USER MANUAL

Coating Thickness Tester

Model CG204

Additional User Manual Translations available at www.extech.com

Introduction
Congratulations on your purchase of the Extech CG204 Coating Thickness Tester. The CG204 is a portable
meter designed for non-invasive coating thickness measurements. The meter uses two measurement
methods: magnetic induction (for ferrous metal substrates) and eddy current (for non-ferrous metal
substrates). Proper use and care of this meter will provide many years of reliable service.

Description
Meter Description
1. USB jack for PC interface
2. Measurement probe
3. Backlit LCD display
4. SET /OK /YES /MENU /SELECT button
5. UP /LEFT ARROW button
6. Power ON/OFF button
7. CANCEL /ESC /NO /BACK button (menu mode) and
Backlight ON/OFF (normal mode)
8. DOWN ARROW /RIGHT button
9. ZERO calibration button
Note: Battery compartment on rear of meter

Display Icon Description

NFe Non-ferrous metals
Fe Ferrous metals
AUTO Automatic substrate recognition
F or N Calibration icons
DIR DIRECT mode
GRO1…4 GROUP Mode
µm Micrometers unit of measure
mils mils = millimeters * 2.54/100
mm Millimeters unit of measure
AVG Average reading
MIN Minimum reading
MAX Maximum reading
SDEV Standard Deviation reading
NO Number of data points
Low battery
USB Connection

Note: The unit of measure icon flashes when in the CONTINUOUS mode of operation. The unit of
measure icon is stable when in the SINGLE mode of operation.

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Quick Start Instructions
Meter Power
Press the power button to switch the meter ON. The display will switch ON. If the display does not switch
ON, replace the batteries.
Measurements
Use the supplied film references and zero reference metal substrates to learn how the meter operates
before moving to a professional application. The round metal substrate is the ferrous (magnetic) substrate
and the rectangular shaped metal substrate is the non-ferrous (non-magnetic) substrate. The meter
automatically senses ferrous or non-ferrous substrates.
1. Place a reference film (250µm, for example) on the round, ferrous substrate.
2. Place the spring-loaded meter sensor against the reference film.
3. In the single mode the meter will emit an audible tone indicating that the measurement has been
taken.
4. In the continuous mode the display will continually measure and update the display
5. The LCD will show the reading (250µm) at the center of the display area.
6. A typical display will also show the following:
• NO = 1 (reading number one) on the lower left of the
LCD
• AVG = 250µm (running average) on the lower right
• DIR = DIR mode of operation on the upper left
• Fe = Ferrous substrate on the upper right of the LCD

Experiment with the remaining reference films and the substrate before using the meter professionally.
Automatic Power OFF
In order to conserve battery life, the meter will automatically turn off after approximately 3 minutes. To
defeat this feature use the programming menu detailed in the next section (menu parameter AUTO POWER
OFF under OPTIONS).
LCD Backlight Button
The LCD is equipped with backlighting for easier viewing, especially in dimly lit areas. Press the backlight
button to turn the backlight on. Press again to turn the backlight off. To enable/disable the LCD backlighting,
use the BACKLIGHT parameter under OPTIONS in the programming menu.
Factory Default Reset
To restore the meter to its original factory default settings:
1. Turn the meter OFF.
2. Press and hold the ZERO button while switching the meter ON.
3. When the meter powers up, the display will prompt for a YES or NO.
4. Press the SET button for YES or the CANCEL button for NO.
5. Note that all data in all memory locations will be erased, in addition to statistics, calibration values,
and alarm limits.

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Programming Menu
The meter can be configured and calibrated through simple button presses in the programming menu. Press
the MENU button to access the menu and refer to the menu ‘tree’ below. The menu uses UP/DOWN,
SELECT, BACK, & ESC presses for navigation and selection. In the table below the factory default settings are
in bold with an asterisk. Each parameter is explained in detail in the subsequent sections.
Top level Sub level 1 Sub level 2 Notes
AVG* Average of a series of readings
MIN Lowest of a series of readings
STATISTICAL VIEW MAX Highest of a series of readings
NO Number of sampled readings
SDEV Standard deviation of a series
Single* One reading at a time
Measure mode
Continuous Continuous measurements
Direct* Readings are not stored in groups
Working mode
Group 1…4 Store readings in groups
Auto* Meter automatically selects mode
Probe used Fe Ferrous measurement mode
No Fe Non-ferrous measurement mode
µm* Micrometers
Unit settings mils Mils = mm * 2.54 / 100
OPTIONS
mm Millimeters
ON* Enables backlight operation
Backlight
OFF Disables backlight operation
AVG* Average of a series of readings
MAX Lowest of a series of readings
LCD Statistics
MIN Highest of a series of readings
SDEV Standard deviation of a series
Enable* Allows auto power off to operate
Auto Power OFF
Disable Defeats the auto power off feature
High Limit High Alarm alerts user when reached
LIMIT Limit settings
Low Limit Low Alarm alerts user when reached
Delete Limits Clear the alarm limit values
Current Data Delete current data
DELETE All Data Delete all stored data
Delete data stored data plus alarm and
Group Data
calibration data
MEASUREMENT VIEW View stored data in all groups
Enable Allow calibration access
Disable Lock out the calibration mode
CALIBRATION
Delete Zero N Clear the zero cal. data (non-ferrous)
Delete Zero F Clear the zero cal. data (ferrous)

NOTE: Disable the Auto Power OFF feature before lengthy programming to avoid inconvenient automatic
power down while programming.

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STATISTICAL VIEWS Menu
1. Press the MENU button to access the programming menu
2. Press SELECT to choose STATISTCAL VIEW
3. Use the UP and DOWN buttons to scroll through the AVERAGE, MINIMUM, MAXIMUM, NUMBER OF
DATA, and SDEV (Standard Deviation) values for the stored readings.
4. ‘NO DATA’ will display if no readings are available for the meter to analyze. Stored readings will clear
when the meter powers down unless the GROUP feature is used (refer to GROUP function explanation
later in this section).
5. Press the BACK and then the ESC soft-keys to return to the normal operating mode.

OPTIONS Menu
1. Press the MENU button to access the programming menu
2. Use the DOWN ARROW button to scroll down to OPTIONS
3. Press SELECT to choose OPTIONS
4. Use the UP and DOWN buttons to scroll to the MEASURE MODE, WORKING MODE, PROBE USED, UNIT
SETTINGS, BACKLIGHT, LCD STATISTICS, AND AUTO POWER OFF parameters. Use the SELECT soft-key to
select the desired parameter. Each parameter is detailed below:

a. Measure Modes
Select CONTINUOUS or SINGLE under MEASURE MODES in the OPTIONS Menu using the arrow buttons
and the SELECT soft-key.
In the CONTINUOUS measurement mode the meter displays a running average of readings as they are
taken. Note that the audible measurement ‘beep’ is not active in this mode.
In the SINGLE measurement mode measurements are taken one at a time. Single mode measurement
readings are accompanied by an audible tone.

b. Working Modes
Select DIRECT or GROUP 1, 2, 3, or 4 under WORKING MODES in the OPTIONS Menu using the arrow
buttons and the SELECT soft-key.
In DIRECT mode, individual readings are logged to memory. When power is switched off or if the meter
is switched to GROUP mode, all DIRECT readings will be cleared. However, the statistical analysis data
will remain. The statistical analysis utility can evaluate up to 80 readings. When the memory is filled,
new readings will replace old readings. Lastly, this mode has its own calibration and alarm limit values.
In GROUP mode each group memory can store a maximum of 80 readings and 5 statistical values.
Calibration and alarm limit values can be individually set and stored for each group. When the memory
is filled, measurements will continue to be taken but readings will no longer log (previously logged
readings are not affected); in addition, statistical data will no longer update. If desired, the group data,
statistical values, calibration data, and alarm limit values can be deleted using Delete under the
programming menu.

