Cygnus 1 Ex User manual

Cygnus 1 Ex Operating Manual
Page 1 of 91
Cygnus 1 Ex
Intrinsically Safe
Ultrasonic Thickness Gauge
Operating Manual &
Instructions for Safety
Cygnus 1 Ex Operating Manual (EN)(Issue 3).docx
November 2022

Cygnus 1 Ex Operating Manual
Page 2 of 91
Important Notices
The Instructions for Safety section at the beginning of this manual
must be followed when using the Cygnus 1 Ex ultrasonic thickness
gauge in an explosive environment.
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.

Cygnus 1 Ex Operating Manual
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Contents
Section 1 - Introduction .................................................................................7
Cygnus 1 Ex .................................................................................................. 7
Cygnus Instruments ....................................................................................... 8
Contact Details ........................................................................................... 8
Kit Contents ..................................................................................................9
Gauge Kit .................................................................................................. 9
Register your Gauge....................................................................................... 9
Section 2 - Instructions for Safety................................................................10
Important Notice.......................................................................................... 10
Ex Information............................................................................................. 10
ATEX, IECEx and UKEX Marking.................................................................. 10
NTRL / MET Marking.................................................................................. 11
Ex Certificate Numbers .............................................................................. 11
SPECIFIC CONDITIONS OF USE .................................................................. 11
Equipment Use ......................................................................................... 11
Standards used for Ex Certification ............................................................. 12
ATEX Standards.................................................................................... 12
UKEX Standards ................................................................................... 12
NRTL Standards.................................................................................... 12
Battery Pack ............................................................................................ 12
Battery Charger........................................................................................ 12
USB Interface........................................................................................... 12
Manufacturers Details................................................................................ 12
Assembling the Instrument ........................................................................... 13
Fitting the Battery Pack ............................................................................. 13
Connecting the Ultrasonic Probe ................................................................. 14
Charging the Battery ................................................................................. 15
Removing the Battery Pack ........................................................................ 15
Charging.................................................................................................. 15
Connecting to a Computer............................................................................. 16
Connecting to the Instrument..................................................................... 17
Cleaning The Instrument............................................................................... 18
Section 3 –Gauge Features..........................................................................19
Upgrading ................................................................................................... 20
Purchasing an Update Code........................................................................ 20
Entering an Update Code ........................................................................... 20
Section 4 –Operating Instructions...............................................................21
Quick Start Guide......................................................................................... 21
Taking Measurements................................................................................... 21
Ultrasonic Probes ...................................................................................... 21
Measuring Metals ...................................................................................... 21

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Measurement Modes..................................................................................22
Single Echo Mode (SE) (Mode 2) .............................................................22
Echo-Echo Mode (EE) (Mode 3)...............................................................23
Multiple Echo Mode (ME) (Mode 3) ..........................................................23
Measuring Non-Steels ................................................................................23
Measuring Non-Metals ...............................................................................24
Twin Element Probes .................................................................................24
Probe Faces or Tips ...............................................................................24
Surface Temperatures ...........................................................................25
Single Element Probes ...............................................................................25
Protective Membranes ...........................................................................25
Changing the Protective Membrane .........................................................27
Measuring Higher Temperatures..............................................................28
Summary of Cygnus Probe Types ................................................................28
Twin Element probes .............................................................................28
Single Element probes ...........................................................................28
The ‘Probe Type’ Code ...............................................................................29
Controls ......................................................................................................29
Function Keys ...........................................................................................29
Changing Values .......................................................................................30
Numbers ..............................................................................................30
Lists ....................................................................................................31
Text ....................................................................................................31
Status Information ....................................................................................32
Measurement Screens................................................................................33
Status Message Area .................................................................................33
Display Colours .........................................................................................33
Operation ....................................................................................................34
Turning the Gauge On ...............................................................................34
Turning the Gauge Off ...............................................................................34
Taking Measurements................................................................................34
Zeroing Twin Element Probes..................................................................34
Echo Indicators in Multiple Echo Mode..........................................................35
Measurement Stability Indication in SE & EE Modes .......................................36
Measurement Freeze Feature......................................................................37
A-Scan Screen ..........................................................................................37
A-Scan Range.......................................................................................38
A-Scan Zoom........................................................................................39
A-Scan Grid..........................................................................................39
A-Scan Rectification...............................................................................40
Calibration...................................................................................................41
Why should I Calibrate my Thickness Gauge? ...............................................41
Calibration Options....................................................................................41
Calibrating to a known thickness (Single or 1 Point) ......................................42
Two Point Calibration .................................................................................43
Ladder Step Wedges..............................................................................44

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Two Point Calibration Procedure.................................................................. 44
Setting the Velocity of Sound ..................................................................... 46
Probe Settings ............................................................................................. 48
Setting the Probe Type .............................................................................. 48
Auto Detect.......................................................................................... 48
Manually Setting the Probe Type............................................................. 48
Probe Zeroing (twin element probes) .......................................................... 49
Probe Gain Auto-Setting ............................................................................ 50
Single Element Probes........................................................................... 50
Twin Element Probes ............................................................................. 51
Datalogging................................................................................................. 51
Overview ................................................................................................. 51
Datalogger Variants .................................................................................. 51
Datalogging Basic ................................................................................. 52
Datalogging Advanced ........................................................................... 52
Record Types ........................................................................................... 52
Datalogger Features.................................................................................. 52
Creating a New Record .............................................................................. 53
Creating a New Record using a Template ..................................................... 54
Record Names .......................................................................................... 54
Reference and Minimum Thicknesses........................................................... 55
Grid Record Patterns ................................................................................. 55
Example Patterns.................................................................................. 55
Logging Measurements .............................................................................. 56
Manual Logging .................................................................................... 56
Auto-Logging Feature ............................................................................ 56
Logging Obstructed (OBS) Measurements ................................................ 56
Logging No-Reading (NOR) Points ........................................................... 58
Navigating, Re-taking and Deleting ............................................................. 58
Navigating to a Specific Point ................................................................. 58
Adding Comments..................................................................................... 59
Adding Radial Points.................................................................................. 60
Protecting Records .................................................................................... 62
Protecting Records with User Access........................................................ 62
Deleting Records....................................................................................... 62
Deleting Individual Records.................................................................... 62
Deleting All Records .............................................................................. 63
Using Templates ....................................................................................... 63
Creating a Template from a Record ......................................................... 63
B-Scans ...................................................................................................... 64
Performing a Scan .................................................................................... 65
Loading a B-Scan...................................................................................... 66
Manual Measurement Mode ........................................................................... 67
Enabling Manual Measuring Mode................................................................ 68
Adjusting Gates ........................................................................................ 68
Gate Modes.............................................................................................. 69

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Dynamic Freeze Mode................................................................................69
Adjusting Gain and TCG .............................................................................70
Measurement Setups ....................................................................................71
User Access .................................................................................................71
Adding Users ............................................................................................73
Gauge Menu ................................................................................................74
Menu Operation ........................................................................................74
Menu Group - Datalogging..........................................................................74
No Record is Open.................................................................................74
A Record is Open ..................................................................................75
Menu Group - Measurement .......................................................................75
Menu Group - Limits ..................................................................................76
Menu Group - Probe ..................................................................................76
Menu Group - Calibration ...........................................................................76
Menu Group - High Temp ...........................................................................77
Menu Group - A-Scan ................................................................................77
Menu Group - B-Scan ................................................................................77
Menu Group - Display ................................................................................78
Menu Group - Setup ..................................................................................79
Section 5 - Information ............................................................................... 80
Cleaning......................................................................................................80
Maintenance ................................................................................................80
Repairs .......................................................................................................80
Part Numbers...............................................................................................81
Common ATEX/IECEx/UKEX/NRTL Parts.......................................................81
Updating your Gauge ....................................................................................81
Update Software .......................................................................................82
Technical Specifications.................................................................................82
Table of Sound Velocities...............................................................................85
Reading Conversions .................................................................................86
Recycling and Disposal (EC Countries) ............................................................88
Warranty Information ...................................................................................89
Revision History ...........................................................................................90
Table of Figures ...........................................................................................90

Cygnus 1 Ex Operating Manual
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Section 1 - Introduction
Cygnus 1 Ex
The Cygnus 1 Ex Ultrasonic Thickness Gauge is a rugged, handheld, battery-
powered, intrinsically safe instrument designed for taking reliable thickness
measurements using ultrasound in Zone 0 (Class 1 Division 1) Explosive
Atmospheres. It features a large colour LCD display which can be viewed in most
light situations including sunlight. A rechargeable battery pack provides 8 hours of
use.
The instrument can be used with a choice of Ex Ultrasonic Probes, which can be
selected to suit the material and thickness range to be measured.
The Cygnus 1 Ex can measure material thickness using the following measurement
modes,
•Single Echo - UT Mode 2
•Echo-to-Echo - UT Mode 3
•Multiple Echo - UT Mode 3
Through-coating measurements are possible using Echo-to-Echo and Multiple Echo
modes.
The instrument can easily be calibrated to a known thickness or to a known
Velocity of Sound.
The instrument is able to operate accurately over a wide range of ambient
temperatures and is environmentally sealed to IP67 for use in wet conditions.
The Cygnus 1 Ex 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, pioneered the development of the
Digital Ultrasonic Multiple-Echo Technique used for measurement through coatings.
This has long since been the standard required to ensure that accurate
measurements are taken without the need to zero the gauge or remove any
coatings first.
Our philosophy is to work closely our customers to provide high quality products,
engineered to serve heavy industry & harsh environments. Cygnus Ultrasonic
thickness gauges are designed to be reliable and simple to use. We have an
unrivalled reputation in over 45 countries around the world.
Contact Details
CYGNUS Instruments Ltd.
Cygnus House, 30 Prince of Wales Road,
Dorchester, Dorset, DT1 1PW England.
Website: www.cygnus-instruments.com
Tel: [phone]
[email protected]
For all Cygnus offices in UAE, USA, Singapore, and Authorised Cygnus Service
Centres and Distributors please refer to the Cygnus website Worldwide Distribution
page.
https://cygnus-instruments.com/about-us/worldwide-distributors/

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Kit Contents
Gauge Kit
1. Cygnus 1 Ex Gauge fitted with hand-strap
2. Two rechargeable battery packs
3. Battery charger and battery cradle
4. Ex Ultrasonic Probe(s)
5. Comms Interface & USB Lead
6. Operating Manual
7. Memory Stick with CygLink Installer
8. Probe accessories including gel-couplant
9. Battery securing screw tool
10.Declarations of Conformity (EU, UK)
11.One 15mm or ½” Steel Test Block
Register your Gauge
Please take a moment to register your gauge with Cygnus and start your 3-year
warranty, by registering you can receive updates on
•Technical Information
•Notification of new firmware
•Product updates
https://cygnus-instruments.com/service/product-registration/
For Intrinsically Safe equipment users it is important the manufacturer
of the equipment is able to contact the end user, should there be a
safety update or product recall notice. In most cases this is stipulated
in the Ex standards used.

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Section 2 - Instructions for Safety
Important Notice
The following information must be read and followed by all users of the
Cygnus 1 Ex ultrasonic thickness gauge when used in an explosive
environment.
The protective features of the device may be impaired if it is used in a
manner not specified by Cygnus Instruments.
Ex Information
The Cygnus 1 Ex gauge is supplied with either,
•ATEX/IECEx/UKEX certificate marking, or
•NRTL / MET-US certificate marking when sold in North America.
ATEX, IECEx and UKEX Marking
I M1 Ex ia Ma
(Tamb = 0°C to +50°C)
II 1G Ex ia IIC T4 Ga
(Tamb = 0°C to +50°C)

Cygnus 1 Ex Operating Manual
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NTRL / MET Marking
I.S. Class I Zone 0 AEx ia IIC Ga T4
I.S. Class I Division 1 Groups ABCD T4
Tamb = 0°C to +50°C
Ex Certificate Numbers
•ATEX ExVeritas 21ATEX0860X
•UKEX ExVeritas 21UKEX0861X
•IECEx IECEx EXV 21.0035X
•NRTL MET-US Listing E115506
SPECIFIC CONDITIONS OF USE
•Only replace or remove the battery in a Safe Area.
•Charge only in a Safe Area, the marked parameters must be compatible to
the charger maximum output parameters.
•The data port can only be used in Safe Area and through the accessory USB
Interface part numbers 060-1002 (ATEX/IECEx/UKEX) or 060-2002 (NRTL).
The use of this port without the Comms Interface accessory invalidates the
approval.
Equipment Use
•The Cygnus 1 Ex is an intrinsically safe portable measuring instrument.
•The Cygnus 1 Ex must be used in accordance with IEC / EN 60079-14.
•The Cygnus 1 Ex EPL is Ga
•Suitable zones are Zone 0, Zone 1, Zone 2

Cygnus 1 Ex Operating Manual
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Standards used for Ex Certification
ATEX Standards
•IEC 60079-0:2017
•IEC 60079-11:2011
•IEC 60079-14:2014
UKEX Standards
•EN IEC 60079-0:2018
•EN 60079-11:2012
•BS EN 60079-14:2014
NRTL Standards
•UL 61010-1, 3rd Ed: 2012.
•UL 60079-0, 7th Ed: 2019.
•UL 60079-11, 6th Ed: 2013.
Battery Pack
•Use only with Cygnus Battery Pack part nos. 060-1003 (ATEX/IECEx/UKEX)
or 060-2003 (NRTL)
•Lithium-Ion, Secondary Cell
•Nominal Output Voltage = 7.4 V
•Capacity = 1960 mAh
•Output current limited by fuse to 750 mA
Battery Charger
•Um = 8.4V current limited to 3 A
USB Interface
•Um = 250 V
Manufacturers Details
Cygnus Instruments Ltd.
Cygnus House, Prince of Wales Road.
Dorchester, Dorset, DT11PW, United Kingdom.
Telephone: [phone]
Website: www.cygnus-instruments.com
Email: [e-mail]

Cygnus 1 Ex Operating Manual
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Assembling the Instrument
The Cygnus 1 Ex instrument comprises of three parts, shown below
Instrument Body
Cygnus Ex
Ultrasonic Probe
Battery Pack
Fig 1. Cygnus 1 Ex Instrument Parts
Fitting the Battery Pack
Never remove or replace the battery pack in an Explosive
Atmosphere.
Always take the equipment into a safe area to remove or
replace the battery pack.
The Battery Pack is fitted to the rear of the instrument body,
•first align and insert the two lugs at the bottom of the battery pack with the
instrument body,
•then drop-in the top of the battery pack so the securing screw falls into the
thread in the instrument body,
•hand-tighten the battery securing screw with a ball-end SW2.5mm hexagonal
screwdriver.

Cygnus 1 Ex Operating Manual
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Take care not to overtighten the battery pack, it should end up flush
with the instrument body.
Fig 2. Cygnus 1 Ex Battery Pack Fitting.
Connecting the Ultrasonic Probe
Only Cygnus Ex Ultrasonic Probes designed to for this product
can be used in an Explosive Atmosphere as they contain energy
limiting devices not found in standard probes.
The Ultrasonic Probes are connected to the instrument using the connector at the
rear of the gauge body,
•Align the dots on both the connector parts,
•Push the probe connector by its body until it snaps into place,
•To release the probe connector, pull back on the probe connector barrel (the
part with the dot), this will release the latch enabling the probe connector to
be pulled free.

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Fig 3. Cygnus 1 Ex Probe Connector.
It is safe to unplug and replace Cygnus Ex Ultrasonic Probes in an
Explosive Atmosphere.
Charging the Battery
The battery pack must only be removed and charged in a Safe
Area.
The battery pack must only be charged with the charger
supplied with the kit.
The Charger comprises of a mains plug-in Charger and Cradle to hold the battery.
Removing the Battery Pack
•Use a ball-end SW2.5mm hexagonal screwdriver to loosed and unscrew the
battery securing screw until the battery can be lifted out from the instrument
body.
Charging
The battery pack is fitted to the Charging Cradle, there is an alignment lug on the
cradle that fits into a recess in the battery, then the battery just drops onto the
cradle and is secured in place with the retaining screw using a SW2.5mm hex
screwdriver.

Cygnus 1 Ex Operating Manual
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Fig 4. Cygnus 1 Ex Battery Charger Cradle and Battery.
Plug the Charger into the AC power socket, having fitted the appropriate plug-
adapter to the Charger.
There is a light on the front of the Charger to show the state of charge,
•Orange = Charging
•Green = Charged
The charge time for a fully exhausted battery is around 4 hours.
Connecting to a Computer
You must only connect the Cygnus 1 Ex Instrument to a
computer using the Cygnus 1 Ex USB Interface.
You must only connect the Cygnus 1 Ex Instrument to a
computer in a Safe Area.
To transfer data between the Cygnus 1 Ex instrument and a Windows®computer, a
USB Interface module is supplied. This module also acts as a Ex Protection Barrier
to protect the instrument from over-voltages from a faulty computer. Connection
to a computer must only be done in a safe area.

Cygnus 1 Ex Operating Manual
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Fig 5. Cygnus 1 Ex USB Interface.
Connecting to the Instrument
The lead coming from the USB Interface has a silver connector that is plugged into
the data port on the rear of the Cygnus 1 Ex instrument.
•Push-down the sealing cap on the data port connector on the rear of the
Cygnus 1 Ex instrument to expose the connector socket,
•Align the red marks on both connector parts,
•Push the connector into the socket until it latches into place.
•To remove the connector, pull-back on the body of the connector to release
the latch, the connector can then be removed.
Fig 6. Cygnus 1 Ex Data Port Connection.

Cygnus 1 Ex Operating Manual
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Cleaning The Instrument
See the section on Cleaning on page 80.

Cygnus 1 Ex Operating Manual
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Section 3 – Gauge Features
The Cygnus 1 Ex gauge is available to order in four variants, you can change the
variant or add certain features at a later date by purchasing an Update Code from
Cygnus.
Feature
Variant
SC
TC
PLUS
PRO
Measurement Units, