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Cygnus 2+ Operating Manual

M5-CYG2P-M-01_Iss6.doc

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 mm to 20.0 mm. You would

typically choose to calibrate using

the 2.5 and 20 mm thicknesses.

Ladder Step Wedges

Two Point Calibration Procedure

Assuming you have a step

wedge of known thicknesses

20.00

2.50

Summary of Contents for Cygnus 2

Page 1: ...Cygnus 2 Multi mode Ultrasonic Thickness Gauge Operating Manual Covers Gauge Model M5 C2P Doc No M5 CYG2P M 01_Iss6 doc 18 October 2016 ...

Page 2: ... 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 measu...

Page 3: ... Measuring Metals 15 Measurement Modes Explained and Compared 16 Multiple Echo Mode ME Mode 3 16 Single Echo Mode SE Mode 2 16 Echo Echo Mode EE Mode 3 17 Measuring Non Steels 17 Measuring Non Metals 18 Single Element Probes and Protective Membranes 18 Summary of Cygnus Probes 21 Twin Element probes 21 Single Element probes 21 The Probe Type Code 22 5 Gauge Operation 23 Gauge Controls 23 Turning t...

Page 4: ...Menu 35 Probe Zero Function 35 Setting the Velocity of Sound 36 7 Gauge Setup 38 Main Menu Operation 38 Settings are Saved with the Probe Type 39 Selecting the Probe Type 40 Automatic Probe Detection 41 Measurement Units 42 Resolution Setting 43 Deep Coat Function multiple echo mode 44 Vibrate Alert Function 46 Display Rotate Function 47 8 General Points On Thickness Gauging 49 9 Troubleshooting 5...

Page 5: ... 53 OLED Display 54 Returning the Gauge for Servicing 54 12 Information 55 Technical Specifications 55 Table of Sound Velocities 59 Reading Conversions 60 13 EU Declaration of Conformity 61 14 Recycling and Disposal EC Countries 62 15 Warranty Information 63 16 Index 64 ...

Page 6: ...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 a...

Page 7: ...hrough surface coatings which are ignored Measurements can be displayed in either Metric mm or in Imperial inch units The gauge has an end mounted OLED Organic LED graphic display which can be easily read in most light situations 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 ...

Page 8: ...red 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 envi...

Page 9: ...h 4 Accessory Pouch containing 3 x AA Batteries Blue Couplant Gel Kit supplied with Single Element Probe 1 Ultrasonic Probe 2 Moulded Probe Cable in side pouch 3 15mm or 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 if ordered ...

Page 10: ...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...

Page 11: ...Cygnus probe lead uses a custom made cable that offers superior flexibility and resistance to oils and ultraviolet light The cable will not stiffen after exposure to ultraviolet light The connector uses original Lemo connectors for reliability The twin connectors are over mounded to form a tough housing that will provide a long lasting probe cable The connector is orientated with a pip and can onl...

Page 12: ...simply pull back on the connector body DO NOT pull the cable Fitting the Hand Strap or Belt Clip The gauge is supplied fitted with an adjustable elasticated Hand Strap This can be easily removed and the optional Krusell belt clip attachment fitted instead Elasticated Hand Strap ...

Page 13: ...Pozidrive screws holding the hand strap or Krusell belt clip attachment in place Two are under the battery cover Fitting the Neck Strap The gauge is supplied with an adjustable Neck Strap The ends of the neck strap clip onto two wire loops fitted to the gauge These wire loops are made from coated stainless steel ...

Page 14: ...2 Operating Manual M5 CYG2P M 01_Iss6 doc 14 Wire loop fitted 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 the loops ...

Page 15: ...al Coating Corrosion Thickness Recommended 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 0 12 S2D Multiple Echo Steels Non Non to Heavy 0 8 mm 0 03 T7A Single Echo Steels Non Non to Heavy 1 5 mm 0 06 T5B Single Echo Cast Iron Non Non to Mode...

Page 16: ...ement 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 no measurement is possi...

Page 17: ... to verify its measurements unlike Multiple echo mode therefore it is liable to give incorrect readings As the Cygnus 2 gauge does not have an A Scan display there is no way the user can check the measurement is correct Echo echo mode must therefore be used with caution and only on thin paint surface coatings less than 0 5mm It is recommended a Single Echo measurement should also be made to help v...

Page 18: ...asured successfully You must use Single Echo mode to measure plastics You must generally use a low frequency probe i e T2C 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 C...

Page 19: ... 19 Check the membrane regularly as it is important the membrane is changed as soon as it shows any signs of wear Single Element Probe Membrane Parts Single Element Probe Membrane Locking Key Probe Body Locking Ring Polyurethane Membrane Knurled Ring ...

Page 20: ...lace 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 t...