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 c. Used Probe
Select AUTO, Fe, or No Fe under USED PROBE in the OPTIONS Menu using the arrow buttons and the
SELECT soft-key.
In the AUTO mode, the meter automatically activates the probe measurement method (ferrous or non-
ferrous) based on the metal substrate that is being measured. When the probe is placed on a magnetic
substrate it will work in the magnetic induction mode. If the probe is placed on a non-ferrous metal it
will work in the eddy current mode.
In the Ferrous (Fe) Mode the Magnetic induction measurement mode is activated.
In the Non-Ferrous (No Fe) Mode the eddy current measurement mode is activated.

d. Units of measure selections

Select mm, m, or mils under UNIT SETTING in the OPTIONS Menu using the arrow buttons and the
SELECT soft-key (mm = millimeters; µm = micrometers; mils = mm*2.54/100)

e. Backlight
Select ON or OFF under BACKLIGHT in the OPTIONS Menu using the arrow buttons and the SELECT soft-
key. If OFF is selected the LCD backlighting will be completely disabled. If ON is selected, the user can
turn the light on or off using the backlight button (CANCEL button).

f. LCD Statistics
Select AVERAGE, MINIMUM, MAXIMUM, or SDEV (Standard Deviation) under LCD STATISTICS in the
OPTIONS Menu using the arrow buttons and the SELECT soft-key. This selection determines which
statistic is shown as default on the LCD display.

g. Auto Power OFF

Select ENABLE or DISABLE under AUTO POWER OFF in the OPTIONS Menu using the arrow buttons and
the SELECT soft-key. When enabled, the meter automatically switches OFF after 3 minutes of inactivity.
When disabled, the meter will only switch OFF with a button press or when the battery power is weak.

LIMIT Menu
High and Low Alarm Limits can be set When an Alarm Limit is reached the meter displays an Alarm Alert
icon (H for High Alarm and L for Low Alarm).
1. Press the MENU button to access the programming menu
2. User the DOWN ARROW button to scroll down to LIMIT and press SELECT
3. Press SELECT again to choose LIMIT SETTING
4. Press SELECT again to choose HIGH LIMIT
5. User the ARROW BUTTONS to set a High Alarm value
6. Press OK to store the limit and press BACK to return to the menu
7. Perform the same steps for the LOW LIMIT
8. Use the DELETE LIMIT parameter to clear Alarm Limit values

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DELETE Menu
The DELETE menus allows for deleting current data, all data, and group data. The following parameters are
available in the DELETE Menu:
Delete Current data: Deletes the current reading and updates the statistics (AVG, MIN, MAX, etc.)
Delete All data: Delete all reading and statistical data.
Delete Group data: This function duplicates the “Delete all data” function with additional, deletions of High
alarm, Low alarm, and one- and two-point calibrations.
1. Press the MENU button to access the programming menu.
2. User the DOWN ARROW button to scroll down to DELETE.
3. Press SELECT to open the DELETE function.
4. User the ARROW keys to scroll to CURRENT, ALL, or GROUP.
5. Press SELECT again to choose CURRENT, ALL, or GROUP.
6. The meter will prompt with an ‘are you sure?” confirmation.
7. Press YES or NO as desired.

MEASUREMENT VIEW Menu

The Measurement View menu allows for scrolling through the readings in all of the groups.
1. Press the MENU button to access the programming menu.
2. User the DOWN ARROW button to scroll down to MEASUREMENT VIEW.
3. Press SELECT to open the MEASUREMENT VIEW parameter.
4. User the ARROW buttons to scroll through the stored readings.

CALIBRATION Menu
The Calibration menu allows the user to enable/disable the calibration utility. The Calibration menu also
allows the user to delete Zero calibration data for both ferrous (Zero F) and non-ferrous (Zero N) modes.
1. Press the MENU button to access the programming menu.
2. User the DOWN ARROW button to scroll down to CALIBRATION.
3. Press SELECT to open the CALIBRATION parameter.
4. User the ARROW to scroll through the available parameters detailed below.
• ENABLE: Enable the calibration mode
• DISABLE: Disable the calibration mode.
• DELETE ZERO N: Delete ZERO calibration data for non-ferrous probe
• DELETE ZERO F Delete ZERO calibration data for ferrous probe

Measurement Considerations
1. After calibration, measurements should meet the published accuracy specifications.
2. Strong magnetic fields can affect the readings.
3. When using the statistical analysis functions for obtaining a mean value, take several readings of the
same measurement area. False readings or outliers can then be removed (deleted) using the
programming menu.
4. The final reading is derived from a statistical calculation with regard to the meter’s published accuracy
specifications.

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Calibration
Calibration Types
Perform a zero calibration and a multi-point calibration before any critical measurements are taken. The
calibration options are listed below. Read the description for each and select the best match for a given
application.
1. Zero Point Calibration: Perform before each measurement session.
2. One Point Calibration: Use for high accuracy with repeated tests on a constant coating thickness.
3. Multi-Point Calibration: Use for high accuracy within a known range of coating thickness.
4. Calibration for shot-blasted surfaces.

Calibration Considerations
The calibration sample must correspond to the product sample in the following ways:
• Curvature radius
• Substrate material properties
• Substrate thickness
• Size of measurement area
• The point at which the calibration is made on the calibration sample must always be identical with
the point of measurement on the product itself, especially in the case of corners and edges of
small parts.
To achieve the highest measurement accuracy, perform several calibrations in succession (for zero values
and calibration film values).

Preparing for calibration

1. Clean the probe tip (grease, oil, metal scrap, and the slightest impurity will affect measurement and
distort readings).
2. Switch the meter ON (at a 4” [10cm] minimum distance from any metal).
3. Ready the supplied metal substrate samples and necessary films (supplied calibration reference
films).
4. Set the meter to:
a. DIR: (MENU-OPTIONS-Working Mode-Direct)
b. CONTINUOUS: (MENU-OPTIONS-Measure Mode-Single mode [flashing units indicator] )
c. MAX: (MENU-OPTIONS-LCD Statistic-Maximum).
d. um: (MENU-OPTIONS-Unit Settings-um).
5. The meter is now ready for calibration.
6. You should perform a Zero calibration prior to a thickness calibration.

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Zero calibration
1. Clean the tip of the meter before calibration.
2. Place the meter on an uncoated section of the material to be
measured or on the reference substrate provided. Use either the
Ferrous or Non-Ferrous reference as required by the
measurement application. If the non-Ferrous reference substrate
is used, place it on a non-ferrous surface.
3. Place the probe on the uncoated substrate and watch the LCD
readings.
4. When the readings appear stable, lift the meter off the substrate
5. Press and Hold the Zero button for 2 seconds (2 beeps).
6. Repeat this procedure at least 5 times to create an accurate mean value.
7. The meter is now ready for thickness calibration or measurements.
Calibration
The meter’s accuracy can be enhanced by performing a calibration using the reference films supplied.
1. Perform a zero calibration as stated above
2. Perform a one point calibration using a reference film.
a. Press “MENU” and then scroll up “▲” to “Calibration”.
b. Press “Select” and highlight the “Enable” function and
then press “Select”.
c. Press “Esc” and the meter will enter the calibration
mode.
d. Place one of the reference films on the substrate used to Zero the meter.
e. Place the meter on the calibration reference film and wait for the meter to beep.
f. Lift the meter off the substrate.
g. Press the Up or Down arrows to set the displayed value to the reference film value.
h. Place the meter back down on the reference film and
wait for the meter to beep.
i. Lift the meter off the substrate.
j. Press the Up or Down arrows to set the displayed value
to the reference film value.
k. Repeat up to 5 times to establish a mean average
reading.
l. Turn the meter OFF to exit Calibration mode and save the calibration data.
3. The meter is now calibrated to the base material and thickness film used.
4. For a Two-point calibration refer to that section below.

Notes:
1. During calibration the ▲ and ▼buttons adjust the internal calibration factors with high resolution.
The display resolution may be such that it may take up to 10 presses to see a 1 digit change on the
display.
2. Calibration data is stored into memory; it is not erased when the meter is turned OFF.

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Two-point calibration
This method requires the use of two films. The thicker film should be, if possible, 1.5 times as thick as the
thinner one. For best results, the expected thickness should be between the two calibration values.
This method is especially suitable for taking high-precision readings. It is advisable to take a mean several
times. This considerably reduces the effect of scattering which occurs during calibration of the upper and
lower values.

1. Perform a Zero-point calibration (previously described)

2. Enable Calibration mode in the Options Programming Menu.
3. Perform a One-point calibration (as previously described) on the thinner calibration film reference and
make 5 measurements.
4. Turn off the meter to save the measured values.
5. Turn on the meter and Enable calibration mode.
6. Perform a One-point calibration using a thicker calibration film and make 5 measurements.
7. Turn off the meter to save the measured values.
8. Turn on the meter, it is now ready to make measurements.

Calibration Notes:
1. The thickness of the calibration films should be roughly equivalent to the estimated coating
thickness to be measured.
2. Calibration can be performed as often as necessary. Old calibration data will be overwritten but the
ZERO calibration data remains in memory until another zero point calibration is made.

Calibrating for Shot-blasted surfaces

The physical nature of shot-blasted surfaces results in higher than normal coating thickness readings. The
mean thickness over the peaks can be determined as follows:
1. The meter should be calibrated according to the calibration instructions. Use a smooth calibration
sample with the same curvature radius and the same substrate as the device to be tested.
2. Take approx. 10 readings on the uncoated, shot-blasted sample to produce the mean value Xo.
3. Take an additional 10 readings on the coated, shot blasted test sample to produce the mean value Xm
4. The difference between the two mean values is the mean coating thickness Xeff over the peaks. The
greater standard deviation ‘S’ of the two values Xm and Xo should also be taken into consideration: Xeff
= (Xm - Xo) ±S

NOTE: For coatings thicker than 300 µm, the influence of roughness generally is of no importance and
therefore it is not necessary to apply the above calibration methods.

Measuring metallic coatings

This meter can measure non-magnetic metal coatings (Zinc) on a magnetic (ferrous) substance base, and
non-metal coatings on a metal base (ferrous or non-ferrous).

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Statistical Analysis Considerations
The meter calculates statistics from a maximum of 80 readings (For Group 1 through Group 4, a maximum
of 400 readings can be stored). Note that readings cannot be stored when in DIRECT mode. However,
statistics on these readings can still be calculated. When the meter is powered off or if the working mode is
changed (in the programming menu), the DIRECT mode statistics will be lost. The following statistical values
can be calculated:
• NO.: Number of readings
• AVG: Average value
• Sdev. : Standard deviation (square root of a data set’s variance)
• MAX: Maximum reading
• MIN: Minimum reading

Statistical Terms

x ) is the sum of readings divided by the number of readings.

Average value (

x = ∑x/n

Standard Deviation (Sdev)

The sample standard deviation is a statistic that measures how the sample value is distributed around
the sample mean. The standard deviation of a set of numbers is the root mean square of the variance S2
The variance of a list is the square of the standard deviation of the list, that is, the average of the
squares of the deviations of the numbers in the list from their mean divided by the(number of readings -
1)

2
Variance: S2= ∑ ( x − x) /( n − 1)
Standard deviation: S= S2
NOTE:
Use the DELETE parameter from the programming menu immediately after an outlier or erratic reading
has been taken. Refer to the Delete function in Programming Menu.

Storage Capacity Overflow

In GROUP mode, if the storage capacity is exceeded, statistics will not be updated, although
measurements can still be made. If the memory is full, subsequent readings will not be included in the
statistics. The meter’s display will show “FULL” (in the SINGLE measurement mode).
In DIRECT mode, when the memory is full, the newest reading will replace the oldest reading and the
statistics will be updated.

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 PC Software
This meter has the capability to connect to and communicate with a PC.
Check the software download page of the website www.extech.com/software for the latest version of the
PC software and its operating system compatibility.

