Technical Manual /Operating Instructions MiniTest 7200 FH / MiniTest 7400 FH Thickness Gauges
Contents Contents 1. INTRODUCTION..........................................................................................................................5 2. FIRST STEPS.................................................................................................................................6 2.1 INSERT BATTERIES AND CONNECT SENSOR .................................................................................6 2.2 SWITCH ON AND TAKE READINGS.......................................................
Contents 5.5.3 Automatic Data Storage (Auto).........................................................................................21 5.5.4 Storing Minimum Reading ................................................................................................21 5.5.5 Storing Maximum Reading................................................................................................21 5.6.1 Correct Sensor Position .........................................................................................
Contents 10.2 STATISTICS ..............................................................................................................................41 10.3 CALIBRATION ..........................................................................................................................41 10.4 ACTIVE BATCH .......................................................................................................................41 10.4.1 Batch Properties ....................................................
1. Introduction Designed for non-destructive thickness measurement, the portable MiniTest 7200 / 7400 FH measuring systems are suitable for in the field or laboratory use. Working on the magneto-static principle, the gauges enable quick and easy measurement on non-ferromagnetic materials. The measuring system consists of a handy sensor, which is connected via a cable to the base and display unit for visualization and processing of readings.
2. First Steps This section refers to persons to use the gauge for the first time. This section explains the main features of the gauge and how to take readings. 2.1 Insert Batteries and connect Sensor a) Take gauge and batteries from the carrying case. b) Push the battery compartment lid at the gauge bottom in arrow direction (as shown below) c) Insert batteries into the battery compartment. Respect polarities (as shown below). d) Close lid.
2.2 Switch ON and Take Readings 2.2.1 Setting language This setting can be made at initial use or as requested at any time (see section 11.1) Press the red ON/OFF button on the left side of gauge and ESC simultaneously to switch on and to go to initialization menu. 1. A banner appears with a language option. User arrow keys ↑↓ to go to your requested language option. Press OK to confirm or ESC to abort. 2. On display appears “Total Reset”. A Total Reset restores factory settings.
d) The factory calibration is for quick and easy measurement when larger measuring errors are acceptable. For other calibration methods please refer to section 6.2. e) For measurement, please use the sensor stand supplied with the gauge. Place the measuring object on the sensor. Place the target ball on the opposite side. For measuring hollow parts, place the ball inside the sample. Equipped with a strong permanent magnet, the sensor attracts the target ball and holds it exactly over its sensor tip.
3. Description of the measuring system 3.1 Basic unit Large 3.1.1 General Remarks backlit display for easy reading of measuring values, statistical data, histogram and trend diagram. Graphics display 160 x 160 Dots Robust scratch resistant plastics housing. 3.1.2 Operating keys ON/OFF button Command and navigation key block Function keys Use the ON/OFF button to switch the gauge ON or OFF.
Press the “Help” Function key for calling the context-oriented on-line “Help“. 3.1.3 Sockets and interfaces Sensor socket Multi-purpose socket IR Interface The basic unit features a sensor socket for connecting the FH 4 or the FH 10 sensor. The multipurpose socket is used for connecting the mains unit, the foot switch, the alarm device or the RS232 interface cable. 3.1.4 Power supply 3.1.4.
• Used or defective batteries or storage batteries may contain hazardous substances and must be disposed according to the legal provisions of your country. 3.1.4.2 Power supply unit For mains operation, the power supply unit must be used. If operated via the power supply unit, batteries should be inserted to supply the internal time clock, otherwise, after approx. 1 minute, the settings of the real-time clock will go lost as soon as supply from the mains is cut.
3.2.3 Sensor Stand Both sensor types come with a spring-loaded V-grooved sensor stand. The use of the sensor stand ensures increased reproducibility of readings by adding stability of the sensor during measurement so that even small parts can be measured without problems.
4. The User Menu 4.1 General Remarks 4.2 Switch-ON / Start Screen At switch on, the company logo, gauge version and type of sensor being connected appear on display. After approx. 2 seconds the gauge switches to the measure screen of the last batch that was active before the gauge was switched off. 4.3 Measure screen /Statistics screens Readings can be displayed numerically only or numerically combined with a diagram (only with MiniTest 7400 FH) 4.3.