Page 21: ...nsure the probe has sufficient time between measurements to cool down Summary of Cygnus Probes Twin Element probes Probe Type Size Frequency Range in Steel SE Mode Typical Uses T2C 12mm 2 MHz 2 5 to 250 mm 0 1 to 10 Attenuative materials Cast irons plastics T5B 8mm 5 MHz 1 5 to 200 mm 0 06 to 8 General purpose Most metals T7A 5mm 7 5 MHz 0 8 to 50 mm 0 03 to 2 Thin metals Single Element probes Pro...

Page 22: ...3C 13mm 3 5 MHz 2 to 150 mm Coated metals S5C 13mm 5 0 MHz 1 to 50 mm Coated metals S5A 6mm 5 0 MHz 1 to 50 mm Small diameter tubes Thin metals Coated metals The Probe Type Code S 2 C Single or Twin Crystal Frequency in MHz Size A 6mm B 8mm C 13mm D 19mm ...

Page 23: ...M5 CYG2P M 01_Iss6 doc Cygnus 2 Operating Manual 23 5 Gauge Operation Gauge Controls End view of gauge Front view of gauge OLED Display Probe Connection Power Cancel Key Select Keys Menu Key ...

Page 24: ...to use Turning the Gauge Off 1 Press Hold the Power key 2 The display shows power off and the gauge turns off Automatic Power Off The gauge will turn off automatically after 5 minutes of in activity Taking thickness measurements or accessing the menu will reset the 5 minute timer back to zero No Probe Message 1 If the gauge cannot detect a probe a message will be displayed 2 This message should di...

Page 25: ...the correct probe you must first perform a Probe Zero before you can begin taking measurements For instructions see Probe Zero Function on page 35 It is recommended to frequently perform a Probe Zero if conditions such as temperature are changing 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 sur...

Page 26: ... 1 Bar Flashing Only 2 echoes detected 4 3 steady 1 Bar Flashing 3 echoes detected but they are not matched 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 r...

Page 27: ...g no more than or the Resolution setting Example The Resolution is set to 0 05mm therefor the thickness measurement must not change by more than 0 05mm or 0 05mm 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 t...

Page 28: ...ery level gauge Note The battery level gauge moves slowly up and down the display to avoid display burn in Battery almost full Battery about 1 3 full Battery flat Low Battery Warning The gauge will periodically flash a Low Battery warning message when the batteries have approximately 1 hour of use remaining Low battery warning When the batteries are exhausted the gauge will display a Flat Battery ...

Page 29: ...ently 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 v...

Page 30: ...ion instructions see Calibrating to a known thickness Single or 1 Point on page 30 and Two Point Calibration on page 30 If there is no test sample available the Gauge can be calibrated by Setting the Velocity of Sound directly A Table of Sound Velocities on page 59 lists common materials and their velocity of sound value For instructions on Setting the Velocity of Sound see page 36 A third method ...

Page 31: ... get to the Calibrate Single Point item 5 Press the Menu key to start calibration 6 While holding the probe firmly on the sample and while a steady thickness measurement is displayed 7 use the Up and Down Select keys to adjust the thickness to the required value 8 When done press the Menu key to save the calibration Or press the Power Cancel to exit without saving the calibration ...

Page 32: ... 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 an...

Page 33: ...be on the sample and verify the gauge can get a thickness value 4 Press the Menu key 5 Press the Up Select key to get to the Calibrate Two Point item 6 Press the Menu key to start calibration 7 Start with the Thick sample Maximum thickness While holding the probe firmly on the thick sample and while a steady thickness measurement is displayed ...

Page 34: ...olding 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 done press the Menu key to save the calibration Or press the Power Cancel to exit without saving the calibration Probe Zero twin element probes Twin element probes must be zeroed to compensate for any wear or operatin...

Page 35: ... the thickness measurement Typically a 20 C change in temperature the measurements can shift by 0 1 mm It is recommended to frequently perform a Probe Zero if conditions such as temperature are changing See also Zeroing the Probe twin element probes on page 25 Starting a Probe Zero from the Main Menu 1 Press the Menu key 2 Press the Up Select key to get to the Probe Zero item 3 Press the Menu key ...

Page 36: ...n Cygnus probe 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 for the material being measured If you perform a Calibration single or two point 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 veloc...

Page 37: ...ound on page 59 1 Press the Menu key 2 Press the Up Select key to get to the Velocity item 3 Press the Menu key to change the velocity value 4 Use the Up and Down Select keys to adjust the velocity value as required 5 When done press the Menu key to save the new value Or press the Power Cancel to exit without saving ...

Page 38: ...ct key will scroll in the other direction 4 Change the Measurement Mode 5 Set the Probe Type 6 Do a Probe Zero twin element probes only 7 Set the Velocity of sound 8 Perform a Single Point Calibration 9 Perform a Single Point Calibration twin element probes only 10 1 Turn the Deep Coat function on or off single element probes only 11 Set the measurement Resolution 1 Deep Coat must be enabled conta...

