Cygnus 6+ Operating Manual

Cygnus 6+
Multi-Mode Ultrasonic Thickness Gauge
Operating Manual
Covers Gauge Model : M5-C6P
Doc No.
M5-CYG6P-M-01_Iss5.doc
18 October 2016
Cygnus 6+ Operating Manual
M5-CYG6P-M-01_Iss5.doc
QUALITY POLICY STATEMENT
Cygnus Instruments’ mission is to be a premier supplier of niche test and
measurement instruments. To achieve this we will:
Customers
• Be dedicated to customer satisfaction by listening to direct and
indirect feedback regarding our performance and product
requirements in general.
• Design state-of-the-art products that are robust, reliable, simple-touse and compliant with applicable industry and regulatory
requirements.
• Provide products and services that meet or exceed customer
expectations in terms of performance, reliability and safety.
Internal Systems
• Operate effective and safe working practices that comply with ISO
9001:2008 and EN ISO/IEC 80079-34 and other applicable regulatory
and statutory requirements.
• Provide adequate resources to ensure product and service quality is
maintained.
• Set, communicate and measure performance objectives and targets
to promote continual improvement.
• Ensure employees are competent and involved in improvement and
customer satisfaction matters.
Suppliers
• Use suppliers and subcontractors who share our passion for customer
satisfaction and who consistently perform reliably.
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Contents
1. Important Notice .............................................................. 9
2. Introduction.................................................................... 10
Cygnus 6+ Thickness Gauge .................................................. 10
Cygnus Instruments ............................................................. 11
Gauge Kit Contents ............................................................... 12
Basic Gauge Kit ................................................................... 12
Kit supplied with Single Element Probe .................................... 12
Kit supplied with Twin Element Probe ...................................... 12
3. Gauge Preparation .......................................................... 13
Fitting the Batteries ............................................................. 13
Connecting the Probe ........................................................... 14
Fitting the Neck Strap .......................................................... 14
4. Selecting the Right Probe................................................ 16
Measuring Metals ................................................................. 16
Measurement Modes Explained and Compared ......................... 17
Multiple Echo Mode (ME) (Mode 3) ....................................... 17
Single Echo Mode (SE) (Mode 2) ......................................... 17
Echo-Echo Mode (EE) (Mode 3) ........................................... 18
Measuring Non-Steels .......................................................... 18
Measuring Non-Metals .......................................................... 19
Single Element Probes and Protective Membranes..................... 20
Summary of Cygnus Probes .................................................. 22
Twin Element probes ......................................................... 22
Single Element probes ....................................................... 22
The ‘Probe Type’ Code ....................................................... 23
5. Gauge Operation ............................................................. 24
Gauge Controls ................................................................... 24
Turning the Gauge On .......................................................... 25
Turning the Gauge Off .......................................................... 25
Automatic Power Off .......................................................... 26
Measurement Screen Views ................................................... 26
Status Information............................................................... 27
Taking Thickness Measurements ............................................ 28
Zeroing the Probe (twin element probes) .............................. 28
Taking the Thickness Measurement...................................... 28
Echo Indicators in Multiple Echo Mode .................................. 29
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Measurement Stability Indication in SE & EE Modes ................ 30
Measuring Small Diameter Pipe & Tubes .................................. 31
Display Hold Feature ............................................................ 31
Battery Life......................................................................... 32
Battery Level .................................................................... 32
Low Battery Indication.......................................................... 33
6. Using the A-Scan Display ................................................ 34
Single Echo Mode ................................................................ 34
Measuring Over Corrosion Pits ............................................ 35
Echo-Echo Mode .................................................................. 36
Multiple Echo Mode .............................................................. 37
7. Calibration ...................................................................... 39
Why should I Calibrate my Thickness Gauge?........................... 39
Calibration Options .............................................................. 40
Calibrating to a known thickness (Single or 1 Point) .................. 40
Two Point Calibration ........................................................... 42
Ladder Step Wedge ........................................................... 42
Two Point Calibration Procedure .......................................... 43
Probe Zero (twin element probes) .......................................... 45
Starting a Probe Zero from the Main Menu ............................ 46
Probe Zero ....................................................................... 46
Setting the Velocity of Sound ................................................ 47
8. Gauge Setup ................................................................... 49
Menu Operation ................................................................... 49
Settings are Saved with the Probe Type .................................. 50
Inputting Numeric Values using the Navigation Keys ................. 51
Inputting Text using the Navigation Keys ................................ 51
Selecting the Probe Type ...................................................... 53
Confirming the Probe Type when Connected.......................... 53
Changing the Probe Type ................................................... 53
Automatic Probe Detection ................................................. 54
Measurement Units .............................................................. 55
Resolution Setting ............................................................... 56
Limit & Alarm Feature .......................................................... 57
Setting the Limit Feature.................................................... 59
Deep Coat Feature (multiple echo mode)................................. 60
9. High Temperature Measurement ..................................... 62
Twin Element Probes ............................................................ 62
Velocity Change Compensation .............................................. 62
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Temperature Compensation Feature .................................... 62
Taking Measurements at High Temperatures ............................ 63
High Temperature Couplant ................................................ 64
Tip - use the B-Scan Feature! ............................................. 64
10. Cross-Section B-Scan Feature ...................................... 65
Scan Menu Options .............................................................. 66
Range ............................................................................. 66
Scan Length ..................................................................... 66
Performing a Scan ............................................................... 66
11. Data Logging ............................................................... 69
Record Types ...................................................................... 69
Reference and Minimum Thicknesses ...................................... 69
Minimum Thickness Limit Alert ............................................ 70
Radial Points ....................................................................... 70
Measurement Comments ...................................................... 71
Loading Measurement Comments from a File ........................ 72
Grid Records ....................................................................... 72
Template Records ................................................................ 74
Data Logging Menu .............................................................. 74
Creating a new Record ......................................................... 74
Your Choices will be Saved for Next Time ............................. 76
Using a Template to Create a new Record................................ 77
User Field Input ................................................................ 77
Reviewing and Editing User Field Choices .............................. 77
Logging Thickness Measurements........................................... 78
Auto-Log Feature .............................................................. 79
Logging Obstructions and No-Readings................................. 80
Changing Measurement Units while Data Logging................... 81
Re-taking the Last Measurement ............................................ 81
Stepping Backwards in the Record.......................................... 82
Adding Radial Points ............................................................ 83
Adding Measurement Comments ............................................ 85
Closing and Opening a Record ............................................... 86
Closing the Record ............................................................ 87
Opening a Record ............................................................. 87
Protecting a Record .............................................................. 88
Opening Protected Records ................................................. 90
Deleting Records ................................................................. 90
Deleting Individual Records ................................................ 91
Deleting All Records .......................................................... 92
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Record Status................................................................... 92
12. Data Logging Templates .............................................. 94
Templates .......................................................................... 94
Integrating with Microsoft Excel .......................................... 95
Measurement Points ............................................................. 95
User Fields ......................................................................... 96
User Field ‘List’ Type ......................................................... 96
13. Manual Gain Adjustment .............................................. 97
Manual Gain Mode ............................................................... 97
Turning on Manual Gain ..................................................... 97
Manual Gain Menu ............................................................ 98
Adjusting the Gain ............................................................ 99
Adjusting the Range ........................................................ 100
Measuring Below the Probes Minimum Thickness Specification 101
14. Setup Menu ................................................................ 102
A-Scan Range ................................................................... 102
Automatic ...................................................................... 102
Manual .......................................................................... 102
Vibrate Feature ................................................................. 102
Brightness Setting ............................................................. 102
Bluetooth®........................................................................ 103
Bluetooth Adapters ......................................................... 103
Turning Bluetooth On ...................................................... 103
Pairing with a Computer ................................................... 104
Finding the COM Port Assigned.......................................... 105
End Display ...................................................................... 106
Rotate (End Display) .......................................................... 107
Power Off Setting .............................................................. 107
Auto-Log .......................................................................... 107
U/D Keys.......................................................................... 107
Temp Units ....................................................................... 107
Comments ........................................................................ 108
Set Time and Set Date ....................................................... 108
15. General Points On Thickness Gauging ........................ 109
16. Troubleshooting ......................................................... 110
The Gauge will not Switch On .............................................. 110
Difficulty obtaining a Reading .............................................. 110
If Readings are Erratic or Unstable ....................................... 110
Tips for Optimising Battery Life ............................................ 110
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17. Updating your Gauge ................................................. 112
Update Software................................................................ 112
Gauge Firmware Files ......................................................... 112
18. Care and Servicing ..................................................... 113
Cleaning the Gauge............................................................ 113
Batteries .......................................................................... 113
Environmental ................................................................... 113
Repairs ............................................................................ 113
Returning the Gauge for Servicing ........................................ 114
19. CygLink Computer Software ...................................... 115
Installing CygLink .............................................................. 116
Requirements ................................................................. 116
Upgrading ...................................................................... 116
Installing ....................................................................... 116
Connecting to the Gauge .................................................... 117
First time USB Connection ................................................ 117
Connecting the Gauge to CygLink for the First Time ............. 118
Connecting using Bluetooth .............................................. 118
Connecting to the Gauge Afterwards .................................. 119
Disconnecting from the Gauge .......................................... 119
Manual Connection Settings .............................................. 119
Status Bar ........................................................................ 119
Surveys ........................................................................... 120
Creating a new Survey..................................................... 120
Opening an Existing Survey .............................................. 121
Editing the Survey Info .................................................... 121
Managing the Survey ......................................................... 121
Sorting Survey Records ................................................... 121
Viewing Record Information .............................................. 122
Ref and Min Thickness ..................................................... 123
Protection State .............................................................. 124
Measurement Summary Stats ........................................... 124
Data Logger Records .......................................................... 124
Transferring Records from the Gauge ................................. 124
Viewing Thickness Measurements in a Record...................... 126
Managing Measurements .................................................. 126
Viewing Measurement Information ..................................... 127
Adding Comments to Measurements .................................. 128
Viewing an A-Scan Graph ................................................. 129
Deleting all Records from the Gauge .................................. 130
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B-Scans ........................................................................... 131
Transferring B-Scans from the Gauge................................. 131
B-Scan Menu .................................................................. 132
Viewing a B-Scan Graph................................................... 132
Viewing a B-Scan Information ........................................... 134
Exporting the B-Scan to a CSV File .................................... 135
Measurement Comment List ................................................ 136
Material Velocity List .......................................................... 137
Creating a PDF Survey Report ............................................. 139
Exporting a Survey to a CSV File .......................................... 140
Templates ........................................................................ 141
Creating New Templates .................................................. 141
Editing Templates ........................................................... 142
Sending Templates to the Gauge ....................................... 145
Deleting Templates from the Gauge ................................... 146
Other Features .................................................................. 146
Setting the Time and Date on the Gauge ............................ 146
COM Port Numbers ............................................................ 146
Finding your COM Port Number ......................................... 146
20. Information ............................................................... 148
Technical Specifications ...................................................... 148
Table of Sound Velocities .................................................... 152
Reading Conversions ....................................................... 153
21. EU Declaration of Conformity ..................................... 154
22. Recycling and Disposal (EC Countries)....................... 155
23. Warranty Information................................................ 156
24. Index ......................................................................... 157
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1. Important Notice
This following important information must be read and
understood by all users of Cygnus ultrasonic thickness
gauges.
The correct use of Cygnus ultrasonic thickness gauges requires
identification of the correct equipment for the specific application
coupled with an appropriately trained and qualified operator or
technician. The incorrect use of this equipment, along with its
incorrect calibration, can result in serious financial loss due to
damage to components, facilities, personal injury and even death.
Neither Cygnus Instruments nor any of its employees or
representatives can be held responsible for improper use of this
equipment. Proper training, a complete understanding of ultrasonic
wave propagation, thorough reading of this manual, proper
transducer selection, correct zeroing of the transducer, correct
sound velocity, correct use of the appropriate test blocks, proper
cable length and proper couplant selection all play a factor in
successful ultrasonic thickness gauging. Of critical importance is
the process of complete and accurate calibration of the
instrument.
This manual will provide instructions in the set up and operation of
the thickness gauge. Additional factors that can affect the use of
ultrasonic equipment are beyond the scope of this manual and to
that end it is understood that the operator of this equipment is a
well-trained inspector qualified by either their own organisation or
another outside agency to the appropriate level of both theory and
practical application of ultrasonics.
Therefore Cygnus Instruments recommends that users of its
ultrasonic thickness gauges should be formally qualified to a
minimum of UT “Level 1” (ASNT or PCN) which will provide
approximately 40 hours of training.
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2. Introduction
Cygnus 6+ Thickness Gauge
The Cygnus 6+ Ultrasonic Thickness Gauge is a rugged,
handheld, battery-powered instrument designed for high-reliability
thickness measurements in harsh environments using ultrasound.
It features a colour LCD display which can be easily read in most
light situations including sunlight.
The gauge can be used with a choice of Ultrasonic Probes, selected
to suit the material and thickness range to be measured.
The gauge can measure material thickness using three methods;
Single Echo, Echo-Echo or Multiple Echo. Both Echo-Echo and
Multiple Echo allow measurements through surface coatings which
are also ignored. An A-Scan display provides the user with
information that can be used to visually verify the thickness
measurement which can displayed in Metric (mm) or Imperial
(inch) units.
A Data Logging function can save thickness measurements and AScans in to a record file which can then be transferred to a
computer for analysis and report generation.
The gauge can easily be calibrated to a known thickness or to a
known Velocity of Sound.
The gauge is able to operate accurately over a wide range of
ambient temperatures and is environmentally sealed to IP67 for
use in wet conditions.
The gauge is a solid-state electronic instrument which, under
normal operating conditions, will give many years of active
service.
Although designed for ease of operation the first time user
should carefully read this manual to familiarise themselves
with the features of the Gauge.
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Cygnus Instruments
Cygnus Instruments Limited, founded in 1983,
were pioneers in the development of the Digital
Ultrasonic Multiple-Echo Technique used for
measurement through coatings. This has long
been the standard required to ensure that
accurate measurements are taken without the
need to first zero the gauge or remove any
coatings.
Our philosophy is to work closely with each of our customers to
provide a range of products specifically for each application.
Cygnus Ultrasonic Thickness Gauges are designed to be simple to
use and to withstand the harsh environments that they are
intended for. We have built up an enviable reputation with our
customers in over 45 countries around the world.
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Gauge Kit Contents
Basic Gauge Kit
1. Cygnus 6+ Gauge fitted with
Hand Strap
2. Operating Manual (in side
pouch)
3. Neck Strap (in side pouch)
4. Accessory Pouch, containing; 3
x AA Batteries, Blue Couplant
Gel.
5. USB Memory Stick with
CygLink Installer
6. USB Lead
Kit supplied with Single Element Probe
1. Ultrasonic Probe
2. Moulded Probe Cable (in side pouch)
3. 15mm (or ½”) Steel Test Block
4. Spare Membranes
5. Membrane Key
6. Membrane Couplant
Kit supplied with Twin Element Probe
1. Ultrasonic Probe
2. Moulded Probe Cable (in side pouch)
3. Ladder Step Wedge, 4 Step1
1
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Recommended Accessory
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3. Gauge Preparation
The gauge is supplied ready to use out of the box. Just insert the
batteries, connect the probe to the gauge, turn on the power,
calibrate and you are ready to begin taking thickness
measurements.