4.3.2 Measure Mode –Graphics Screen with MiniTest 7400 FH Time clock Power supply indicator Target ball size, measuring unit Reading DATA LOGGING MODE Set point ⇑ UPPER LIMIT REAL-TIME TREND MAX = MAXIMUM READING N = NUMBER OF READINGS MINIMUM READING ⇓ LOWER LIMIT CALIBRATION METHOD NAME OF ACTIVE BATCH The current function key proper-ties are indicated in the line above the function keys. STATUS LINE For setting the Real-Time Trend display option, select “Active Batch” form the Main Menu.
4.4 User Menu The numerous MiniTest FH 7400 / 7200 features can be accessed via the different menus that are divided into submenus. Press the Function key “Main menu“ in order to get access to the main menu. Select an item from the Main Menu (e.g. Database) and press OK to confirm. You will go to a submenu. Use the arrow keys to select the requested item and press OK to confirm. To go back to the previous menu level press ESC. According selected submenu you can - View settings (e.g.
4.4.2 Numerical Entries As soon as the alphanumeric block is activated, ESC and OK will assume navigation functions to the left or right. Choose your character by placing the cursor over the requested character. After a certain period of time, the entry will be accepted automatically without the need to confirm. This period of time can be specified under User Preferences in the “Entry accepted” option. See also section 10.5.5 for further reference.
5. Measure Mode 5.1 Important Notes on Thickness Measurement Make sure that the operator has been properly instructed regarding the use of thickness gauges and has basic knowledge of the specific requirements for measurement of the application.
5.2.2 Target Ball Size According to sensor type and the shape of measuring object, a suitable target ball must be set. This can be made in the Configuration menu, menu item “Target ball” (also refer to section 6 “Calibration”. Use arrow keys to move to “Target Ball” size and press OK. Use arrow keys to adjust the requested target ball size. Press OK to confirm your setting or press ESC to undo your setting.
5.3.2 Measurement without Sensor Stand For measuring large-sized parts, the sensor can be guided manually over the measuring sample. For measuring thick samples (6 mm and thicker) make sure to keep the sensor in vertical position to the sample. When holding the sensor in horizontal position, due to the influence of gravity on the steel ball, the readings will be higher than the actual thickness. 5.3.
5.4.2 Using the sensor stand If you are using the sensor stand, position the sample on the sensor tip and keep it in right-angle position to the sensor. Place the appropriate target ball on the opposite side of object. Make sure to keep the right-angle position while moving the object continuously over the sensor. For storing readings, please refer to section 5.5.1. When measuring small hollow parts such as bottles e.g.
5.5.2 Manual Data Storage During the measuring procedure, current readings can be stored manually into the active batch by pressing OK or by actuating a footswitch. For this option set Data logging mode to “Curr. reading”. 5.5.3 Automatic Data Storage (Auto) Auto option In the auto mode, readings will be stored automatically during the measuring procedure as soon as you press OK. To stop the automatic data storage press OK again.
5.6 Error Sources during Measurement After calibrating the gauge according to your application and appropriate target ball size, the gauge is ready for measurement. The readings will be correct as long as you measure within the range as specified for this target ball. The target ball is placed on one side of the sample to be measured and will be attracted by the sensor tip on the other side of the sample. The target ball serves as a reference to the sensor.
5.6.3 Incorrect readings through Blocked Target Ball Error source: The target ball has got stuck through a bulge, e.g. inside the sample. It is out off the correct measuring position. Remedy: Move the sample in order to release the target ball. 5.6.4 Air gap Error source: Due to the shape of sample, an air gap is between target ball and measuring object. The reading will be higher than the actual thickness. Remedy: If the target ball is too large, use a smaller one.
6. Calibration Calibration is made in the batch being active and will always refer to this batch, i.e. each batch has its own calibration. Before calibration, an appropriate target ball diameter must be set in the Calibration menu. Please refer to section 5.2.2 “Target ball size”. There are two options to go to the Calibration menu: - from the Main menu choose Calibration - from the Measure Mode menu press Calibration function key.
measuring mode by putting the matching precision standard with the appropriate target ball on the sensor. • Please note that large target balls will compress soft material more than small target balls. Please note: If the gauge switches off during the calibration procedure due to low battery voltage, calibration must be repeated after installing fresh batteries.