Download and unzip the software. Run ExtechInstaller.exe and then refer to the instructions provided in
the HELP Utility within the software program.

Error Messages

The following error messages will appear on the meter’s LCD if a problem arises.

Err1: Eddy current probe error

Err2: Magnetic induction probe error
Err3: Eddy current and Magnetic induction errors
Err4, 5, 6: Unused error displays
Err7: Thickness error
Please contact Extech Instruments if a problem exists.

Maintenance

Cleaning and Storage

Periodically wipe the meter housing with a damp cloth and mild detergent; do not use abra-sives or solvents.
If the meter is not to be used for 60 days or more, remove the batteries and store them separately.

Battery Replacement/Installation instructions

1. Remove the Phillips head screw that secures the rear battery door
2. Open the battery compartment
3. Replace/install the two 1.5V ‘AAA’ batteries
4. Secure the battery compartment

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Specifications

Sensor probe Ferrous Non-Ferrous

Measurement principle Magnetic induction Eddy current principle
Measuring range 0~1250μm 0~1250μm
of coating thickness
0~49.21mils 0~49.21mils
Accuracy1 0~850μm: ±(3% + 1μm) 0~850μm: ±(3% + 1.5μm)
(% of reading) 850μm ~1250μm: (±5%) 850μm ~1250μm: (±5%)
0~33.46mils: ±(3% + 0.039mils) 0~33.46mils: ±(3% + 0.059mils)
33.46mils ~49.21mils: (±5%) 33.46mils ~49.21mils: (±5%)
Resolution 0~50μm: (0.1μm) 0~50μm: (0.1μm)
50μm ~850μm: (1μm) 50μm ~850μm: (1μm)
850μm ~1250μm: (10μm) 850μm ~1250μm: (10μm)
0~1.968mils: (0.001mils) 0~1.968mils: (0.001mils)
1.968mils~33.46mils: (0.01mils) 1.968mils~33.46mils: (0.01mils)
33.46mils~49.21mils: (0.1mils) 33.46mils~49.21mils: (0.1mils)
Min. curvature radius 1.5mm (59.06mils) 3mm (118.11mils)
of substrate
Diameter of Min. area 7mm (275.6mils) 5mm (196.9mils)
of substrate
Basic critical thickness 0.5mm (19.69mils) 0.3mm (11.81mils)
of substrate
Industrial standards Conforms to GB/T 4956-1985, GB/T 4957-1985, JB/T 8393-1996, JJG 889-
95, and JJG 818-93
Operating Temperature 32°F~104°F (0°C~40°C)
Operating Relative Humidity 20%~90% Relative Humidity
(R.H.)
Dimensions 4.3 x 2.0 x 1.0” (110 x 50 x 23mm)
Weight 3.9 oz. (100g)
Accuracy statement applies on a flat surface, with a zero and a calibration performed near the thickness
of the film to be measured, with an identical base metal and with the meter stabilized at ambient
temperature. The accuracy of the reference films or any reference standards should be added to
measurement results.

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Two-year Warranty
Teledyne FLIR warrants this Extech brand instrument to be free of defects in parts and
workmanship for two years from date of shipment (a six-month limited warranty applies to sensors
and cables). To view the full warranty text please visit:
http://www.extech.com/support/warranties.

Calibration and Repair Services

Teledyne FLIR offers calibration and repair services for the Extech brand products we sell. We
offer NIST traceable calibration for most of our products. Contact us for information on calibration
and repair availability, refer to the contact information below. Annual calibrations should be
performed to verify meter performance and accuracy. Product specifications are subject to change
without notice. Please visit our website for the most up-to-date product information:
www.extech.com.

Contact Customer Support

Customer Support Telephone List: https://support.flir.com/contact
Calibration, Repair, and Returns: repair@extech.com
Technical Support: https://support.flir.com

Copyright © 2022 Teledyne FLIR Commercial Systems, Inc.

All rights reserved including the right of reproduction in whole or in part in any form
www.extech.com

This document does not contain any export-controlled information

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