensates for the roughness described above, using an
optical averaging process. This allows a reliable determination of the coating thickness, even with
changing parameters.
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Figure 2: Sketch of surface roughness of a powder coating after curing
①Substrate
②Coating
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5. Safety and Responsibility
This section provides an overview of all relevant safety features for optimum personal protection and
safe and trouble-free operation. Keep the operating instructions with the safety instructions so that
you can refer to them later.
5.1. Warning Symbols
For your safety, it is important to read and fully understand the following table showing the different
warning signs and their definitions!
Symbol Definition
DANGER
Warning of an immediate danger that, if not avoided, will result in death or
very serious injury.
•Measures to avoid the danger.
WARNING
Warning of an immediate danger that, if not avoided, will result in serious
injury.
•Measures to avoid the danger.
CAUTION
Indication of a hazardous situation that, if not avoided, may result in minor
or moderate injury.
•Measures to avoid the situation.
Warning of optical radiation.
Warning of electrical voltage.
Warning of hazards associated with charging batteries.
CAUTION
Indication of a hazardous situation that, if not avoided, may result in
property damage; however, no action is required with regard to personal
injury.
•Measures to avoid the damage.
Table 2: Warning symbols
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5.2. Signs and Icons
Symbol Definition
This symbol means that your device meets the safety requirements of all applicable EU
directives.
This symbol means that you may only dispose the device at an approved local disposal
site.
Information: A highlight containing particularly important information for better
understanding.
Table 3: Signs and icons
Intended Use
The coatmaster® Flex is intended exclusively for the measurement of coating thicknesses.
The device should only be used as a handheld device. The device should not be mounted on a robot or
fixture or operated for an extended period of time.
The instrument may only be operated and cleaned by trained personnel. The intended use also
includes compliance with these instructions and the maintenance intervals must be observed.
Have your device repaired only by qualified personnel and only with original spare parts. This ensures
that the safety of the device is maintained.
The device is not approved for operation in environments with potentially explosive atmospheres.
Keep the device away from rain or moisture. Penetration of water into an electrical appliance increases
the risk of electric shock. Do not place the measurement device in a place where components could
come into contact with corrosive gases or salty air.
Do not block ventilation openings. The ventilation openings prevent the interior of the unit from
overheating.
Remove the battery before cleaning. Do not use solvents for cleaning, to avoid damaging the housing
surface. Use a clean, dry cloth.
In accordance with Directive 2012/19/EU, please take old parts to the appropriate recycling facilities
for proper disposal, reprocessing, and reuse. Never throw electrical equipment into the household
waste! By properly disposing of the electrical appliances, you help to protect valuable resources and
prevent possible negative effects on health and the environment, which could otherwise occur due to
improper waste disposal. Accessories and packaging should also be recycled in an environmentally
friendly manner.
5.3. Improper Use
Use not mentioned above or use that does not comply with the technical specifications, is considered
to be improper use. The operator is solely responsible for any damage caused by improper use.
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