Fitting the Batteries
The gauge requires 3 x AA/LR6/UM3 Batteries. Cygnus supplies
and recommends Duracell Alkaline batteries. The batteries are
located behind a cover on the rear of gauge. The hand strap can
be separated by a push-button buckle to gain access to the battery
cover. The battery cover is removed by pressing in with your
thumb the at the base to release the clip.
Press the bottom of the
battery cover to release
the retaining clip and lift
up the battery cover.
The batteries are located
underneath.
The gauge is protected
against electrical damage
from incorrect battery
insertion.
The battery compartment
itself is sealed to contain
any battery fluids that
may leak out.
The gauge can be fitted with NiCad or NiMH rechargeable
batteries but this may alter the specified operating time.
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To avoid damage from leaking batteries always remove the
batteries if the gauge will be unused for any length of time.
If the batteries run flat they may leak acid into the battery
compartment and damage the electrical contacts. This would
not be covered by the warranty.
Connecting the Probe
The Cygnus probe lead uses a custom made cable that offers
superior flexibility and resistance to oils and ultraviolet light. The
twin connectors are over-mounded to form a tough housing that
will provide a long lasting probe cable. Depending on the type of
probe supplied the probe end will have either a BNC or single
Lemo® ‘00’ connector.
The connector is
orientated with a ‘pip’
and can only be plugged
in one-way around.
To release the connector
simply pull back on the
connector body. DO NOT
pull the cable.
Fitting the Neck Strap
The gauge is supplied with an adjustable Neck Strap. The ends of
the neck strap clip onto two wire loops. These wire loops are made
from coated stainless steel.
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To fit the wire loop to the gauge body
simply pass the loop through the hole
in the gauge and back over the other
end.
The neck strap can then be clipped on
to these two loops.
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4. Selecting the Right Probe
The performance of any thickness gauge and its ability to get a
reliable measurement depends on selecting the right ultrasonic
probe for the application and conditions. Cygnus gauges are
therefore offered with a selection of probes suitable for most
thickness gauging applications.
The following section helps you select the right probe for the
application.
The gauge must be set for the probe connected to it, see
Selecting the Probe Type on page 53.
Measuring Metals
Recommended..
Material Coating Corrosion
Typical
Thickness
Probe
Measurement Mode
Steels
Any
Non to
Moderate
1 mm+
S5A
Multiple Echo
Steels
Any
Non to
Moderate
2 mm+
S3C
Multiple Echo
Steels
Any
Non to
Moderate
3 mm+
S2C
Multiple Echo
Steels
Any
Non to
Moderate
3 mm+
S2D Multiple Echo
Steels
Non
Non to
Heavy
0.8 mm+
T7A
Single Echo
Steels
Non
Non to
Heavy
1.5 mm+
T5B
Single Echo
Cast
Iron
Non
Non to
Moderate
2.5 mm+
T2C
Single Echo
(0.04”+)
(0.08”+)
(0.12”+)
(0.12”+)
(0.03”+)
(0.06”+)
(0.1”+)
The table above shows to be able to measure both coated and uncoated steels with non to heavy corrosion ideally you will require
at least two probes, in almost all applications this will be a S2C
probe and a T5B probe.
When measuring in Multiple Echo mode the coating will be
ignored and just the metal thickness measured.
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It is possible to use a Twin Element (T**) probe in EchoEcho Mode to ignore thin paint coatings. However this
method does not have the ability to verify measurements
and without observing the A-Scan display it is possible to get
incorrect measurements.
Measurement Modes Explained and Compared
Multiple Echo Mode (ME) (Mode 3)
Multiple Echo measurement mode is by far the most reliable and
quickest method for thickness measurements because it works by
looking for three matched echoes it can verify the thickness
measurement is valid. This method has been used in all Cygnus
gauges since the late 1970s.
Multiple echo mode will ignore surface coatings (Through Coating
mode) there is no need to remove the paint to take a
measurement.
Also because it uses a single element (or single crystal) probe
there are no errors due to the V-path of the ultrasound beam
found in all twin element probes. This makes it simple to calibrate
– two point calibrations are not required.
However because it requires three echoes to take a measurement,
in heavily corroded steels there is often an insufficient number of
echoes so measurements may not be possible.
Single Echo Mode (SE) (Mode 2)
Single Echo measurement mode is most useful on heavily corroded
metals where Multiple Echo fails. Because it only needs the first
return echo to take a measurement it performs well on virtually all
steel conditions.
However single echo mode will not ignore any surface coatings, so
if you measure through a coating it will give an incorrect metal
thickness measurement. If the surface coating is very thin (0.2mm
/ 0.01”) paint you can make an allowance for this error, but
thicker coatings introduce too much error to be practical.
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Single echo measurements use a twin element (twin crystal)
probe, because there are two elements angled to a focal point
there is a v-path error introduced. However this v-path error is
mostly corrected by the gauge, and furthermore by performing a
two point calibration.
Twin element probes require “zeroing” at regular intervals,
especially if the ambient temperature is changing.
To overcome some of the drawbacks of Single Echo measurements
the gauge has an A-Scan display that can be used to visually
verify the thickness measurements are sensible and therefore
reliable. See section Using the A-Scan Display on page 34.
Echo-Echo Mode (EE) (Mode 3)
Echo-Echo mode uses a twin element probe, but measures
between the first two echoes. This method is intended to ignore
any thin surface coatings whilst still using a twin element probe.
Echo-echo mode is not able to verify its measurements unlike
Multiple echo mode, therefore it is liable to give incorrect readings.
But as the Cygnus 6+ gauge has an A-Scan display you can use
this to visually decide if the measurement given is correct.
Echo-echo mode must therefore be used with caution, and only on
thin paint surface coatings (less than 0.5mm/0.02”). It is
recommended a Single Echo measurement should also be made to
help verify the measurement makes sense (the Single Echo
measurement should always be thicker due to the coating
thickness).
Measuring Non-Steels
The gauge will measure the following non-steels;
• Aluminium alloys
• Copper and Brass alloys
• Titanium
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Use the same rules as steels when selecting a suitable probe. The
gauge will ideally be re-calibrated to suit the metal being
measured, or the standard velocity of sound for that material
would be entered into the gauge.
Measuring Non-Metals
You can measure certain types of plastics with the gauge using a
twin element probe and the gauge set to Single Echo
measurement mode. Generally the harder the plastic the better,
soft materials like rubber or TPEs tend to absorb too much
ultrasound so only thin samples can be measured.
Engineering plastics like Acetal, Tufset (Polyurethane), Nylon and
High-density polyethylene (HDPE) can be measured successfully.
Rotationally Moulded parts can generally be measured
successfully.
• You must use Single Echo mode to measure plastics.
• You must generally use a low frequency probe (the T2C
probe is recommended) to measure plastics, but this will
depend on the properties of the material.
• Any material with a closed-cell construction cannot be
measured.
• Any material with internal voids, air bubbles or honeycomb
cannot be measured.
Typically these materials cannot be measured with the gauge;
•
•
•
•
•
Concrete
Wood
Thermal insulation materials
Foams
Composites
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Single Element Probes and Protective Membranes
All Cygnus single element probes have a soft face and are
therefore fitted with a Polyurethane Membrane which provides
better contact on rough surfaces and protects the probe face from
wear and prolonging the life of the probe.
Check the membrane regularly as it is important the
membrane is changed as soon as it shows any signs of wear.
Probe Body
Locking Ring
Polyurethane Membrane
Knurled Ring
Single Element Probe Membrane Parts.
.
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Changing the Protective Membrane on Single element Probes
1.
Unscrew the Knurled Ring from the
end of the Probe.
2.
Use the Membrane Key to unscrew
the Locking Ring from inside the
Knurled Ring. The old membrane
can then be removed and
discarded.
3.
Place a new membrane into the end
of the Knurled Ring ensuring it
locates in the groove.
4.
Screw the Locking Ring back inside
the Knurled Ring and tighten with
the Membrane Key.
5.
Place a few drops of Membrane
Couplant on to the probe face.
6.
Screw the Knurled Ring back onto
the probe. Use your thumb to
squeeze the couplant from under
the membrane as you tighten the
Knurled Ring down.
7.
You should see the membrane has
a very thin film of couplant between
itself and the probe face with no air
bubbles.
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Measuring Higher Temperatures
The polyurethane membranes fitted to the single element probes
are suitable for measuring surface temperatures up to 70°C
(160°F). For measuring higher temperatures Teflon membranes
are available and suitable for surface temperatures up to 150°C
(300°F) with intermittent contact. Contact Cygnus instruments to
order Teflon membranes.
When measuring high temperatures limit the time the probe is in
contact with the hot surface to less than 4 seconds and ensure the
probe has sufficient time between measurements to cool down.
Summary of Cygnus Probes
Twin Element probes
Range in
Steel
(SE Mode)
Probe
Type
Size
Frequency
T2C
12mm
0.5”
2 MHz
2.5 to 250
mm
0.1 to 10”
Attenuative materials
Cast irons, Plastics
T5B
8mm
0.32”
5 MHz
1.5 to 200
mm
0.06 to 8”
General purpose
Most metals
T7A
5mm
0.2”
7.5 MHz
0.8 to 50 mm
0.03 to 2”
Typical Uses
Thin metals
Single Element probes
Probe
Type
Size
Frequency
S2C
13mm
0.5”
2.25 MHz
3 to 250 mm
0.12 to 10”
General purpose probe suitable
for most applications that can
use Multiple Echo
measurement.
Coated metals
S2D
19mm
0.75”
2.25 MHz
3 to 250 mm
0.12 to 10”
As S2C but has longer focal
point (33 mm) and narrower
beam so may perform better
on thicker materials
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Range in
Steel
Typical Uses
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S3C
13mm
0.5”
3.5 MHz
2 to 150 mm
0.08 to 6”
Coated metals
S5C
13mm
0.5”
5.0 MHz
1 to 50 mm
0.04 to 2”
Coated metals
S5A
6mm
0.25”
5.0 MHz
1 to 50 mm
0.04 to 2”
Small diameter tubes
Thin metals
Coated metals
The ‘Probe Type’ Code
S
Single or Twin
Crystal
2
C
Frequency in MHz
Size
A 6mm / ¼”
B 8mm / 0.32”
C 13mm / ½”
D 19mm / ¾“
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5. Gauge Operation
Gauge Controls
End
Display
Probe
Connections
End view of gauge
Navigation
Keys
Power
Key
Menu
Key
Select
Keys
Front view of gauge
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Turning the Gauge On
1. Press the Power key
2. Cygnus Instruments Logo is
displayed
3. The gauge details are displayed;
Model
Serial Number
Version Number
Run Time
4. The gauge is ready to use
Turning the Gauge Off
1. Press & Hold the Power key,
2. The display shows ‘power-off’ and
the gauge turns off.
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Automatic Power Off
By default the gauge will turn off automatically after 5 minutes of
in activity.
Taking thickness measurements or accessing the menu will reset
the activity timer back to zero.
You can change the activity time value the Setup menu, see Power
Off Setting on page 107.
Measurement Screen Views
The gauge has three measurement screens that can be quickly
changed using the left and right navigation keys. These screens
offer three views to suit the situation.
1. Use the Left and Right
navigation keys to move
between the three screens
2. Basic Screen
Just shows a large thickness
measurement value.
3. A-Scan Screen
Show the thickness
measurement and a live A-Scan
display of the ultrasound signals
received.
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4. Data Logging Screen
When data logging is active this
screen shows details of logged
measurements.
Status Information
At the top of the display is an area that shows information about
the gauge’s status;
•
•
•
•
•
•
Battery Level
Velocity of Sound value / Calibration Status
Probe Type
Measurement Mode
Deep Coat Feature
Temperature Compensation
Battery
Level
Probe
Type
Measurement
Mode
Velocity, or
‘Calibrated’
Deep Coat
Function
Probe Type; when the probe is connected the background colour is
green, when disconnected it is grey.
Measurement Modes;
ME
EE
SE
Multiple Echo
Echo-echo
Single Echo
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Taking Thickness Measurements
Taking ultrasonic thickness measurements is a straight forward
process that involves first making sure the surface is clean and
prepared, applying an ultrasonic couplant gel then placing the
probe on the surface and observing the display for the
measurement.
Zeroing the Probe (twin element probes)
When a twin element probe is connected to the gauge (and the
gauge is set to the correct probe) you must first perform a Probe
Zero before you can begin taking measurements. For instructions
see Probe Zero Function on page 46.
It is recommended to frequently perform a Probe Zero
especially if conditions such as temperature are changing. At
least every 30 minutes.
Taking the Thickness Measurement
1. Remove all scale, rust, dirt or loose
coatings and brush the test area clean.
2. Apply ultrasonic couplant to the test
surface.
3. Place the probe-face on the clean,
lubricated test surface and make firm
contact applying gentle pressure.
4. The gauge will display a thickness
measurement.
(Or an indication of Echo Strength if no
valid measurement has been found in
Multiple Echo mode).
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Echo Indicators in Multiple Echo Mode
Should the gauge be unable to detect a stable multiple echo signal
it displays an Echo Indication to help the operator locate a suitable
position.
1. 1 Bar Flashing:
No echoes detected
2. 1 steady + 1 Bar Flashing:
Only 1 echo detected
3. 2 steady + 1 Bar Flashing:
Only 2 echoes detected
4. 3 steady + 1 Bar Flashing:
3 echoes detected but they are
not matched
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To help obtain a multiple echo reading the operator should
continue to move the probe around to locate a suitable reflector,
using a slight rocking motion.
Measurement Stability Indication in SE & EE Modes
To help indicate when a Single Echo or Echo-Echo measurement is
stable – and thus probably reliable – the gauge changes the
thickness measurement number colour from Red to Green when
the measurement has been stable for 2 consecutive seconds.
When measuring using Single Echo or Echo-Echo mode once you
have a measurement keep the probe still and wait for the gauge to
signal a “stable reading”.
If the ultrasound signal is poor or erratic then the thickness value
may remain red – thus indicating the measurement may not be
reliable.
1. Initial measurements will be
displayed as red numbers.
2. If the measurement remains stable
for 2 consecutive seconds then the
measurement will change to
green.
Stable is defined as; the thickness measurement changing no
more than + or - the Resolution setting.
Example.
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The Resolution is set to 0.05mm, therefore the thickness
measurement must not change by more than +0.05mm or
-0.05mm for 2 seconds or more to be “stable”.
The Resolution is set to 0.002”, therefore the thickness
measurement must not change by more than +0.002” or
-0.002” for 2 seconds or more to be “stable”.
Measuring Small Diameter Pipe & Tubes
When measuring small diameter pipe and tubes with a twin
element probe, 75mm (3”) or under, you must ensure the face of
the probe is correctly aligned to the curvature of the pipe
otherwise measurements may be inaccurate.
The dividing line on the face of the probe should be at
right angles to the length of the pipe.
Pipe
Probe Face
Probe Face Division is at
right angles to the pipe
Display Hold Feature
The thickness measurement can be ‘Held’ or frozen by simply
pressing the X key while in any measurement screen.
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1. A thickness measurement is
displayed
2. Press the X key to hold the
thickness measurement.
The measurement value now has
a light blue border to indicate it’s
held or froze.
3. Press the X key to un-hold the
thickness measurement.
Battery Life
The gauge will operate for approximately 10 hrs when fitted with
Duracell Alkaline 1500 mA/hr batteries.
Battery Level
A battery level graphic is displayed at the top left position of the
display (arrowed);
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Battery almost full
Battery about 1/2 full
Battery low
Low Battery Indication
The gauge will periodically flash a red Low Battery warning sign
when the batteries have approximately 1 hour of use remaining.
Low battery indication
When the batteries are exhausted the gauge will display a Flat
Battery message for 5 seconds then turn off automatically.
Flat Battery message
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6. Using the A-Scan Display
To help ensure reliable measurements in Single Echo and EchoEcho measurements the gauge has an A-Scan display that can be
used to visually verify the thickness measurements are sensible
and therefore reliable. With some practice any user can quickly
and easily use the A-Scan to decide if the measurement is correct.
To view the A-Scan display use the Left and Right navigation keys
to switch between the measurement screen views (see
Measurement Screen Views on page 26).
The A-Scan display shows the actual ultrasound echo pulses as
received by the gauge; these echo pulses are used by the gauge
to determine the thickness measurement if possible.
The gauge works by generating a short pulse of ultrasound that is
coupled into the object you are measuring. This pulse then travels
through the object and is reflected back to the probe as an echo
by either the back-wall of the object and/or any internal flaws or
corrosion pits. When the echo pulse hits the probe surface a signal
is received by the gauge, this signal is shown on the A-scan
display as an echo peak, the taller the peak the stronger the
signal.
Single Echo Mode
The A-Scan display is very useful when measuring in Single Echo
modes, as there is no verification of the thickness measurement
observing the A-Scan display will help the user verify the echo
detected is the correct one – the back-wall echo.
This A-Scan shows a good clear
ultrasound signal.
There is a well-defined back-wall echo
and the arrow is correctly placed.
The measurement value of 12.7 mm is
stable when green in colour.
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This A-Scan shows a very weak
ultrasound signal.
There is no clear correct back-wall echo
and the gauge is unable to determine a
thickness measurement.
You should try moving the probe to find
a better reflector, first rotate the probe
to see if that gets a measurement, if that
fails then try another position.
Weak Signal
Measuring Over Corrosion Pits
You should be careful not to attempt to take a single echo
thickness measurement when there is a void or corrosion pit
directly underneath the probe face as the gauge will
incorrectly measure the depth of the couplant.
Large Corrosion Pits.
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Couplant
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Probe
Pit
Corroded Metal
Avoid Measuring Directly Over Corrosion Pits.
The A-Scan display can assist you - you will see an unclear
ultrasound signal with unclear back wall reflections.
This A-Scan shows an incorrect
measurement that may be from
measuring couplant inside a pit.
Echo-Echo Mode
Like Single Echo mode the A-Scan can be very useful when taking
measurement through coating using Echo-Echo mode. Echo-Echo
mode measures thickness by measuring the time between two
consecutive echo signals, in ideal conditions this is a good reliable
method of thickness measurement thorough coating, but when
corrosion starts to degrade the echoes the gauge could measure
between two incorrect echoes and give a wrong reading. Here the
A-Scan can assist, by observing the echo signals you can decide of
the thickness measurement given makes sense and is reliable.
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The gauge measures between these two echo
signals to calculate the thickness. This is a good
clear signal so the measurement is reliable.
The two purple arrows mark the points the gauge
has measured between.
This A-Scan shows an unclear Echo-Echo
measurement.
The echoes are scattered and although
the gauge has given a thickness
measurement of 5.5mm it may not be
accurate. Try first rotating the probe
then another location.
Multiple Echo Mode
Although Multiple Echo mode has the benefit of providing “echo
matched” verified thickness measurements and can be used
reliably without observing the A-Scan display, the A-Scan display
can sometimes help where measurements are difficult or suspect.
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This A-Scan shows a good Multiple-Echo
measurement on a new steel sample.
The echo signals are distinct and clear.
The three purple arrows mark the
positions the gauge used for the
thickness measurement.
This A-Scan shows a Multiple-Echo
measurement from a corroded steel
sample.
The three echo signals have been picked
out ok, but there is less clarity around
echo 2 and 3.
This A-Scan shows no Multiple-Echo
measurement.
The echo signals are all over the display,
there are no distinct echoes for the
gauge to pick out. You should move the
probe to another location, or try using
SE or EE mode.
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7. Calibration
Why should I Calibrate my Thickness Gauge?
Ultrasonic thickness gauges measure time in order to measure the
thickness of the material being tested. It relies on the principal
that sound travels through a material at a constant velocity or
speed. If you can accurately measure the time it takes to travel
through a material and you know its velocity then you can
calculate its thickness;
Thickness = time x velocity
2
Modern thickness gauge are easily capable of measuring time
accurately to 10 Nano seconds (0.000,000,01 seconds) so this is
considered to be more than sufficiently accurate.
This means the accuracy of any thickness gauge measurement
relies principally on the velocity being correct for the material
being measured.
There are tables listing the velocity of most common metals and
materials, but these velocities are only “typical” values. For
example Mild Steel has a typical velocity of 5920 m/s – but in
practice when measuring a variety of mild steel samples the
velocity can range anywhere from 5860 to 5980 m/s.
This means if you want to achieve the most accurate thickness
measurements you must calibrate your thickness gauge to a
sample of the same material you will be testing – and a sample
that you can accurately measure the thickness of with a Vernier or
micrometer.
Your measurements are only as good as your calibration
Instructions for calibrating the gauge can be found on page 40
onwards.
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Calibration Options
The Gauge is supplied tested and calibrated. The Gauge will have
been calibrated to measure thickness through steel (grade
S355JO) with a velocity of sound of 5920 m/s.
Either a 15mm or 1/2” Test Block is supplied with the kit so the
Gauge can be quickly checked for correct operation. Note, this test
block is not intended to be used for calibration of the Gauge.
The best way to calibrate the Gauge is to Calibrate using a
Known Thickness using a sample of the material you intend to
measure. This method determines the velocity of sound for
the material sample, which will always be more accurate than
using a ‘general’ velocity value. For calibration instructions
see page 40.
If there is no test sample available the Gauge can be calibrated by
Setting the Velocity of Sound directly. A table on page 152 at the
back of this manual lists common materials and their velocity of
sound value. For calibration instructions see page 41.
A third method is to leave the Gauge set to its factory-pre-set
value for Steel [5920 m/s or 0.2332 in/us], and then use a
Conversion Factor from the table of velocities on page 152.
Calibrating to a known thickness (Single or 1 Point)
This method of calibrating the gauge is more accurate than using a
standard velocity value as the gauge calculates the velocity of
sound for the sample material.
You can use this calibration method for all measurement modes.
1. Accurately measure the
thickness of your sample
material.
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2. Place the Probe on the sample
and verify the gauge can get a
thickness value.
3. Access the Menu and scroll down
to the ‘Calibration’ group. Then
scroll right to the ‘1 Point Cal’
item.
Press the √ key to open the ‘1
Point Cal’ function
4. While holding the probe firmly
on the sample and while a
steady thickness measurement
is displayed..
5. ...use the Up and Down keys to
adjust the thickness to the
required value.
6. When done press the √ key to
save the calibration. A
Calibration Saved message will
be shown.
Or press the X key to exit
without saving the calibration.
When a Calibration has been made a ‘1PC’ indictor is displayed at
the top of the measurement screen in the status area (1PC =
Single Point Calibration).
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‘1PC’ Indicator
Two Point Calibration
The Two Point Calibration option is only available in Single Echo
and Echo-Echo modes.
Two point calibration allows the gauge to be calibrated against two
reference thicknesses of the same material, one at the minimum
(thin) thickness range the other at the maximum (thick) thickness
range.
To achieve maximum accuracy in Single Echo mode
you must perform a Two Point Calibration – your
measurement is only as good as your calibration.
When performing a two point calibration both sample thicknesses
should be made from the same material. The temperature of the
sample material should be the close to the temperature of the
material to be measured.
The gauge will automatically compensate for v-path error in
addition to either single or two point calibrations.
Ladder Step Wedge
Typically a Ladder Step Wedge is
used to calibrate the probe and
gauge for Steel. The ladder step
wedge has 4 or 5 different
thicknesses typically ranging from
2.5 to 20.0 mm (0.1 to 0.5”). You
would typically choose to calibrate
using the 2.5 and 20 mm
thicknesses.
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Two Point Calibration Procedure
1.
Assuming you have a step
wedge of known thicknesses
2.
Wipe clean the step wedge then
add some fresh couplant to the
step wedge
3.
Place the Probe on the sample
and verify the gauge can get a
thickness value.
4.
Access the Menu and scroll down
to the ‘Calibration’ group. Then
scroll right to the ‘2 Point Cal’
item.
20.00
2.50
Press the √ key to open the ‘2
Point Cal’ screen
5.
Start with the Thick sample –
Maximum thickness.
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6.
While holding the probe firmly
on the thick sample and while a
steady thickness measurement
is displayed..
...use the Up and Down Select
keys to adjust the thickness to
the required value.
7.
When the correct measurement
is displayed press the √ key
8.
Next measure the Thin sample –
Minimum thickness.
9.
While holding the probe firmly
on the thin sample and while a
steady thickness measurement
is displayed..
...use the Up and Down Select
keys to adjust the thickness to
the required value.
10. When the correct measurement
is displayed press the √ key
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rd
11. The 3 screen lets you check the
calibration is correct my
checking a few different
measurements on the step
wedge.
12. When done press the √ key to
save the calibration. A
Calibration Saved message will
be shown.
Or press the X key to exit
without saving the calibration.
Probe Zero (twin element probes)
Twin element probes must be zeroed to compensate for any wear
or operating temperature changes. The gauge will always perform
a Probe Zero when first turned on or when a twin element probe is
connected.
If the probe gets significantly warmer during use this can cause a
shift in the zero position and thus introduce small errors in the
thickness measurement. Typically a 20°C (68°F) change in
temperature the measurements can shift by 0.1 mm (0.04”).
It is recommended to frequently perform a Probe Zero
especially if conditions such as temperature are
changing.
See also Zeroing the Probe (twin element probes) on page 28.
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Starting a Probe Zero from the Main Menu
1. Access the Menu and scroll down
to the ‘Probe’ group. Then scroll
right to the ‘Zero’ item.
Press the √ key to start the
‘Zero’ process
Probe Zero
2. Display shows the Zero Probe
message.
Important - Wipe any couplant
from the probe face
3. Press the √ key to proceed
The gauge measures the probe
zero point…
..this takes about 2 seconds.
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4. If the Probe Zero fails a message
will be displayed.
• Check the probe has not
been unplugged or the
cable is damaged/faulty.
• The probe face must be
clean and in the air.
• Are you using a nonCygnus probe?
You must un-plug the probe,
then plug it back in to re-try the
Probe Zero process.
Setting the Velocity of Sound
The gauge uses the Velocity of Sound value to calculate the
material thickness value. It is therefore important the velocity
value is set correctly for the material being measured.
If you perform a Calibration the Velocity of Sound will be set
for you during the calibration – so you don’t need to adjust it
afterwards.
You can manually set the velocity of sound value if required;
normally you would do this if;
• You can’t perform a calibration
• You want to use the same velocity setting as last time
• You want to use a velocity from a material list
A list of velocity of sound values for common material can be
found on page 152.
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1. Access the Menu and scroll down
to the ‘Calibration’ group. Then
scroll right and select ‘Velocity’.
Press the √ key to open the
‘Velocity’’ screen
3. If there has been a previous
Calibration a message will warn
that changing the velocity will
alter the calibration;
Press the √ key to continue, or
X to abort.
4. Use the Up and Down keys to
adjust the velocity value as
required
Use the Left and Right keys to
highlight the digit to change.
5. When done press the √ key to
save the changes.
Or press the X key to exit
without saving.
When the velocity has been manually set the value is displayed at
the top of the measurement screen in the status area.
Velocity of Sound value ‘5920 m/s’
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8. Gauge Setup
Menu Operation
1.
Press the Menu key,
2.
the Main Menu is displayed
3.
Use the four Navigation keys to
scroll around the Main Menu
4.
Use the Up and Down keys to
select a group in the left
column..
5.
Press the Right key to move to
the items in that group in the
right column.
Then use the Up and Down keys
to select from the right column
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6.
If you want to change or select
the item currently displayed
simply press the green √ button
7.
Then use the Navigation keys to
highlight the required setting or
option
8.
Press the green √ key to save
your choice
9.
Or press the red X key to abort
6.
Press the Left key to go back to
the main group if you want to
make another selection
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12. To exit the menu press the Menu
or red X key once.
Settings are Saved with the Probe Type
Certain gauge settings are saved against the probe type. This
allows each probe type to have different settings that will be
recalled when that probe is re-connected and the probe type is
correctly set. The following settings are saved with each probe
type;
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Units
Resolution
Velocity of sound
Calibration
Deep Coat
Inputting Numeric Values using the Navigation Keys
Some menu screens require the user to input a numeric value
using the navigation keys. This is done ‘digit’ as a time, using the
Left and Right keys to select the digit, then the Up and Down keys
to change the highlighted digits value.
1. The units digit is highlighted.
Pressing Up or Down will change
the units value only.
2. Pressing the Left key will move
the highlight to the tens digit.
Pressing Up or Down will change
this value only.
3. Pressing the Left key will move
the highlight to the hundreds
digit. Pressing Up or Down will
change this value only.
4. Pressing the Left key will move
the highlight to the thousands
digit. Pressing Up or Down will
change this value only.
Inputting Text using the Navigation Keys
Some functions may require alphanumeric text to be input into the
gauge. This is done using a special alphanumeric entry screen and
the navigation keys.
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1. The screen is divided into ‘virtual’
keys like a QWERTY keyboard.
You move the Blue highlight
around using the 4 navigation
keys.
Then press the √ key to enter the
character or perform the selected
function.
2. To enter the word CYGNUS you
would move the blue highlight
from Ok to ‘C’ then press the √
key, then move to the ‘Y’…
3. There are ‘keys’ for
Delete last = Del
Space = Spc
Clear all = Clr
Move = ◄ ►
Toggle case = ▲
4. When you have entered your
word just move the highlight to
the green ‘Ok’ at the bottom and
press the √ key.
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Selecting the Probe Type
The Probe Type must be set to match the probe connected to
the gauge. If the wrong probe is selected the gauge will not
measure accurately if at all.
The gauge has an Automatic Probe Detection feature than can
identified certain types of probes when they are first connected to
the gauge, or you can manually select the probe from a list.
These probes can be Auto Detected;
T2C, T5B, T7A, T5B-H & S2C
These probes must be selected manually;
S2D, S3C, S5A & S5C
Confirming the Probe Type when Connected
When a probe is connected to the gauge that can’t be identified
the gauge will ask the user to select the correct probe from a list
on the screen. You must select a probe to continue.
Changing the Probe Type
The Probe Type is displayed is displayed at the top of the
measurement screen in the status area. When a probe is
connected the background is green. When no probe is detected the
background is grey.