6.3 How to calibrate Using the sensor stand will add additional comfort during the calibration procedure. For more details please refer to section 5.3.3. For all calibration methods the following applies: - To call the Calibration menu from Measure mode menu, press the Calibration function key. - Use the arrow keys to go to “Target Ball”. Press OK to confirm. Use arrow keys to adjust to the requested target ball size. Press OK to confirm. - Use arrow key to go to “Calibration Mode”.
Zero calibration standard with target ball put on it 6.3.3 Multi-point calibration (Zero + 1 to 4 point(s) ) For multi-point calibration you must first carry out a zero point calibration. The precision standards must be used (1 to 4 as requested) to calibrate for the further calibration points. The precision standards have different thickness values. 1.
In the alphanumerical input field, you can enter the thickness of the precision standard along with the unit. ESC and OK assume navigation functions to the left or right. You can select the requested character via the numerical block. Your selection will be automatically accepted after the specified period of time. This period of time can be specified in the Setup menu. Chose User Preferences and select “Entry accepted” (see also section 10.5.5).
6.5 Calibration Error Sources The following situations may lead to erratic calibration: Error: Remedy: Wrong target ball: Select an appropriate target ball suitable for your measuring sample and the thickness to be expected. Adjust to the correct target ball size via the menu. Calibration range does not match to the Calibrate within the thickness range to be thickness to be expected: expected.
7. Data Storage 7.1 Batches 7.1.1 General Readings and their statistics will be stored in batches. Batches can be named alphanumerically and stored in the database directly or under a certain directory. One batch is firmly installed under the name “Direct Mode”. This batch cannot be deleted nor can it be renamed. The model MiniTest 7200 FH does not include the database feature, but it offers one predefined measuring batch. 7.1.2 Batch Data 7.1.2.
7.2 Database of the MiniTest 7400 FH 7.2.1 General Remarks The database includes numerous features for data management. Measuring batches can be stored in directories and subdirectories. In total, as many as 500 directories may be created in a maximum of 5 levels. Directories and batches can be named alphanumerically. 7.2.2 Tree structure Example for a tree-structured database divided in directories and batches. At first use of the MiniTest 7400 FH, the database only includes one batch named “Direct Mode”.
7.2.4 Create a New Batch From Measure Menu press function key “Main Menu”. Then select “Database” and press OK. Use arrow down key of the navigation block to place the cursor below “Direct mode” or, if other directories have already been created, to the requested position where a new directory should be created. This may be below or between directories or batches. Now press function key “Actions” and move cursor to “New Batch” which is highlighted. Press OK to confirm.
7.2.6 Delete a Batch / a Directory From Measure Menu press function key “Main Menu“ and select „Database“. Press OK to confirm. Use arrow keys to select the directory or batch to be deleted. Press function key “Actions”. Select “Delete” from the “Actions” submenu. A confirmation appears. Press OK to confirm or ESC to abort. If you have chosen a directory, the delete action will only delete empty directories. If the directory includes subdirectories and batches, these must be deleted previously.
8. Statistics From Measure Menu press function key “Statistics“. From Main Menu use arrow keys to select “Statistics” and press OK to confirm. 8.1 Statistical Parameters 8.1.1 Upper and lower specifications limits (USL and LSL) Tolerance limits can be set as requested and offer you the following features: - Readings beyond the specification limits will be indicated by a signal tone and marked in the statistics.
8.1.2 Set Point (Differential Mode) In quality control, it may be interesting to measure the difference between a set point and the actual thickness. Once you have specified a set point, the difference between this set point and the actual thickness will be displayed. A set point must be entered BEFORE storing the first reading. If you change a preset set point, the stored readings must be deleted previously. The set point can be set in the “Configuration” submenu.
8.2.3 Delete all Readings From Main Menu chose “Statistics“. Use arrow keys to move to “Delete all readings“. Press OK to confirm. From Measure Menu press function key “Statistics” followed by function key “Help/Extras”. Use arrow keys to move to “Delete all readings“. Press OK to confirm. To abort, press ESC. The delete action will delete all readings of the active batch. Batch name, sensor configuration and calibration for this batch will remain in memory. 8.
8.4 Histogram on MiniTest 7400 FH From Main Menu chose “Statistics“. Use arrow keys to move to “Histogram“. Press OK to confirm. From Measure Menu press function key “Statistics” followed by function key “Histogram”. A histogram is a kind of plot that summarizes how data are distributed. It gives you information on how the production process might be changed in order to be optimized. The limit range is the gray-highlighted area. See also 8.1.1 “Upper and lower spec. limits”.
9. Data Output / Data Transfer Both models, MiniTest 7200 FH and MiniTest 7400 FH are equipped with a bi-directional RS232 interface and an infrared interface (IrDA 1.9). Readings and statistics of a batch can be transferred to a PC or to the MiniPrint 7000 data printer (available as an option). 9.1 Data Print-Out Data transfer of readings and statistics to the data printer MiniPrint 7000 is made via the infrared interface (IrDA 1.0). Before printing out, go to the Main Menu and select “Setup”.
Press OK to confirm your selection and go to the next position on the printing list and proceed as described above. The print-out list can also be limited to fewer items (e.g. statistics and measuring values only, Fig. 4) Fig. 4 Now align the infrared windows of the MiniTest and MiniPrint 7000. Press function key “Print” to start the print-out. To abort, press “ESC”. 9.1.1 Screen Shot Please refer to section 11.2 “Special functions“. 9.1.2 Print-out a Batch Please refer to section 9.
9.2 Transfer Data to a PC Before transferring data, go to the Main Menu and select “Setup”. Use arrow keys to move to “Data Output” and press OK to confirm. Use arrow keys to select “RS232 cable” or “Infrared (IrDA). Press OK to confirm. See also section 10.5.4. If you adjust to RS232, please make sure to make the correct settings for baud rate and transmission protocol.
10. Main Menu 10.1 Database Please refer to section 7.2. 10.2 Statistics Please refer to section 8. 10.3 Calibration Please refer to section 6. 10.4 Active Batch From Main Menu chose “Active Batch” and press OK to confirm. Now you can select from the options as shown on the left. 10.4.1 Batch Properties Select “Batch properties” and press OK to confirm. Now you can view: Batch name (with MiniTest 7400 FH) Create date, Modified date User name.
10.4.2 Readings This menu is for viewing readings. To view the corresponding statistics, press function key “Batch” followed by function key “Statistics”. See also section 8. 10.4.3 Configuration In this menu you can set the following parameters to define your batch as requested: Target ball size (see section 5.2.2) Data logging mode (see section 5.5) Logging rate (see 5.5) Graphics on/off (see section 4.3.2) Upper spec. limit (see section 8.1.1) Lower spec. limit (see section 8.1.
10.5 Setup 10.5.1 General Remarks In this menu both models, MiniTest 7200 FH and 7400 FH can be adjusted to customer requirements. From Measure Menu press function key “Main Menu”. Use arrow key to select “Setup”. Press OK to confirm. Use arrow keys to go to the requested item and press OK to confirm. 10.5.2 Display In this menu you can adjust the backlight of display and keys (on/off); brightness and contrast). Please refer to section 4.4.1 for more details. 10.5.
10.5.4 Data Outputs In the “Data Output” menu you can choose RS232 cable or Infrared (IrDa). Please refer to section 4.4.1 for more details. 10.5.4.1 Data Output RS232 Cable If “RS232 Cable” has been selected, you can adjust the data format to the requested baud rate: 57600 (default), 38400, 19200, 9600 The settings 8 data bits, 1 Stop-Bit, No Parity do not change. The Transmission Protocol option must be “off” when using the Msoft 7000 Basic. (Description of transmission protocol available on request).
permanent signal. 10.5.5 User Preferences In the User Preferences menu the following settings can be made: - Language - Measuring system (metric / imperial) - Loudspeaker (ON/OFF). - Signal Volume (low, high, medium) - Auto Switch OFF (after 1, 3, 10, 30 minutes, disabled) - Entry accepted (numeric or alphanumeric entries accepted (after 0,5, 1, 1,5 or 2 seconds).
11. Special functions 11.1 Initializing At first use or on demand the initializing sequence may be called. Press ON/OFF button and ESC simultaneously to go to the initializing sequence. A language flag symbol appears. Use arrow keys to make your selection. Press OK to confirm or ESC to abort. Now a Total Reset query appears. Press “No” if you do not wish to perform a Total Reset to delete all data. Attention! Pressing “Yes“ will irrevocably delete all data and settings stored in memory.