Page 39: ...a number of choices you can use the Up and Down keys to step through each option Example Units goes from mm to inch 18 To save your choice press the menu key To cancel without saving press the Power Cancel key 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...

Page 40: ...connected to it If the wrong probe is selected the gauge will not measure accurately if at all The gauge can Auto Detect 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 S2C These probes must be selected manually S2D S3C S5A S5C 1 Press the Menu key 2 Press the Up Select key to get to t...

Page 41: ...hange the probe type you may find a setting has changed this is normal The reason settings are saves with each probe type is so you can swap probes during a survey without having to re calibrate each time Also you may want Multiple Echo measurements in 0 1mm resolution but Single Echo measurements in 0 01mm resolution Automatic Probe Detection The Automatic Probe Detection works by listening to ho...

Page 42: ... correctly detect the probe type then you must select it manually from the list of probes See Selecting the Probe Type on page 40 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 Press the Menu key 2 Press the Up Select key to get to the Units item 3 Press the Menu key to change the ...

Page 43: ...hout saving Resolution Setting The gauge can display thickness measurements in three resolution settings 0 1 mm 0 005 inch 0 05 mm 0 002 inch 0 01 mm 0 001 inch For general metal corrosion measurement the 0 1 mm setting is recommended To change the Resolution setting 1 Press the Menu key 2 Press the Up Select key to get to the Resolution item ...

Page 44: ...In Multiple Echo mode with the Deep Coat turned Off the gauge can measure through most protective coatings up to 3 mm 0 11 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 In Multiple Echo mode with Deep Coat turned On will allow the gauge to measure through coat...

Page 45: ...he calibration Turn Deep Coat Off when NOT measuring through thick coatings otherwise this may cause inaccurate measurements 1 Press the Menu key 2 Press the Up Select key to get to the Deep Coat item 3 Press the Menu key to change the value 4 Use the Up and Down Select keys to switch from On to Off 5 When done press the Menu key to save the new setting Or press the Power Cancel to exit without sa...

Page 46: ... or off as required In Single Echo and Echo Echo measurement modes the vibrate alert will be triggered when a stable measurement is detected See Measurement Stability Indication in SE EE Modes on page 26 1 Press the Menu key 2 Press the Up Select key to get to the Vibrate item 3 Press the Menu key to change the value 4 Use the Up and Down Select keys to change the setting from On to Off ...

Page 47: ...he display so it can be read set the Display Rotate function to yes Now the thickness measurement display will be rotated 180 degrees When you remove the gauge from the belt clip and access the Main menu the display will rotate back the normal way around so you can hold the gauge normally 1 Press the Menu key 2 Press the Up Select key to get to the Rotate Display item 3 Press the Menu key to chang...

Page 48: ...Cygnus 2 Operating Manual M5 CYG2P M 01_Iss6 doc 48 no don t rotate yes rotate 180 degrees 5 When done press the Menu key to save the new setting Or press the Power Cancel to exit without saving ...

Page 49: ...lenty 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 tec...

Page 50: ...o consider using a twin element probe in single echo mode 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...

Page 51: ...oded 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 ...

Page 52: ...nloads 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 ...

Page 53: ...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 Storage Do not store the Gauge in temp...

Page 54: ...ncluding 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 your 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...

Page 55: ...line 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 vel...

Page 56: ...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 Ech...

Page 57: ...onnector under battery cover Can be used to update the gauge firmware and load gauge settings 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...

Page 58: ...Cygnus 2 Operating Manual M5 CYG2P M 01_Iss6 doc 58 Specifications are subject to change for product improvement ...

Page 59: ...ssional wave velocity cl Material Velocity of Sound V Conversion Factor f m s in us 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 Copper 4700 5000 0 1850 0 1969 0 794 0 845 Core Ten 5920 0 2331 1 000 Grey Cast Iro...

Page 60: ...ay 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 f VCOPPER VSTEEL where T true thic...

Page 61: ...M5 CYG2P M 01_Iss6 doc Cygnus 2 Operating Manual 61 13 EU Declaration of Conformity ...

Page 62: ... 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 a...

Page 63: ... 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 CYGN...

Page 64: ...p 12 Ignore Coatings 16 Imperial 42 Main Menu 38 Measurement Pitted surface 49 Measurement Resolution 43 Rough surfaces 49 Small Pipes 27 Stability 26 Units 42 Metric 42 Multiple Echo 16 Echo Bars 26 Neck Strap 13 No Probe Message 24 Plastics 18 Power button 24 Probes Automatic Detection 41 Cable 11 Connector 23 Knurled Ring 20 Membrane Couplant 20 Membrane Key 20 Polyurethane Membrane Membrane 18...

Page 65: ...a 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 ...

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