S2C Probe Selected and Connected
S2C Probe Selected but NOT Connected
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1. Access the Menu and scroll down
to the ‘Probe’ group. Then scroll
right and select ‘Type’.
Press the √ key to open the
‘Select Probe’ screen
2. Use the Up and Down keys to
select the Probe Type required
3. Press the √ key to save.
Or press the X key to exit
without saving.
Remember settings and calibration is saved with each probe
type. So if you change the probe type you may find a setting
has changed – this is normal.
The reason settings are saved with each probe type is so you
can swap probes during a survey without having to recalibrate each time.
Automatic Probe Detection
The Automatic Probe Detection feature works by listening to how
the probe behaves when it is first plugged in. For that reason the
probe MUST BE in the air and not coupled to a surface when
plugging in or turning on the gauge.
You can turn the automatic probe detection feature on or off from
the Probe menu using the Auto Detect item.
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When Auto Detect is set to On and a probe is connected the
gauge will try and determine the probe type – this will be
displayed at the top of the screen on the right.
S2C Probe Selected and Connected
Observe the probe type displayed and check it matches the probe
connected to the gauge.
If the gauge fails to correctly detect the probe type then you must
manually select from the list of probes. See Selecting the Probe
Type on page 53.
Manual Probe Selection – Single Element Probe Detected.
Measurement Units
The Gauge can display thickness measurements in either Metric
(mm) or Imperial (inch). Changing the measurement units will not
affect the calibration.
1. Access the Menu and scroll down
to the ‘Measurement’ group.
Then scroll right and select
‘Units’.
Press the √ key to open the
‘Units’ screen
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2. Use the Up and Down keys to
switch from mm to Inch
4. Press the √ key to save.
Or press the X key to exit
without saving.
Resolution Setting
The gauge can display thickness measurements in three resolution
settings:
• 0.1 mm
0.005 inch
All Modes
• 0.05 mm
0.002 inch
All Modes
• 0.01 mm
0.001 inch
SE and EE Modes only
For general metal corrosion measurement the 0.1 mm
(0.005”) Resolution setting is recommended.
To change the Resolution setting:
1. Access the Menu and scroll down
to the ‘Measurement’ group.
Then scroll right and select
‘Resolution’.
Press the √ key to open the
‘Resolution’ screen
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2. Use the Up and Down keys to
select the required Resolution
3. Press the √ key to save.
Or press the X key to exit
without saving.
Limit & Alarm Feature
The gauge has a Limit feature that can be used to;
• Give visual indication of measurements between minimum,
reference and maximum limits.
• Vibrate Alert the operator if measurements are outside the
minimum or maximum limits
The Limit feature can be turned ON or OFF as required and the
Vibrate Alert can be enabled as required.
There are three Limit measurement values you can set;
• Minimum Limit – this is the lowest thickness measurement,
measurements under this value will cause an Alert
• Reference Limit – this is the ‘correct’ thickness value, or
when corrosion monitoring this is usually set to the thickness
of the steel/material when it was new.
• Maximum Limit – this is the highest thickness measurement,
measurements over this value will cause an Alert. This limit is
optional and can be set to zero.
When Limits are enabled the measurement screen displays a
horizontal bar-graph showing the limits and the current
measurement in relation to these limits. The colour of the bar also
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changes from light green to dark green to red as the measurement
moves from the reference value to the minimum or maximum
limits.
Thickness Measurement = Reference = Light Green Bar.
Limit Example
Limits are setup;
Minimum = 5.00 mm
Reference = 10.00 mm
Maximum = 20.00 mm
The thickness measurement is 10.05
mm so the bar-graph shows a green
bar positioned at the Reference point.
Now the thickness measurement is
8.05 mm so the bar-graph shows a
dark green bar positioned left of the
Reference point.
Now the thickness measurement is
5.10 mm so the bar-graph shows a
red bar positioned at the Minimum
point.
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Now the thickness measurement is
20.00 mm so the bar-graph shows a
red bar positioned at the Maximum
point.
Now the thickness measurement is
25.45 mm so the bar-graph shows a
red bar positioned past the Maximum
point.
This exceeds the Maximum limit so
will cause a Vibrate Alert if enabled.
Setting the Limit Feature
1. Access the Menu and scroll down
to the ‘Limits’ group. Then scroll
right and select ‘Limits’.
Press the √ key to open the
‘Limits’ screen
2. Use the Up and Down keys to
turn Limits On or Off…
Press the √ key to save.
Or press the X key to exit
without saving.
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3. Use the Up and Down keys to
select the Minimum, Reference,
Maximum or Vibrate settings
Press the √ key to open the
selected item
4. Use the navigation keys to
change the setting..
Press the √ key to save.
Or press the X key to exit
without saving.
Deep Coat Feature (multiple echo mode)
With the Deep Coat feature turned Off and in multiple echo (ME)
mode the gauge can measure through most protective coatings up
to 3 mm (0.12”) thick when using a S2C type probe. Coatings like
paint, anti-foul, hard plastics and epoxy should present no
problems as long as they have not de-laminated/de-bonded from
the metal surface.
With the Deep Coat feature turned On this will allow the gauge to
measure through coatings over 3mm (0.12”) thick up to a
maximum of around 20 mm (0.8”) depending on the properties of
the coating material.
Measuring through thick coatings is ultimately limited by how well
the coating material allows the ultrasound to pass through, soft
coatings like rubber or bitumen don’t transmit ultrasound very
well.
Using Deep Coat will not affect the calibration.
Turn Deep Coat Off when NOT measuring through thick
coatings otherwise this may cause inaccurate measurements.
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1. Access the Menu and scroll down
to the ‘Measurement’ group.
Then scroll right and select
‘Deep Coat’.
Press the √ key to open the
‘Deep Coat’ option
2. Use the Up and Down keys to
select Deep Coat On or Off
3. Press the √ key to save.
Or press the X key to exit
without saving.
When the Deep Coat feature is turned On a ‘DC’ indicator will be
displayed in the status area at the top of the measurement screen.
DC = Deep Coat is ON.
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9. High Temperature Measurement
Twin Element Probes
Standard twin element probes may be used to measure surface
temperatures up to 75°C (160°F). However for measuring at
higher temperatures the T5B-H probe is available which can be
used on surfaces up to 300°C (570°F) with intermittent contact
and cooling.
Velocity Change Compensation
When taking thickness measurements of metal at elevated
temperatures the velocity of sound for the metal will increase as
the temperature increases, this will introduce an error in the
thickness measurement and must be compensated for using a
simple general formula;
Reduce 1% per 55°C (100°F) rise in temperature
Temperature Compensation Feature
The gauge has a facility to apply this correction based on the
surface temperature measured. The user simply inputs the
temperature of the metal being measured and the gauge will
calculate and apply the correction factor to the thickness
measurements.
Excerpt from ASME V Art 23 UT;
“A rule of thumb often used is as follows:
The apparent thickness reading obtained from steel walls having
elevated temperatures is high (too thick) by a factor of about 1%
per 55°C (100°F). Thus, if the instrument was calibrated on a
piece of similar material at 20°C (68°F), and if the reading was
obtained with a surface temperature of 460°C (860°F), the
apparent reading should be reduced by 8%.
This correction is an average one for many types of steel.
Other corrections would have to be determined empirically for
other materials.”
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1. Access the Menu and scroll down
to the ‘Measurement’ group.
Then scroll right and select
‘Temp Comp’.
Press the √ key to open the
‘Temp Comp’ option
2. Use the Up and Down keys to
select Temp Comp On or Off as
required followed by the √ key
3. If Temp Comp = On you will be
asked to input a temperature
value followed by the √ key
This temperature can be in °C or
°F depending on setup.
4. A ‘TC’ icon at the top of the
measurement screen informs the
user that Temp Compensation is
active.
Taking Measurements at High Temperatures
When using the T5B-H probe you should limit the time the
probe is in contact with the hot surface when above 150°C
(400°F) to 4 seconds or less otherwise the probe may be
permanently damaged.
In-between measurements you should allow time for the probe to
cool down, typically 4 seconds on, 60 seconds off at 300°C.
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You can also use cold water to cool the probe down by dipping the
probe face in the water between measurements.
A basic procedure for talking high temperature measurements
follows, this should only be used as a guide as the operator should
have the required training and experience to perform high
temperature measurement.
1.
Wear the appropriate PPE
2.
Clear the test area ready for the UT probe
3.
Manual Gain Mode is recommended so the gain can be set
to an optimum level, the gain will always higher than
measuring on ambient temperature surfaces and more
gain is required as the surface temperature increases
4.
Set the scan rate to High
5.
Set the Temperature Compensation
6.
Re-Zero the probe as the temperature has changed
7.
View the A-Scan
8.
Place the couplant on the probe face
9.
Place the probe firmly on the hot surface and observe the
A-Scan and measurement, when you see a good
measurement hit the Freeze button. Don’t cook the probe!
10. Remove the probe and allow to cool
11. Repeat from step 6.
High Temperature Couplant
Cygnus recommend EchoTherm Extreme couplant from Echo
Ultrasonics (www.echoultrasonics.com). EchoTherm can be used
for measurement up to 1250°F (675°C).
Tip - use the B-Scan Feature!
You could use the B-Scan feature to get a quick high temperature
reading as the scan rate is much faster in B-Scan mode. You can
use the B-Scan graph to pick the correct thickness measurement
and save it to the data logger record.
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10. Cross-Section B-Scan Feature
The Cross-Section B-Scan feature can be used to take a series of
continuous thickness measurements and display the results
graphically to represent a cross section through the material.
Transducer
Scan Direction
Material being Measured
The results of the scan include a minimum thickness value. A
cursor can also be positioned to pinpoint individual thickness
measurements and log these to a data logger record if required.
The B-Scan data is saved to a file on the SD card which can be
transferred to CygLink for viewing and including in a Survey
Report.
For the best results the transducer must remain in continuous
contact with the surface and be moved at a constant rate – in
practice however this can be tricky to achieve especially on rough
surfaces.
Typical B-Scan Screen.
The Cross-Section B-Scan feature is only available in Single
Echo and Echo-Echo measurement modes using twin element
probes.
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Scan Menu Options
Range
This sets the vertical axis range which is thickness measured. You
would normally set this just greater than the thickest
measurement you expect.
Scan Length
This is an optional setting that can be used to specify the length of
the B-Scan section. Although there is no encoder this can be used
to add information to a B-Scan graph, especially when included in
a PDF report.
Performing a Scan
Before starting a scan setup the probe and measurement options
so you are able to take spot thickness measurements as required.
Next set any of the Scan menu options as required.
1. Access the Menu and scroll down
to the ‘Scan’ group. Then scroll
right and select ‘Start Scan’.
Press the √ key to open the
Scan screen.
2. The B-Scan screen is now
waiting for the probe to make
contact with the surface and
begin getting thickness
measurements..
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3. When the gauge detects the
probe is coupled to a surface it
will begin scanning.
You will see the B-Scan start to
build from the left to right
direction.
If you lift the probe off the
surface, or it loses signal, the BScan will pause.
If you place the probe back on
the surface the B-Scan will
resume.
4. You can press the Menu key to
view the B-Scan options;
Review Review the B-Scan
with a movable cursor
Reset
Start a new B-Scan
Save
Save the B-Scan to a
file
Exit
Exit the B-Scan screen
5. In the Review screen the BScan is displayed.
You can move the yellow Cursor
line using the Left and Right
keys. The [Cursor] value shows
the thickness measurement at
the cursor position.
The Minimum point in the B67
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Scan is marked with Red vertical
line(s).
Pressing the √ key will log the
measurement at the cursor
position into the current data
logger record.
6. If you Save the B-Scan you will
be prompted for an optional
Name for the B-Scan – this can
be used to identify the scan in
CygLink.
B-Scan files are saved to the SD
card with a date-time filename.
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11. Data Logging
The Cygnus 6+ gauge has a comprehensive Data Logging feature
that allows thickness measurements and A-Scans to be saved in a
data logging Record. These Records can be quickly created by the
user so the measurements can be organised in separate records
according to the survey being carried out. Records can later be
transferred to a computer for viewing, analysis and report
generation or export to a CSV file.
The process of data logging is simply;
1. Create a new Record
2. Log your thickness measurements - pressing the Ok key to
save each thickness measurement
3. Complete the Record when all the measurements have been
taken – the record is safely saved on the removable SD card
Record Types
There are three record types available;
1. Linear – this is simply a list of thickness measurements
saved in the order they are taken.
2. Grid – this arranges the thickness measurements into a row
and column grid layout. You can choose from 16 different grid
patterns.
3. Template – this uses a custom template to specify how
many thickness measurements are required along with
optional additional information such as serial numbers or
lists.
Reference and Minimum Thicknesses
Each record can have an optional Reference and Minimum
thickness value set. When logging measurements these limits are
used to colour the measurement values and in the case of the
minimum limit alert the user if the measurement is under that
limit.
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1. Ref. Thk. – This is the Reference Thickness value for the
whole record. If you are surveying steel that was 12mm thick
when new then this would be your reference thickness.
2. Min. Thk. – This is the Minimum Thickness value for the
whole record. If you take any measurements under this value
they will be coloured Red to highlight them.
Minimum Thickness Limit Alert
When logging thickness measurements if a logged measurement
falls under the Min. Thk. limit a double-vibrate alert is produced to
alert the user.
Radial Points
Both Linear and Grid Records can have a set of Radial Points
added to any logged thickness measurement to further detail an
area of interest or heavy corrosion. The user can add up to 12
additional thickness measurements around the principal
measurement in a ‘clock-face’ pattern.
For example, when logging thickness measurements on a pipe,
tank or plate it is sometimes necessary to add additional
measurement points radially around a badly corroded or thin area
to detail the extent of the thinning or corrosion.
8 additional radial
measurement points.
plate
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See Adding Radial Points on page 83.
Measurement Comments
Each measurement point can optionally have comments added to
it. There is a list of 8 pre-set comments each of up to 24
characters in length. By having a list of pre-set comments the user
can quickly add comments by just selected the ones that are
appropriate, this also standardises the information you want
recording.
Typical comments for a corrosion survey could be;
1.
2.
3.
4.
5.
6.
7.
8.
Pitted Surface
Corrosion Blister
Corrosion Pin-holes
Delamination
Coating damaged
Heavy corrosion
Repair Patch
Holed
See Adding Measurement Comments on page 85.
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Loading Measurement Comments from a File
You can load a new set of
measurement comments from
a file on the SD card. The file
must be named
‘commentlist.txt’ and contain a
list of up to 8 text comments
each up to 24 characters in
length.
You can use Microsoft® Excel
to create a list of comments,
then save the file as a Text
file;
Grid Records
Grid Records are used to organise thickness measurements across
a two dimensional grid. The grid can be applied to flat plate or
cylinders alike.
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Columns across 1..50
Rows
Down
1..100
8.6
8.5
8.5
8.4
8.7
8.6
8.7
8.5
8.6
8.5
8.4
8.3
8.5
8.7
8.6
8.5
8.4
8.5
8.4
8.4
You can also choose which direction measurements will be taken,
there are 16 patterns available;
Horizontal surveying
Vertical surveying
When a Grid Record is created the measurement point names are
assigned as follows:
1. R1C1
2. R1C2
3. R1C3 etc.
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The maximum number of rows and columns is 50 columns and
100 rows (5000 points).
Template Records
Templates are created with CygLink and describe the whole
thickness measurement survey, defining each measurement point
along with a name, reference thickness, minimum thickness and
destination cell in a spreadsheet. Additional information can also
be specified with 40 User Fields that can be used to prompt the
user when each Record begins. Templates are normally created to
cover a specific type of survey and the actual Template would be
distributed to all the Cygnus 6+ gauges in use within your
company.
Read more about Templates in Data Logging Templates on page
94
Data Logging Menu
The Data Logging menu is conveniently at the top of the main
menu list, the items listed on the right hand side will depend on
whether a Record is open or closed.
Record Closed
Record Open
Creating a new Record
When you create a new record to contain your thickness
measurements there are a few options you may need to edit,
these will depend on the type of Record you select;
1. Record Type – choose from Linear, Grid or Template
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2. Name – the gauge will automatically create a file name
based on the date and time (format is ‘ddmmyyhhmmss’). You can keep this filename or input a name of
your own
3. Template – (Template only) name of the Template to use
4. Points – (Linear only) number of thickness measurements
expected
5. Columns – (Grid only) number of columns required
6. Rows – (Grid only) number of rows required
7. Direction - (Grid only) grid measurement pattern, there
are 16 to choose from
8. Ref. Thk – Reference thickness
9. Min. Thk – Minimum thickness
10. Surveyor –(optional) name of the surveyor
11. Location –(optional) location of the survey
1. Access the Menu and scroll down
to the ‘Data Logging’ group.
Then scroll right and select
‘New’.
Press the √ key to open the
function
2. Use the Up and Down keys to
scroll down through the New
Record list.
To set the highlighted item press
the √ key.
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3. Example. Setting the number of
measurement points to take in a
Linear record.
4. When all the items are set as
required move the highlight
down to the ‘Create’ item and
press the √ key.
5. You can now start logging
thickness measurements.
The measurement screen will be
moved to the Data Logging view.
6. At the bottom of the screen
details of the record are
displayed;
Record Type (Lin)
Name of the Record
Number of Points Taken/Total
Your Choices will be Saved for Next Time
All the items listed in the New Record list will be saved and
presented next time you create a new Record (except the Name).
This means you can quickly create identical records without having
to re-input data each time.
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Using a Template to Create a new Record
When you create a Template Record you must also select a
Template to use. This Template defines the number of
measurement points, their names, the measurement units, the
velocity of sound and also may contain up to 40 user-defined data
fields to capture text, numeric, date or list information from the
user.
The process of starting a new Record from a Template is identical
to starting a Linear or Grid Record, except you may be prompted
for User Field information after the Record is created.
User Field Input
User Fields can prompt for Alphanumeric, Numeric, Date, List or
Yes/No input from the user.
1. Here the User Field is requesting
a Numeric Entry called “Serial
No”.
The user would set the numeric
value and press the √ key to
proceed.
2. Here the User Field is requesting
selection from a List called
“Condition”.
The user would select an item
and press the √ key to proceed.
Reviewing and Editing User Field Choices
You will be prompted for User Field information when starting a
new Record based on a Template. If you decide you need to
modify these choices you can access the User Fields from the
menu.
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1. Access the Menu and scroll down
to the ‘Data Logging’ group.
Then scroll right and select ‘User
Fields’.
Press the √ key to open the
screen
2. The User Fields will be
displayed; you can select using
the Up and Down keys, then
press the √ key to edit the
values.
Press the X key to exit the
Review User Fields screen.
Logging Thickness Measurements
To Log a thickness measurement you simply press the √ key when
a thickness value is displayed. You can do this in ANY of the three
measurement screens.
1. With a thickness measurement
displayed press the √ key once…
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2. …the thickness measurement is
added to the list, in this example
it’s at ‘P1’ as it’s the first
measurement.
3. The ‘number of records’
indication changes colour to light
blue for a second after wards to
indicate the measurement has
just been logged ok.
Auto-Log Feature
The gauge has an Auto-Log feature that will automatically log
thickness measurements when the measurement remains stable
for two seconds. This means the operator can log measurements
using one hand.
See Auto-Log on page 107 to turn the Auto-Log feature On or Off.
The Auto-Log sequence is as follows;
1. Place the probe on the surface and obtain a measurement
2. Hold the probe still to ensure the measurement remains
stable..
3. After 2 seconds of stable measurement the value will be
Auto-Logged
4. Remove the probe from the surface and wait until the
‘number of records’ indication turns from blue to grey before
taking the next measurement, this is about 1 second.
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Logging Obstructions and No-Readings
When surveying there may be measurement points that are
inaccessible due to an object being in the way or there may be
points where thickness readings can’t be obtained (due to
excessive corrosion and thinning for example). The Gauge allows
the user to record either a No-Reading or Obstructed
measurement point as required
Obstruction
preventing access to
measurement points.
8.6
8.5
8.5
OBS
8.7
8.6
8.7
8.5
OBS
8.5
8.4
NOR
8.5
OBS
8.6
NOR
8.4
8.5
OBS
8.4
plate
Measurement point
logged as No-reading
(NOR)
1. With NO thickness measurement
displayed press the √ key once…
Then choose No Reading or
Obstructed using the √ and
Cancel keys.
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2. …the tag is added to the list, in
this example its No Reading ‘NR’
at ‘P4’
3. in this example its Obstructed
‘Obs’ at ‘P5’
Changing Measurement Units while Data Logging
When a Record is active you will be unable to change the
measurement units. This is because each record can only contain
measurements of the same units. If you try and change the
measurement units you will get this message;
Re-taking the Last Measurement
If you make a mistake and need to Re-Take the last measurement
the Retake Last menu item will do this quickly.
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1. Access the Menu and scroll down
to the ‘Data Logging’ group.
Then scroll right and select
‘Retake Last’.
Press the √ key to select
2. Confirm by pressing the √ key.
3. The last measurement point has
now been removed from the
record.
Stepping Backwards in the Record
If you need to step backwards in the record and re-take the
measurement points from that point then use the Step Back menu
item.
1. Assume you have logged 4
measurements (C1, C2, C3 &
C4) but need to go back to the
second measurement (C2) and
re-take from that point.
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2. Access the Menu and scroll down
to the ‘Data Logging’ group.
Then scroll right and select ‘Step
Back’.
Press the √ key to select
3. A view of the Record’s
measurement points is
displayed; you can use the
navigation keys to move back to
the required point (C2) in the
record. The selected point is
highlighted purple (arrowed).
Press √ to select.
Press Cancel to abort.
4. You can start logging
measurements from that point.
Note. Subsequent measurement
will be overwritten.
The next position that will be
logged into is filled Yellow in
colour (C2).
Adding Radial Points
You can only add Radial Points to a thickness measurement you
have just logged. So you must have logged at least 1 thickness
measurement in the current Record before adding Radial Points.
You cannot add Radial Points to a Template Record.
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1. Access the Menu and scroll down
to the ‘Data Logging’ group.
Then scroll right and select ‘Add
Radials’.
Press the √ key to select
2. Press the √ key again to confirm
3. Set the number of Radial Points
- this can be any number from 4
to 12
Press the √ key to continue
4. The Measurement Screen now
shows the Radial Point view
There will be empty white boxes
arranged around the Parent
measurement..
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5. ..these boxes will fill clockwise
with the Radial Points
measurements as they get
logged
6. When the last Radial Point has
been logged the screen will
revert back to the normal data
logging view.
A small ‘R’ is added to the
measurement point to show it
has Radial Points added.
Adding Measurement Comments
You can add comments to ANY measurement point in the current
Record, this includes Radial Points also.
1. Access the Menu and scroll down
to the ‘Data Logging’ group.
Then scroll right and select
‘Comment’.
Press the √ key to select
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2. Use the Up and Down keys to
select the measurement point
you want to add Comments to,
then press the √ key.
3. Use the Up and Down keys to
select the required comment,
Use the Left and Right keys to
Select or Clear the comment – a
solid black box means the
comment is Selected.
When you have selected the
required comments press the √
key to save and exit, or the X to
cancel.
4. In the measurement screen any
measurement points that have
comments will have a ‘C’
displayed in the measurement
cell.
5. When Reviewing a Record any
measurement point with a ‘C’
(having comments) these
comments can also be displayed.
Closing and Opening a Record
You can close the record and stop data logging at any time and
continue to use the gauge as normal. Then later open the record
again and resume where you left it.
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Closing the Record
1. Access the Menu and scroll down
to the ‘Data Logging’ group.
Then scroll right and select
‘Close.
Press the √ key to select
2. Confirm by pressing the √ key.
4. Data logging has been stopped
and the record has been closed.
The record details at the bottom
of the screen bar shows “Off”
Opening a Record
1. Access the Menu and scroll down
to the ‘Data Logging’ group.
Then scroll right and select
‘Open’.
Press the √ key to select
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2. Select the Record to open, the
most recent is at the top of the
list.
Confirm by pressing the √ key.
3. Confirm by pressing the √ key.
4. The record has been opened and
data logging record has been
resumed.
Protecting a Record
If you want to Protect a record from being deleted or modified
then you can use the Protect Record feature. Once protected
records cannot be deleted from the gauge and they cannot be reopened and amended or changed.
Once you protect a record then you will be unable to unprotect the record from the gauge. You can however remove
the SD card and deleted the record files from the SD card
using a computer.
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1. Access the Menu and scroll down
to the ‘Data Logging’ group.
Then scroll right and select
‘Protect’.
Press the √ key to select
2. You will see a list of all the
records stored on the gauges SD
card listed in newest first order.
Use the navigation keys to select
the record to protect, and then
press the √ key.
3. Confirm by pressing the √ key.
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4. Confirm again by pressing the √
key.
5. The selected record has now
been protected. When the record
list is shown in the future a ‘P’
will appear next to any protected
records.
Opening Protected Records
If you open a protected record then you will not be able to make
changes to the record, you will only be able to review the records
contents.
Deleting Records
You have two options for deleting Records from the gauges SD
card; deleting each Record at a time, or deleting all Records at
once.
Once deleted records cannot be restored – there is no undo
function.
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Deleting Individual Records
1. Access the Menu and scroll down
to the ‘Data Logging’ group.
Then scroll right and select
‘Delete’.
Press the √ key to select
2. You will see a list of all the
records stored on the gauges SD
card listed in newest first order.
Use the navigation keys to select
the record to delete, and then
press the √ key.
3. Confirm by pressing the √ key.
4. The selected record has now
been deleted.
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Deleting All Records
1. Access the Menu and scroll down
to the ‘Data Logging’ group.
Then scroll right and select
‘Delete All’.
Press the √ key to select
2. Confirm by pressing the √ key.
3. Confirm again by pressing the √
key.
4. All unprotected records will have
been deleted from the SD card.
A message will inform how many
records have been deleted.
Continue by pressing the √ key.
Record Status
The Data Logging menu has a Status item at the bottom. This
screen will display the status of the current Record.
1. Access the Menu and scroll down
to the ‘Data Logging’ group.
Then scroll right and select
‘Status’.
Press the √ key to select
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2. Depending on the Record type
you will see various items listed.
Some items such as Ref Thk and
Min Thk can be changed.
For Linear Records the number
of Points can also be increased.
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12. Data Logging Templates
Templates
Templates allow structured data logging of thickness
measurements when repeatedly surveying identical or similar
objects. A Templates is first created using CygLink then the
Template is transferred to each Gauge ready for use.
Templates contain the following;
1. A name and description
2. Measurement units and velocity of sound
3. A list of thickness Measurement Points with minimum and
reference thicknesses.
4. User Fields (optional)
5. Spreadsheet cell locations (optional)
The user can then create many new data logger Records using a
single Template which specifies how the survey is carried out.
Template
‘Tank’
Record for
Tank #01
Many Records created from one
common Template which specifies
content and format.
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Integrating with Microsoft Excel
Cygnus offer an Excel Add-In tool that can be used to directly
extract the thickness measurement data from the data logger files
stored on the SD card in the gauge.
The data in a Record produced from a Template can be inserted
into an Excel® Spreadsheet - so each piece of data has an optional
destination cell reference – this is the spreadsheet cell the data
will be copied into, i.e. cell ‘D12’.
An XLT file (Excel® Template) can also be specified to be used as a
template for the Excel document produced. So a company report,
as an XLT file, can be used to create each new blank report
document that will then receive the thickness measurement and
other data collected by the Gauge.
Template
Gauge
Record(s)
on SD card
New Excel
Report
Finished
Report
XLT File
Measurement Points
Templates contain measurement points for each thickness
measurement required. Each measurement point consists of a
“Name”, a “Reference Thickness”, a “Minimum Thickness”, a “Cell
Reference” and the “Thickness Measurement” itself.
The “Reference” and “Minimum Thickness” are optional, but when
included they allow wastage calculations in reports and minimum
alarm alerts when measuring.
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User Fields
Templates can contain up to 40 User Fields which can be used to
collect extra information from the Gauge user when they start a
new Record from a template.
Each User Field can prompt for the following types of data;
1. Alphanumeric
i.e. “ABC123”
2. Number
i.e. “24501”
3. Date (dd-mm-yyyy)
i.e. “21-07-2008”
4. List
i.e. “Red, Blue, Yellow, Green..”
5. Boolean
i.e. “Open” or “Closed”
Each User Field has: a ‘Name’ field, this is used to prompt the
Gauge user to enter in information, and a ‘Value’ field to hold the
information. An optional ‘Cell Ref.’ field to specify where the Value
should be inserted in the spreadsheet.
For example;
If the User Field Type = Alphanumeric
If the User Field Name = ‘Vessel Name’
If the User Field Cell Ref = ‘Sheet 1!E20’
When the Gauge user starts a new record they will be prompted
to enter in a ‘Vessel Name’.
The vessel name the user types in will be stored against the
‘Vessel Name’ field and be included in the report data.
As the ‘cell ref.’ was also specified the vessel name will be
inserted into the spreadsheet report into cell ‘E20’ on ‘Sheet 1’.
User Field ‘List’ Type
When the User Field type is set to List you must provide a list of
text choices that will be presented to the gauge user. This list can
contain up to 40 items each of 16 characters in length.
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13. Manual Gain Adjustment
The gauge will normally operate in automatic gain mode and this
will be suitable for virtually every measuring scenario. The
automatic gain mode has been designed to find the optimum gain
setting during the measurement process and is imperceptible to
the operator. It is therefore only recommended to use manual gain
mode if you have suitable ultrasonic training and experience and
understand the consequences to the measurement if the gain is
set incorrectly.
The gauge will default back to Automatic Gain mode when
the gauge is turned on or the probe is changed.
Manual Gain Mode
When the gauge is in manual gain mode the operator can
manually adjust either the Gain or A-scan Range using the Up and
Down keys during measurement.
The Gain value is in dB can be adjusted in 1 dB steps with each ⇧
or ⇩ key press.
When in manual gain mode the Basic measurement screen is
disabled as the A-scan screen should be observed.
Turning on Manual Gain
1. Access the Menu and scroll down
to the ‘Measurement’ group.
Then scroll right and select ‘Gain
Mode’.
Press the √ key to select
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2. Use the ⇩ key to select Manual
gain mode.
Or select Automatic to turn off
manual gain mode.
Press the √ key to select
3. When Manual gain mode is
selected a message is displayed
informing how the Gain or Range
is adjusted.
Press the √ key to continue.
4. [MG] is displayed in blue at the
top to show Manual Gain mode
is active.
The Gain setting is shown in blue
to show it is active [60]
Manual Gain Menu
When in manual gain mode a small ‘quick menu’ is first displayed
at the bottom of the screen when the Menu key is pressed, this
allows quick selection of Gain, Range or Menu.
A tick is displayed next to Gain or Range to indicate which will be
adjusted when the ⇧ or ⇩ keys are pressed.
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1. Pressing the Menu key displays
the Manual Gain menu as the
bottom of the screen.
The √ shows that Gain
adjustment is currently selected.
2. Pressing the Menu key again will
go straight to the Main Menu as
normal.
3. Use the Left and Right keys to
navigate between Menu, Gain
and Range. The selected item
will be highlighted in blue.
Use the √ key to select.
Use the X key to cancel.
Adjusting the Gain
Press the Menu key and check that Gain is ticked – select it if it
isn’t. Then in the measurement screen with the A-scan displayed
use the ⇧ or ⇩ keys to adjust the gain as required.
1. The Gain is set to 37 dB.
The A-Scan shows a back wall
echo signal around 50% height
but there is a thickness value.
Ideally you would increase the
gain to get a 100% high signal.
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2. The Gain is set to 42 dB.
The A-Scan shows a back wall
echo signal around 100% height
and there is a thickness value.
This is the optimum setting.
3. The Gain is set to 55 dB.
The A-Scan shows a back wall
echo signal which goes off the
screen, there are also other
earlier smaller echoes that are
becoming significant. The
thickness measurement is still
ok however.
Ideally you would reduce the
gain down to get a 100% high
signal.
Adjusting the Range
Press the Menu key and check that Range is ticked – select it if it
isn’t. Then in the measurement screen with the A-scan displayed
use the ⇧ or ⇩ keys to adjust the Range as required.
1. When Range is selected the
range value is highlighted blue.
Here the range is set to 20mm
[20]
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2. Use the ⇧ or ⇩ keys to adjust
the value.
Here it’s set to 40mm [40]
Measuring Below the Probes Minimum Thickness
Specification
The minimum thickness measurement specified for the Twin
Element probes is valid for when Automatic Gain Mode is selected
- this is the default gain mode when the gauge is turned on.
By manually adjusting the gain and observing the A-Scan display it
may be possible to measure less than the minimum specified
thickness.
This should only be attempted by experienced operators with
a good understanding of ultrasound principals.
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14. Setup Menu
The Setup group is found at the bottom of the menu, it holds
various gauge setup options.
1. Access the Menu and scroll down
to the ‘Setup’ group. Then scroll
right to select the required item
Press the √ key to open the
highlighted item.
A-Scan Range
The A-Scan range setting sets how the A-Scan X axis scale is set.
This can be either Manually or Automatically.
Automatic
When set to Automatic (Auto) the X scale is set using the
measured thickness value and the measurement mode. This
means when measuring a range if thicknesses the A-Scan range
will always be set so you can observe the required number of
echoes.
Manual
When set to Manual (Man) you can set the A-Scan range to any
value between 5 mm and 1000 mm (0.2” and 39”).
Vibrate Feature
The Vibrate feature will vibrate the gauge when a verified
thickness measurement is found to alert the user. You can use this
menu item to turn this On or Off as required.
Brightness Setting
The display brightness can be set Manually or Automatically using
the ambient light level sensor.
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Higher brightness will consume more power and so reduce
the battery life. To maximise the battery life choose the
lowest brightness that still allows you to read the display.
In Automatic mode the brightness is
dimmed when in dark conditions and
increased when in bright light
conditions.
In Manual mode you can adjust the
brightness over 20 levels, 0 is the
lowest level.
Manual Brightness Setting.
Bluetooth®
The gauge has a Bluetooth module that can
be used to connect and pair with a Windows
computer so you can transfer Data Logger
records and settings wirelessly. The process of pairing the gauge
with a computer is simple, once paired the gauge will retain the
link information so subsequent connections are automatic.
The Bluetooth module is intended for short range connections
(<10 meters), however the actual distance achieved will also
depend on the Bluetooth transceiver at the computer end
and the environment.
Bluetooth Adapters
If your computer does not have a Bluetooth adapter you will need
to source one, generally any Bluetooth 4.0 USB adapter will be
suitable. Cygnus recommend Belkin® adapters.
Turning Bluetooth On
By default the Bluetooth module is turned off to save power, when
you want to connect or you must turn Bluetooth on using the
Setup menu’s Bluetooth item.
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When Bluetooth is turned on the USB port is disabled.
1. Access the Menu and scroll down
to the ‘Setup’ group. Then scroll
right to select the ‘Bluetooth’
item
Press the √ key to open the
item.
2. Select On or Off as required.
Press the √ key to save your
choice.
3. A Blue box will appear in the
measurement screen to show
the Bluetooth connection status;
Empty box : not connected
Solid box : connected
Pairing with a Computer
This is intended to be a basic overview of how to pair the gauge to
a Windows computer. It assumes you have a working Bluetooth
module fitted and in range.
1. On the gauge turn Bluetooth On
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2. On the computer’s start menu
type in “Add a Bluetooth
Device” to find the control panel
wizard. Start the wizard.
3. You should get a Add Device
screen
You should see the Cygnus M5C6 Gauge displayed
4. Click [Next] to start the pairing
process..
A 6 digit code will be displayed
on the gauge screen and the
computer – if they match then
click [Next]
5. The gauge should now be added
to the Bluetooth Device list.
Windows may now take a
moment to search for any
drivers that may be required.
Finding the COM Port Assigned
When you use Bluetooth to connect the gauge to the computer
you will need to know the COM Port number assigned to the
Bluetooth device, you will need to set this COM Port number when
using CygLink.
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1. On the gauge turn Bluetooth On.
(Assuming it has been paired).
2. On the computers start menu
type in “View Devices” to find
the View Devices and Printers
control panel wizard. Start the
wizard.
3. Click on the ‘Cygnus M5-C6’
device, then right click and
select Properties.
4. Click on the Services tab.
You should see “Serial port
(SPP) ‘M5-TG’” listed along
with the port number ‘COMxx’.
‘COM20’ = COM Port 20
Make a note of this COM Port
number.
5. Close all the Windows’ dialog
boxes.
End Display
The End Display can be turned On or Off as required with this
setting. Turning off the end display when not required will improve
battery life.
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Rotate (End Display)
The End Display can be rotated 180 degrees for when the gauge is
clipped on to a belt. The Rotate setting will rotate the display 180
degrees when set to Yes.
Power Off Setting
You can choose from three powersaving settings, these determine how
long before the gauge will dim the
display and ultimately turn off when
the gauge is inactive (inactive = no
key presses and no thickness
measurements).
Power Save Modes.
Auto-Log
When Data Logging the Auto-Log feature will automatically ‘log’
the current thickness measurement when it has been stable for 2
seconds. This setting turns the Auto-Log feature On or Off as
required.
U/D Keys
In any of the measurement screens the Up and Down keys can be
set to control certain features of the gauge. This setting selects
which feature is controlled.
• Non – keys have no function.
• A-Scan X Range – keys change the A-Scan X range.
Temp Units
The Temperature Compensation feature can have its temperature
displayed in °C or °F units. This setting selects either °C or °F
units.
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Comments
The Data Logger includes a feature where users can select
Comments to add to logged thickness measurements, they can
have up to 8 pre-set comments to choose from. This setting allows
you to edit the list of Comments.
1. Use the Up and Down keys to
select the comment.
Press the √ key to edit the
comment text.
Press the X key to save the
comments and exit this screen.
Set Time and Set Date
These two items allow the user to set the gauges Time and Date.
The time and date are used by the Data Logger.
Set Time and Date Screens.
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15. General Points On Thickness Gauging
On very rough surfaces and especially if both sides are badly
corroded, it is often necessary to move the probe around to locate
a back wall reflector. Sometimes a slight rocking movement can
help find reflectors which are otherwise impossible.
Badly corroded sections can also be soaked with a light lubricating
oil to improve ultrasound coupling through to the good material.
On heavily corroded steel the use of a
Chipping Hammer is recommended to
dislodge and loose or delaminated layers,
the surface can also be ‘prepared’ by the
action of the hammer’s edge removing any
uneven surfaces.
A Carbide Scraper can also help to prepare
the surface and remove any loose rust or
debris.
Good quality hammers and scrapers are
available from Cygnus.
Always ensure that there is plenty of couplant present for good
contact, but beware that on a pitted surface the Gauge may just
measure the couplant-filled pit, always avoid measuring directly
over external pits.
Beware that in extreme conditions or if the plate is of poor quality
and contains many inclusions the ultrasound will be scattered to
such an extent that measurement may not be possible.
Beware that the multiple-echo technique will not work if the front
and back surfaces of the material being measured are not close to
parallel. Also note that long narrow bars cannot be gauged along
their length with the multiple-echo method.
The Gauge should not be used near arc-welding equipment, as this
affects its performance.
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16. Troubleshooting
The Gauge will not Switch On
• Are the batteries exhausted?
• Check the batteries are inserted correctly.
Difficulty obtaining a Reading
• Check that the Probe lead is properly connected to both Probe
and Gauge.
• Check the gauge is set for the probe connected.
• Check the condition of the lead, replace if necessary.
• Check the Probe and its membrane are properly assembled (if
a single element probe).
• On heavily corroded areas this is often a problem, try and
take measurements in adjacent areas of the same material.
• Check the Gauge and Probe together on a test block, if there
is still no reading the Gauge may require servicing.
If Readings are Erratic or Unstable
• Check that the Probe-lead is properly connected to both
Probe and Gauge.
• Check that the Probe and its membrane are correctly
assembled with sufficient couplant between the probe face
and membrane (if a single element probe).
• Check the Probe Type is suitable for the probable minimum
thickness of the material being measured. Probe frequencies
too low cause doubling and tripling of the actual thickness.
Tips for Optimising Battery Life
• Couplant left on the probe face will stop the gauge entering
low power saving mode – so wipe couplant off the probe face
between measurement sessions.
• Turning down the backlight brightness will extend battery life.
• Turn Bluetooth off if you are not using it.
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• When measuring on very heavily corroded metal with single
element probes the gauge uses more power searching for a
multiple echo match – this can significantly reduce battery
life. So if you are frequently measuring on very heavy
corrosion consider using a twin element probe as this will
require less power to get measurements.
• Performing a B-Scan will require lots more power than normal
thickness measurements as the gauge is taking many more
measurements per second, even when the probe is not
coupled and scanning – so don’t leave the gauge in the BScan screen when not scanning.
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17. Updating your Gauge
As part of our policy of ongoing development and product
improvement Cygnus may issue firmware updates for your model
of gauge. The firmware on the gauge can be easily updated by
the user using update software downloaded from the Cygnus
website.
Before updating your gauge note the model and serial number of
the gauge (see Turning the Gauge On on page 25). You can then
check on the Cygnus website if your gauge has the latest firmware
version, and if not proceed to download the update software.
You can check for the latest gauge firmware on the Cygnus
website [ http://www.cygnus-instruments.com ]. Navigate to
Support -> Downloads -> Technical Software and look for a
PDF document called ‘M5 Surface Gauge Firmware Version Info’
view this document to find the latest version for your gauge along
with any changes made. Note you will need to create an account
to access this section of the website.
Update Software
To update a gauge you must first download and install the ‘Cygnus
M5 Surface Gauge Updater’ software. This is available from the
Cygnus website in the Support -> Downloads -> Technical
Software section. There is a PDF document with instructions
available.
Gauge Firmware Files
You must download the appropriate Gauge Firmware file for the
model of gauge, there are three to choose from; Cygnus 2/2+,
Cygnus 4/4+ or Cygnus 6+ PRO.
Once downloaded the gauge can be easily updates via the USB
cable connecting the gauge to the computer. The whole process
takes about 2 minutes. There is a PDF document with detailed
instructions available on the website.
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18. Care and Servicing
Cleaning the Gauge
Clean the Gauge and accessories with a damp cloth. Use
water with a mild detergent household cleaner.
Do not use solvents to clean the Gauge.
Do not use any abrasive cleaner, especially on the display
window.
Do not immerse the Gauge in liquid when cleaning.
Batteries
Always remove the batteries if the Gauge will not be used for
more than a few days.
Only use leak-proof batteries, Cygnus recommend Duracell
batteries.
Environmental
Do not immerse the Gauge in liquids. The gauge is designed
to be IP67 but it is not intended for use in water.
Do not subject the Gauge to temperatures greater than 50˚C
(122˚F).
Do not store the Gauge for long periods in conditions of high
humidity.
Repairs
There are no user serviceable parts inside the Gauge.
Therefore all repair work should be carried out by Cygnus
Instruments or by an Authorised Cygnus Service dealer.
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Returning the Gauge for Servicing
A full Manufacturer’s Factory Service is available from Cygnus
Instruments.
The Complete Kit should always be returned for Service or
Repair, including all Probes and Leads.
Cygnus Gauges are renowned for their reliability, very often
problems with getting measurements are simply due to the way
the Gauge is being used.
However, if you do need to return you’re Gauge for Repair please
let us know the details of the problem, to help us guarantee the
best possible service:
• Is the problem Intermittent Behaviour?
• Is there a problem turning the Gauge On?
Or a problem with the Gauge turning itself Off?
• Does the Gauge constantly give Incorrect Readings, or
Unsteady Readings?
• Is it not possible to Calibrate the Gauge?
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19. CygLink Computer Software
CygLink V5 is a Windows® program that is used to transfer data
logger records from the gauge so they can be inspected, edited
and reports produced. CygLink offers the following features;
• Create a Survey to contain your data logged records and
measurements
• Transfer your data logged records and B-Scans from the
gauge
• Organise your records and measurement points
• View A-Scan graphs
• View B-Scan graphs
• Add comments to individual measurement points
• Create a PDF report of a survey
• Export data from the survey to a CSV 2 file
• Create and manage Templates
Data is transferred using the USB port on the gauge (under the
battery cover) using a standard USB Mini B lead supplied in the
kit, or by Bluetooth for wireless connectivity.
USB Port Location
2
USB Mini B Lead
CSV (Comma Spaced Variable) for opening in a spreadsheet like Microsoft Excel.
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Installing CygLink
CygLink V5 is supplied with the kit on a USB Flash Drive, or it can
be downloaded from the Cygnus Instruments website. If you want
to make sure you are installing the latest version then
downloading from the website is the best route.
Requirements
To install and run CygLink the computer must:
1. Be running Windows 7 or a newer version
2. Have sufficient resources for Microsoft .NET Framework
installation
3. We recommend a screen resolution of 1280 x 720 or greater
4. We recommend at least 1GB of memory
5. If using Bluetooth a Bluetooth radio must be fitted.
Upgrading
You can check the Cygnus Instruments website for the latest
version of CygLink V5.
If you are upgrading from an older version of CygLink then
you must uninstall the old version of CygLink first.
Installing
If you downloaded the CygLink installer file from the Cygnus
website then this is a single self-extracting ZIP file.
Simple double click the ‘setup’ or ‘CygLink…’ exe file to start
installation. You will need to agree to the license terms and
conditions. There are no options to select so installation is straight
forward.
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Connecting to the Gauge
First time USB Connection
When you first connect the gauge to the computers USB port
Windows will search for a suitable driver, you may notice this
message from the taskbar;
If you click the message you should see the driver installation
process;
You can ‘Skip’ this process, but otherwise let it proceed and
eventually you should see the following message;
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Connecting the Gauge to CygLink for the First Time
1. Turn on the gauge
2. Run CygLink V5
3. From the Menu click;
Connect
└ Discover new Gauge and Connect
4. CygLink will search all the
available Com ports listening for
a Cygnus gauge..
If a gauge is detected then it will
connect and save these settings
for next time.
5. When connected you should see details of the gauge in
the status bar at the bottom and ‘Connected’
6. If the connection is ever lost the status bar will show ‘Lost
Connection’
Connecting using Bluetooth
To use a Bluetooth connection with CygLink simple connect using
the Discover new Gauge and Connect menu option and CygLink
should locate the Bluetooth Com port if connected.
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To pair a gauge to the computer see Pairing with a Computer on
page 104.
Connecting to the Gauge Afterwards
1. Once you have discovered the
Gauge the connection settings
will be stored for next time, so
to connect next time simply click
from the menu;
Connect
└ Connect to M5-C6 Gauge
Disconnecting from the Gauge
1. To disconnect from the Gauge
simply click from the menu;
Connect
└ Disconnect from Gauge
Manual Connection Settings
If you need to manually set the connection settings then select the
Connection Settings option from the Connect menu, here you
can specify the COM Port number, gauge type and baud rate.
Status Bar
At the bottom of the CygLink screen is the Status Bar, it shows
information about the gauge and the connection.
Status Bar
From left to right;
1. Received message counter (increase as message arrive from
the gauge)
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2. The Gauge Model number
3. The gauge’s serial number
4. The probe type connected to the gauge
5. The gauge’s measurement mode
6. The connection state (Connected, Lost Connection,
Disconnected)
7. The gauge’s battery level
Surveys
A Survey is a container for all your data logger records and
measurements. A Survey can be saved to a single file which can
be copied or send electronically to another CygLink user. The
Survey file is binary and cannot be tampered with.
Creating a new Survey
You don’t have to create a Survey but it does create the container
for any records that you transfer from the gauge. If you intend to
save the records transferred then you will need to create a survey
file anyway.
1. From the Menu click;
File
└ New Survey
2. Complete as many fields as
required, you can always go
back and edit this
information.
This information will appear
on the PDF report and the
export to CSV file output.
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3. You can save your new Survey to a file, from the Menu click;
File
└ Save Survey
Entering your filename and location.
Opening an Existing Survey
1. From the Menu click;
File
└ Open Survey
2. You may be prompted to
save any unsaved data first
Editing the Survey Info
1. From the Menu click;
File
└ Edit Survey Info
Managing the Survey
Sorting Survey Records
You can sort some of the columns in the Survey Records list by
clicking on the column header. A column that has been sorted is
marked with an asterisk after the column name. Clicking the
column header a second time will toggle between an ascending or
descending sort.
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Survey Records List
Survey list columns that can be sorted;
• Name (ascending or descending)
• Points (ascending or descending)
• Type
• Date (ascending or descending)
Viewing Record Information
You can view the details of a record by right-clicking on the record
in the list which will display a context menu, select the Properties
item.
Record Properties Screen
The Record Properties will be displayed;
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Record Properties Screen
You can edit the fields in this screen, the Details table is read only
and contains details about the record and summary information
about its measurements.
Ref and Min Thickness
You can set and apply a Reference and Minimum thickness value
for the record, click the Apply.. button to apply this values to the
measurement points in the record.
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Protection State
You can set a record to be Protected or Open, when Protected it
will prevent users from editing the measurement points or deleting
them.
Measurement Summary Stats
If you scroll down the Details table you will see summary
information about the measurements contained in the records;
Record Properties Screen - Stats
2. This information will appear
on the PDF report and the
export to CSV file output.
Data Logger Records
Transferring Records from the Gauge
You need to be connected to the gauge to transfer records.
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1. From the Menu click;
Gauge
└ Transfer Records from Gauge
2. A list of records stored on
the gauge will be
displayed. You can select
the individual record you
wish to transfer, or click
Select All.
If you check Delete
records after Transfer
they will be deleted from
the gauges memory card
after transferring.
3. To start the transfer click
Transfer from Gauge
Click Transfer to
confirm..
During the transfer
process a progress screen
is displayed
4. When all the records have been transferred they will be
listed in the Survey Records list
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5. You should save the Survey file now, from the Menu click;
File
└ Save Survey
Viewing Thickness Measurements in a Record
To display the list of thickness measurements in a record click on
the record in the Survey Records list, the Measurements tab
below will display the measurements belonging to the record;
Record and Measurements Tab
Managing Measurements
You can right-click a selected measurement to display the contextmenu;
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Measurements Context Menu
This menu allows you to Find, Rename and Delete a
measurement point, you can also view information about the
measurement or display it’s A-Scan graph if it has one.
Note there is no undo function - once deleted the
measurement point is lost, unless you have saved a copy of
the survey or the record is still saved on the gauge.
Viewing Measurement Information
Clicking Properties from the context menu will display the
measurement properties screen;
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Measurements Properties Screen
Adding Comments to Measurements
You can add comments to a measurement point using the
measurement properties screen. The Notes field can be directly
typed into or you can click the Add From Comments button to
select a comment from the pre-defined list.
Comments will appear next to the measurement in the PDF report.
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Selecting Measurements Comments from the List
Just select the required comments in the list and click Ok.
Viewing an A-Scan Graph
You can select the View A-Scan item from the measurements
context menu or double click the measurement row. The A-Scan
graph will be displayed in the Logged A-Scan tab section on the
left.
Logged A-Scan Graph
You can toggle the measurement cursors on and off by clicking the
Cursors button;
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Logged A-Scan Graph with Measurement Cursors
The thickness values of the two cursors (c1 = yellow, c2 = blue)
are displayed to the right of the Cursor button along with the
difference between the two cursors for relative measurements (d).
Deleting all Records from the Gauge
After you have transferred your records from the gauge in to the
Survey and saved the survey file you can delete these records
from the gauges SD card so the gauge is ‘clean’ and ready for new
records to be created.
1. From the Menu click;
Gauge
└ Delete All Records in Gauge
2. When successful the gauge will show a “Records Deleted”
message on its display.
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B-Scans
Transferring B-Scans from the Gauge
You can transfer selected B-Scan files from the gauge and add to
the Survey, these B-Scans can also be included in the Survey PDF
report.
Note. Because B-Scan files can be large in size transferring
many large B-Scans will take a significant time. It is also not
recommended to use Bluetooth to transfer large number of
B-Scan files as this is slower than the USB connection.
1. From the Menu click;
Gauge
└ Transfer B-Scan from Gauge
2. A list of B-Scans stored on
the gauge will be
displayed. You must
select the individual
record you wish to
transfer.
If you check Delete Files
after Transfer they will
be deleted from the
gauges memory card after
transferring.
3. To start the transfer click
Transfer from Gauge
Click Transfer to
confirm..
During the transfer
process a progress screen
is displayed
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4. When all the B-Scans have been transferred they will be
listed in the B-Scan list tab
5. You should save the Survey file now, from the Menu click;
File
└ Save Survey
B-Scan Menu
You can right-click a selected B-Scan in the list to display the
context-menu;
B-Scan List Context Menu
You can add Notes to the B-Scan, Rename it, Delete it or
Export the Data to a CSV file.
Viewing a B-Scan Graph
You can select the View B-Scan item from the B-Scan context
menu or double click the B-Scan row. The B-Scan graph will be
displayed in the B-Scan tab section on the left.
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B-Scan Graph
You can toggle the measurement cursors on and off by clicking the
Cursors button;
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B-Scan Graph with Cursors
The values of the two cursors (c1 = yellow, c2 = blue) are
displayed to the right of the Cursor button along with the
difference between the two cursors for relative measurements (d).
Zooming the B-Scan Graph
You can Zoom into the B-Scan graph by holding the CTRL key
down while using the mouse to draw a zoom area while holding
the Left mouse button.
You can use the Zoom All button to zoom back to the whole BScan.
Viewing a B-Scan Information
To view information about the B-Scan click the Properties item
from the context menu, a screen will the display the properties;
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B-Scan Properties Screen
Exporting the B-Scan to a CSV File
The B-Scan data can be exported to a CSV file which can be read
into a spreadsheet or other application, click the Export to CSV File
option from the context-menu after selected the required B-Scan
in the list.
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B-Scan Data Exported to CSV file and opened in Excel
Measurement Comment List
The Measurement Comment List is a list of 8 pre-set text
comments that can be added to data logged measurement points.
The C6+ gauge also holds a copy of these comments for use during
data logging. You can edit these comments using CygLink then
send them to the gauge when connected to CygLink.
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1. From the Menu click;
File
└ Measurement Comments
2. You can then Add, Edit, or Remove the entries in the
comment list
3. To send the new comments to the gauge, from the Menu
click;
Gauge
└ Transfer Measurement Comments to Gauge
The gauge will display a conformation message when the
new comments list has been received successfully.
Material Velocity List
The Material Velocity List is a table of materials along with their
velocity of sound value. CygLink comes with a pre-defined list but
you can create your own list of materials specifically to suit your
application. This list can be send to the gauge when connected to
CygLink.
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1. From the Menu click;
File
└ Material Velocity List
2. You can Edit, Add, Delete or Re-arrange the items in the list.
Note the velocity is in metric (m/s) by default. You can edit
the table in imperial (in/µs) by setting the Measurement
Units to Inch from the Setup – Measurement Setup item.
3. To send the velocity list to the gauge, from the Menu click;
Gauge
└ Transfer Material Velocity List to Gauge
The gauge will display a conformation message when the
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new velocity list has been received successfully.
Creating a PDF Survey Report
A PDF report can be produced containing all the Survey Records
and thickness measurements in the Survey, grouped by each
Survey Records. Once the export process is complete, your report
will automatically be displayed in your installed PDF viewer. The
export may take a few seconds, depending on the number of
measurements contained in the survey.
1. From the Menu click;
File
└ Create Survey Report PDF
2. You can choose to include A-
Scan and/or B-Scan graphs in
the report.
3. A report filename may be suggested, you can continue with
the filename or type your own as required.
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4. The report is then created and
will open in your PDF viewer.
5. The PDF report is arranged into the following sections;
•
•
•
•
•
Title Page
Survey Details Page
Survey Record details and measurements for each survey
Appendix of all the A-Scan Graphs
Appendix of all the B-Scan Graphs
Exporting a Survey to a CSV File
You can export the textual and numeric data from the whole
survey to a CSV3 file that can be opened with a spreadsheet such
as Microsoft Excel. An example of a CSV export opened in Excel is
shown below;
1. From the Menu click;
File
└ Export Survey to CSV File
2. A filename may be suggested, you can continue with the
filename or type your own as required.
3
CSV - Comma Spaced Variable
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Survey CSV Export opened in Excel.
Templates
Creating New Templates
1. To create a new Templates, from the Menu click;
Setup
└ New Template
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2. You can select
various options at
this stage such as
the layout of the
template, its units
and how many
measurement
points it will have.
Click Create to
generate the
template
3. The new template is opened in the Edit Template screen
where you can further arrange the contents and add User
Fields if required.
Editing Templates
You can Edit (or Delete) a Template from the Setup-> Manage
Templates menu item. You can read more about Templates in
Data Logging Templates on page 94
1. To view a list of the Templates, from the Menu click;
Setup
└ Manage Templates
2. The Template Manager screen lists all your Templates.
Here you can Delete or Edit the selected Template.
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3.
Editing the Template.
4. There are 4 tabs that group various sections of the
Template.
Details : Name, Reference Minimum, Units, Velocity
Excel Template : Optional spreadsheet cell locations
Measurement Points : Thickness measurement points
User Fields : User field items
5. The Details tab contains the basic settings such as Units
and the default velocity of sound value. You can also specify
a Reference and Minimum thickness value and apply to all
the measurements.
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6. The Measurement Points tab lists each thickness
measurement point in the order they will be taken. You can
set the name, reference and minimum thicknesses and
spreadsheet cell location.
7. User Fields can be added by clicking the New button. You
must then enter a Name, Cell location and select a Type.
If using the ‘List’ type click on the List button to edit the list
of text items.
8. When you template is complete click Save to save the
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template. Your new template will appear in the Template
Managers list.
Sending Templates to the Gauge
1. To send Templates to the gauge, from the Menu click;
Gauge
└ Transfer Templates to Gauge
2. You will see the Template Manager screen. Select the
template you wish to send to the gauge by clicking the
Select checkboxes required.
3. To start sending click the Send to Gauge button
4. The gauge will display a progress message while the
template are being transferred
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Deleting Templates from the Gauge
1. To delete all the Templates from the gauge, from the Menu
click;
Gauge
└ Delete all Templates in Gauge
2. The gauge will display a conformation message when the
Templates has been deleted successfully.
Other Features
Setting the Time and Date on the Gauge
You can send the computers current Time and Date to the
connected gauge so it can update its internal clock calendar.
1. To set the Time and Date in the gauge, from the Menu click;
Gauge
└ Set Time and Date in Gauge
COM Port Numbers
CygLink should automatically find the COM port number assigned
to the USB converter when you click “Connect” so you don’t need
to search for the port number Windows has assigned.
Finding your COM Port Number
With the USB lead plugged into your computer, open Windows
Device Manager – to do this press the Windows® key
and the
‘R’ key together, then type “devmgmt.msc” into the prompt
followed by enter key. In the Ports section, look for the USB
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Serial Port entry. Remember the COM number listed as this will
need to be selected within CygLink’s settings menu.
Windows® Device Manager
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20. Information
Technical Specifications
Cygnus M5-C6P Technical Specifications
General Attributes
Size
84 mm x 130 mm x 35 mm (W x H x D)
(3.3 in x 5.1 in x 1.4 in)
Weight
Gauge with batteries 300 g (10.5 oz.)
Power Supply
3 x AA / R6 Batteries.
Probe Sockets
2 x Lemo 00
Operating Temperature Range
-10°C to +50°C (14°F to 122°F)
Storage Temperature Range
-10°C to +35°C (14°F to 95°F)
Battery Operation Time
Approximately 10 hrs. of measurement with fully charged
Duracell Alkaline LR6 batteries.
Battery Voltage Range
Min 3.0 V dc, Max 4.5 V dc
Battery Type
AA Size. LR6 Alkaline / HR6 NiMH.
Low Battery Indication
Battery level indication on display with low battery warning
message.
PRF
N/A
Monitor Outputs
N/A
Through Coating
Measurements
Multiple-Echo mode with Single element 0° probe;
• Through coating measurement for coatings up to 3 mm
thick as standard depending on coating velocity.