11.2 Special functions Press ON/OFF button for more than one second while the gauge is switched on. Now a Special functions menu appears with the following setting options: - Print Screen (print-out of screenshot on MiniPrint 7000 data printer) - Backlight (of display and keyboard) ON - Backlight (of display and keyboard) OFF - Metric system - Imperial system All these setting options except the Print Screen item may also be accessed via the menu system.
12. Quick Reference Measure Mode Calibration Target Ball Calibration Mode Main Menu Statistics Database (MiniTest 7400 FH only) Statistics Calibration Active Batch Setup Backlight Numerical Statistics Display Brightness Date / Time Contrast Data Output User Preferences Day Month Year Hour Minute Histogram (MiniTest 7400 FH only) Trend diagram (MiniTest 7400 FH only) Readings Delete all Readings Gauge Specs Batch properties Readings Configuration Data output Language Meas.
13. Care and Maintenance 13.1 Care Use a soft damp cloth with water or a mild detergent to clean the gauge and accessories. Caution: Do not use solvents because they might damage the plastic parts. Do not use metal brushes or other tools for cleaning the sensor tip. 13.1.1 Using NiMH storage batteries To achieve optimal service life of the NiMH storage batteries, please respect the following instructions. • Make sure to use the full battery capacity before your recharge it.
14. Technical specification 14.1 Gauge and Sensor Specification Measuring principle: magneto-static principle, suitable for nonmagnetic materials Measuring rate: 20 readings per second (factory set) Number of readings to be logged for statistics: 1, 2, 5, 10 or 20 readings per second (user adjustable) Sensor types: FH4 FH10 Low range resolution: 0.1 µm 0.2µm Display resolution Ranges 0.0 µm – 59.9 µm 60.0 µm – 149.9 µm 150.0 µm – 299.5 µm 300.0 µm – 599.0 µm 600.0 µm – 998.0 µm 1.000 mm – 1.
Calibration modes: Factory calibration, Zero point calibration and multi-point calibration ((Zero plus 1 to 4 calibration points) Display: LCD 160 x 160 pixel, backlit (user adjustable) Measuring system: metric (µm, mm) and imperial (mils) Statistics functions: Single readings, number of readings, min, max, average, standard deviation, variation coefficient and process capability indices Cp and Cpk (only available with MiniTest 7400 FH) Data memory: 7200 FH 7400 FH Maximum number of directories:
14.2 Delivery Schedule 14.2.1 Thickness gauge MiniTest 7200 FH / 7400 FH Description Order number Thickness gauge MiniTest 7400 FH for non-magnetic materials 80-176-0000 or Thickness gauge MiniTest 7200 FH for non-magnetic materials 80-177-0000 including: Instruction manual in German/English/French on CD-Rom Short instructions 4 x batteries AA (LR06), Plastics carrying case, rubber protection case with positioning device and shoulder belt, 1 magnetic screwdriver 14.2.
14.3 Accessories Description Order number Data printer MiniPrint 7000 incl. charger unit 80-202-0000 Quick charger for NiMH storage batteries 02-070-0001 NiMH storage baby cells, AA HR6 1,2V (4 pcs required for MiniTest FH) 02-064-0001 Baby cells AA LR6 1,5V (4 pcs required for MiniTest) 02-064-0008 Power supply unit 80-900-0004 Footswitch for storing readings into the data memory, incl.
1 set precision standards for sensor FH 4 for multi-point calibration for 1.5 mm dia. 82-174-0010 target ball size, comprising: 1 precision standard set for approx. 0.15 mm, 0.25 mm, 0.43 mm, 0.75 mm and 1.3 mm 1 set precision standards for sensor FH4 for multi-point calibration for 2.5 mm 82-174-0011 target ball size, comprising: 1 precision standard set for approx. 0.25 mm, 0.43 mm, 0.75 mm, 1.3 mm and 2.
1 set precision standards for sensor FH10 for multi-point calibration for target ball 82-175-0017 dia. 4.0 mm, comprising: 1 set precision standards approx 0.43 mm, 0.75 mm, 1.3 mm, 2.2 mm and 3.6 mm 1 set precision standards for sensor FH10 for multi-point calibration for target ball 82-175-0010 dia. 6.0 mm, comprising: 1 set precision standards approx 1.0 mm, 1.7 mm, 3.0 mm, 5.2 mm and 9.0 mm 1 set precision standards for sensor FH10 for multi-point calibration for target ball 82-175-0037 dia. 9.