• Deep Coat mode provides ability to measure through
thicker coatings depending on coating material.
Echo-Echo mode with Twin element probe;
• Through coating measurement for coatings up to 1 mm
thick as standard depending on coating velocity.
Materials
148
Sound velocity from 1000 m/s to 9000 m/s
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Cygnus M5-C6P Technical Specifications
Measurement Ranges
(in steel)
Single element 0° probes in Multiple Echo mode;
S2C/D probe
3.0 to 250 mm
[0.120 in. to 10.00 in.]
S3C probe
2.0 to 150 mm
[0.080 in. to 6.000 in.]
S5C/A probes
1.0 to 50 mm
[0.040 in. to 2.000 in.]
Twin element probes in Single Echo mode;
T2C probe
2.5 to 250 mm
[0.098 in. to 10.00 in.]
T5B probe
1.5 to 200 mm
[0.059 in. to 7.900 in.]
T7A probe
0.8 to 50 mm
[0.031 in. to 2.000 in.]
T5B-H probe
1.0 to 150 mm
[0.059 in. to 6.000 in.]
Twin element probes in Echo-Echo mode;
Probe Zero
T2C probe
5.0 to 50 mm
[0.200 in. to 2.000 in.]
T5B probe
4.0 to 50 mm
[0.160 in. to 2.000 in.]
T7A probe
3.0 to 25 mm
[0.120 in. to 1.000 in.]
T5B-H probe
2.0 to 50 mm
[0.080 in. to 2.000 in.]
Twin element probes are zeroed in the air without the need of
a zero block. The user is prompted to zero the probe at power
up and after a probe change.
Single element probes in multiple echo mode do not need to
be zeroed.
Measurement Modes
Single Echo mode with Twin element probe. Measures
thickness using the time from the delay line (zero point) to the
first back-wall echo. (UT Mode 2)
Echo-Echo mode with Twin element probe. Measures thickness
using the time between the first and second back-wall echoes.
(UT Mode 3)
Multiple Echo using Single element probe. Uses three matched
and verified back-wall echoes to determine the material
thickness and ignore surface coatings.
High Temperature
Measurement
All standard single element and twin element probes:
Allows continuous measurement up to 75°C (160°F).
T5B-H probe:
Allows continuous measurement up to 150°C (300°F) and
measurement with intermittent surface contact to 300°C
(570°F). Compensation for velocity change at high
temperature using ASME rule “Reduce 1% per 55°C (100°F)”
Measurement Technology
Zero-crossing detection with interpolation.
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Cygnus M5-C6P Technical Specifications
Resolution
Single Echo and Echo-Echo measurement modes;
Low
0.1 mm
[0.005”]
Medium
0.05 mm
[0.002”]
High
0.01 mm
[0.001”]
Multiple Echo measurement modes;
Accuracy
Low
(measurement > 120 mm)
0.1 mm
[0.005”]
Medium
(measurement < 120 mm)
0.05 mm
[0.002”]
±0.1 mm (±0.004”) or 0.1% of thickness measurement
whichever is the greatest.
Display
Type of Display
Colour TFT LCD with LED Backlight (front) and monochrome
OLED (end).
Display Size
TFT : 320 x 240 Pixels QVGA. 2.4“, 47 mm (W) x 37 mm (H)
OLED : 128 x 32 Pixels. 25.58 mm (W) x 6.38 mm (H)
Display Information
Digital Thickness Value. A-Scan. B-Scan. Logged
Measurements. Settings. Battery Level.
Transmitter
Shape of Pulse
Square
Pulse Energy : Voltage (peakto-peak)
70 V p-p
Pulse Energy : Rise Time
3 ns (max)
Pulse Energy : Pulse Duration
S2C : 220 ns
S2D : 220 ns
S3C : 100 ns
S5A / S5C : 67ns
T2C : 220 ns
T5B : 100 ns
T7A : 67 ns
T5B-H : 100 ns
Receiver
Gain Control
Automatic Gain Control depending on probe and measurement
mode (default).
Manual Gain control option in 1dB steps from 20 to 70 dB.
Frequency Range
1.0 MHz to 10.0 MHz (-6dB)
Other Information
Data Output and Storage
Data stored on removable micro-SD card.
Data output via USB serial connection to computer.
Data Connector
USB Mini B Connector under battery cover.
Can be used to update the gauge firmware and load gauge
settings.
Data Logger
Maximum number of measurement points per Record : 5000
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Cygnus M5-C6P Technical Specifications
Maximum
Maximum
Maximum
Maximum
number of Records : 100 (soft limit)
Grid Record size : 100 rows x 50 columns
number of User Data Fields : 40
number of Template measurement points : 5000
Data stored on removable micro-SD card formatted for
Windows (FAT32). Supplied 8 GB.
Cross-Section B-Scan
Function
Scan Rate SE Mode : 30 Measurements per second
Scan Rate EE Mode : 15 Measurements per second
Max. Points : 5000 (166 seconds in SE Mode).
Calibration setting storage
Calibration Data stored to Internal Flash Memory
Calibration Mechanisms
Not required for Multiple Echo mode.
Automatic V-path correction for twin element probes.
Option of two point calibration for twin element probes.
Display & Recall Facilities
N/A
Display Response Time
125 ms / 500 ms
Printer Output
N/A
Bluetooth
Class 1. V2.1 +EDR. 10.5dBm TX Power.
SPP/RFCOM Profile.
Environmental Rating
IPX67 (Water immersion 1 metre depth for 30 minutes)
MIL STD 810G Method 501.6 (High Temp +55°C)
MIL STD 810G Method 502.6 (Low temp -20°C)
MIL STD 810G Method 507.6 (Humidity 95%)
MIL STD 810G Method 512.6 (Immersion 1m, 30min)
Shock & Impact
MIL STD 810G Method 514.7 (Vibration)
MIL STD 810G Method 516.7 (Shock 20g)
MIL STD 810G Method 516.7 (Transit Drop 1.22m)
Use in Explosive Atmospheres
Locations : Class I, Division 2, Group D only.
Tested : using MIL-STD-810G, Method 511.5, Procedure I.
Compliance
RoHS Compliant.
Designed for BS EN 15317:2000.
CE Marked including EMC.
Specifications are subject to change for product improvement.
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Table of Sound Velocities
Velocities will vary according to the precise grade and processing
conditions of the material being measured.
This table is included as a guide only.
Wherever possible, the Gauge should always be calibrated on
the material under test.
These Velocities are given in good faith and are believed to
be accurate within the limits described above.
No liability is accepted for errors.
Velocities given are the compressional wave velocity cl.
Velocity of Sound (V)
m/s
in/us
Conversion
Factor (f)
Aluminium (alloyed)
6380
0.2512
1.078
Aluminium (2014)
6320
0.2488
1.068
Aluminium (2024 T4)
6370
0.2508
1.076
Aluminium (2117 T4)
6500
0.2559
1.098
Brass (CuZn40)
4400
0.1732
0.743
Brass (Naval)
4330
0.1705
0.731
Brass (CuZn30)
4700
0.1850
0.794
4700 - 5000
0.1850 – 0.1969
0.794 – 0.845
Core Ten
5920
0.2331
1.000
Grey Cast Iron
4600
0.1811
0.777
Inconel
5700
0.2244
0.963
Lead
2150
0.0846
0.363
Monel
5400
0.2126
0.912
Nickel
5630
0.2217
0.951
Phosphor Bronze
3530
0.1390
0.596
Mild Steel
5920
0.2331
1.000
Tool Steel
5870
0.2311
0.992
Stainless Steel 302
5660
0.2228
0.956
Stainless Steel 347
5790
0.2279
0.978
Material
Copper
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Stainless Steel 304
5664
0.2229
0.956
Stainless Steel 314
5715
0.2250
0.965
Stainless Steel 316
5750
0.1163
0.971
Tin
3320
0.1307
0.561
6100 - 6230
0.2402 – 0.2453
1.030 – 1.052
6660
0.2622
1.125
Titanium
Tungsten Carbide
Reading Conversions
If only a few measurements are to be taken on a material other
than Steel, it may be easier to leave the calibration set for Steel
and merely convert the readings by multiplying by the
Conversion Factor for the material being measured.
This method avoids unnecessary recalibration.
Example.
The Gauge is calibrated for Steel [5920 m/s], but the reading is
being taken on Copper [4700 m/s] :
T
= t x VCOPPER / VSTEEL
= t x 4700 / 5920
= t x 0.794
thus :
T = t x f
where :
T = true thickness of Copper being measured
t = actual reading obtained
f = Conversion Factor (from table)
VCOPPER = Sound Velocity in Copper : 4700 m/s
VSTEEL = Sound Velocity in Steel : 5920 m/s
[ where: f = VCOPPER / VSTEEL ]
The Conversion Factor f: is given for various materials in the
Table of Sound Velocities
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21. EU Declaration of Conformity
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22. Recycling and Disposal (EC Countries)
The WEEE Directive (Waste Electrical and Electronic Equipment
2002/96.EC) has been put into place to ensure that products are
recycled using best available treatment, recovery and recycling
techniques to ensure human health and high environmental
protection.
The Gauge has been designed and manufactured with high quality
materials and components which can be recycled and reused. It
may contain hazardous substances that could impact health and
the environment. In order to avoid the dissemination of those
substances in our environment and to diminish the pressure on
natural resources we encourage you to dispose of this product
correctly.
DO NOT dispose of this product with general household
waste.
DO dispose of the complete product including cables,
plugs and accessories in the designed WEEE collection
facilities.
This product may also be returned to the agent or manufacturer
who supplied it for safe end-of-life disposal.
Cygnus Instruments Ltd registration number for The WEEE
Directive is WEE/HE1274RU.
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23. Warranty Information
LIMITED THREE YEAR WARRANTY
FOR CYGNUS ULTRASONIC THICKNESS GAUGES
1.
Cygnus Instruments Limited (“CYGNUS”) warrants that, subject as set out below,
the Products manufactured by it (excluding consumables, batteries, probes, leads,
microphones and telescopic extensions) will be free from defects in materials and
workmanship for a period of three years from the date of purchase either from
CYGNUS or from an Authorised CYGNUS Distributor. Batteries, probes, leads,
microphones and telescopic extensions are warranted for 6 months. This warranty is
limited to the original Purchaser of the Product and is not transferable. During the
warranty period, CYGNUS will repair, replace or refund, at its option, any defective
Products at no additional charge, provided that the product is returned by the
original Purchaser, shipping prepaid, to CYGNUS or an Authorised CYGNUS
Distributor. If shipped by mail or any common carrier, the Purchaser must insure
and accept all liability for loss or damage to the Product and must use shipping
containers equivalent to the original packaging. Replacement products or parts will
be furnished on an exchange basis only. All replaced products or parts become the
property of CYGNUS.
2.
Any defects in materials or workmanship must be notified to CYGNUS by the
Purchaser within seven days after the discovery of the defect or failure.
3.
Dated proof of purchase must be provided by the Purchaser when requesting
warranty work to be performed or making any other claim under this warranty.
CYGNUS will not be liable under this warranty unless the total price for the Product
was paid by the due date for payment.
4.
This warranty does not extend to any products which have been damaged as a
result of, accident, misuse or abuse, natural or personal disaster, service,
modification or repair by anyone other than CYGNUS or an Authorised CYGNUS
Service Centre, failure to properly store or maintain the Product, negligence,
abnormal working conditions, fair wear and tear, or failure to follow the instructions
issued by CYGNUS in relation to the Product.
5.
Except as expressly set forth above or in the CYGNUS Terms of Sale, subject to
which the Products were purchased, all warranties, conditions or other terms implied
by Statute or Common Law are extended to the fullest extent permitted by law.
6.
Except in respect of death or personal injury caused by the negligence of Cygnus,
Cygnus shall not be liable to the Purchaser or to any other person by reason of any
representation (unless fraudulent), or any implied warranty, condition or other term,
or any duty at common law, or under the express terms of the contract for purchase
of the Products, for loss of profit or for any indirect, special or consequential loss or
damage, costs, expenses or other claims for compensation whatsoever (whether
caused by the negligence of Cygnus, its employees or agents or otherwise) which
arise out of or in connection with the supply of the Products or their use or resale by
the Purchaser or by any other person. The entire liability of Cygnus under or in
connection with the Products shall not exceed the price paid for the Products, except
as expressly provided in this warranty.
156
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Cygnus 6+ Operating Manual
24. Index
A-Scan
Auto Range, 102
Backwall Echo, 34
Range Adjustment, 100
Automatic Power Off, 26
Batteries
Fitting, 13
Level, 33
Life, 32
Low Battery Warning, 33
NiCad, 13
NiMH, 13
Bluetooth, 103
Pairing, 104
Port Number, 105
BS EN 15317:2007, 40
Calibration
Conversion Factor, 153
Known Thickness, 40
Ladder Step Wedge, 42
Single Point, 40
Two Point Calibration, 42
Velocity of Sound, 47
Chipping Hammer, 109
CygLink
COM Port, 146
Drivers, 117
Requirements, 116
Data Logging
Auto-Logging, 79
Grid Pattern, 73
Measurement Comments, 71
Minimum Alert, 70
Obstructions, 80
Points Taken, 79
Radial Points, 70
Re-Take, 82
Deep Coat, 60
Disposal, 155
Echo-Echo, 18
Gain
dB Values, 97
Manual Gain, 97
Gauge
Cleaning, 113
Display, 24
Keys, 24
Run Time, 25
Serial Number, 25
Version Number, 25
High Temperature
Correction Factor, 62
Duty Cycle, 63
General Formula, 62
Units, 107
Ignore Coatings, 17
Imperial, 55
Main Menu, 49
Measurement
Pitted surface, 109
Measurement
Resolution, 56
Rough surfaces, 109
Small Pipes, 31
Stability, 30
Units, 55
Metric, 55
Multiple Echo, 17
Echo Bars, 29
Neck Strap, 14
Plastics, 19
Power button, 25
Probes
Automatic Detection, 54
Connector, 24
Knurled Ring, 21
157
Cygnus 6+ Operating Manual
Membrane Couplant, 21
Membrane Key, 21
Polyurethane Membrane
Membrane, 20
Type, setting, 53
Zero, 45
Recycling, 155
Repair, 114
Resolution, 56
Scan
Average, Min, Max, 65
Cross-Section Scan, 65
Service, 114
Single Echo, 17
Sound Velocities, 152
158
M5-CYG6P-M-01_Iss5.doc
Templates
Creating new Records, 77
User Field Input, 77
Test block, 40
Thick Coatings, 60
Thickness Measurement, 28
Through Coating, 17
Troubleshooting, 110
Units, 55
USB Port, 115
Vibrate
Turn On/Off, 102
Warranty, 156
WEEE Directive, 155
Zeroing, 45
ALPINE
COMPONENTS
Postal Address
Alpine Components Ltd
Innovation Centre, Highfield Drive
Churchfields
St. Leonards-on-Sea
TN38 9UH
United Kingdom
Telephone
01424 858118
Website Address
www.alpine-components.co.uk
"Alpine Components" is the abbreviated trading name for "Alpine Components Limited"
The company has been trading since 1991 and was incorporated on 13/11/2006 in the United Kingdom
Company Registration Number: 05996485
VAT Number: GB583598190