15. Appendix 15.1 Troubleshooting Error message “Please check clock settings“ Problem If you insert batteries at initial use Remedy Reset clock (s. section 10.5.3) or if the gauge has been cut from power supply for more than 5 minutes “Low Bat !!!” Though you can continue to Change batteries. Dispose measure, it is recommended to batteries according to your local change batteries. If battery regulations. voltage is below minimum, the gauge will switch off automatically.
Function key “Infinite”. Now the message should disappear and the gauge is ready for measurement. Attention: Make sure not to press the Infinite function key unless you have removed the error sources (target ball, magnetic field or metallic parts). “Refresh infinite value !!!” (The infinite value should be To ensure the guaranteed Remove target ball from sensor. measuring accuracy, the infinite If the message persists, please value must be refreshed. press Refresh function key. See also section 6.
Target ball: (adjusted ball size) “Full memory capacity !” measurement. Probable cause: Delete readings, batches or You have reached maximum directories in the database which number of storable readings. you do not need any more. You have reached maximum number of entries in the data base (MiniTest 7400 only) “Memory optimization in Message appears briefly on Automatic procedure. No further progress” display. action required.
15.2 Detection of Error sources (INF flag) Measurement may be influenced by static or alternating magnetic fields and by metallic objects near the sensor. If no target ball is placed on the sensor, the “INF” flag appears on display. That means that the probe is in the infinity range. INF flag Make sure that INF is shown so that correct readings can be taken. If the sensor is subject to some interference (e.g.
15.3 Statistical Terms The statistical evaluation will help you to assess the quality of your product. Average (Mean) The sum of single readings divided by the total number of readings. x= ∑x n Standard Deviation (STD. DEV.) s (s = σ = sigma) The sample standard deviation is a statistic that measures how “dispersed“ the sample is around the sample mean. The sample standard deviation increases with increasing spread out.
Process capability index (Cp) The cp index is a measure of the spread of the readings as related to the specification limits. Only the spread is of importance here. The cp index is calculated as follows: Cp = USL − LSGL 6s where USL = Upper specification limit where LSL = Lower specification limit Process capability index (Cpk) In addition to the spread, the cpk index also takes into account the location of midpoint as related to the specification limits.
15.4 Safety Notes Safe operation will be ensured as far as the instructions and notes in this manual and/or gauge will be observed. For installation work, please cut power supply. Use only original spare parts and/or accessories. If not in use, the sensor must always be stored with the protection tube put on it. Risk through exposure to magnetic fields Within a distance of 15 cm, the sensor creates static magnetic fields of up to 1 mTesla.
Risk of injury Within a distance of 15 cm, the sensor creates static magnetic fields of up to 1 mTesla Keep a safety distance of at least 15 cm in order to avoid injury through metallic parts being attracted by the sensor Risk of injury through metallic splinters The magnetic field may attract metal parts damaging the hard metal sensor tip. Through the impact, the hard metal housing of sensor might go into splinters.
15.5 Declaration of Conformity We, ElektroPhysik, Pasteurstr. 15, D-50735 Cologne, Germany, declare in sole responsibility that the products MiniTest 7400 FH, MiniTest 7200 FH and MiniPrint 7000 to which this declaration relates is in conformity with the provisions of directive 89 / 336 / EEC (Electromagnetic compatibility), in Germany: EMVG (Gesetz über die elektromagnetische Verträglichkeit) of November, 9th, 1992.
15.6 After Sales Service MiniTest 7200 FH / MiniTest 7400 FH models are manufactured according to state-of-the-art production methods using high-class components. Careful production controls along with a Certified Quality Management according to DIN EN ISO 9001 ensure optimum product quality. In case of errors please contact ElektroPhysik. If repairs should become necessary, please send the gauge to ElektroPhysik or contact your local ElektroPhysik representative for return and repair instructions.
Index A L average ...................................................51, 60 Average ...................................................38, 40 language...................................................7, 46 lower specification limit ..............................14 LSL ..................................................14, 34, 61 B backlight.......................................................43 batteries inserting......6, 10, 11, 25, 49, 51, 56, 58, 63 battery symbol..................................
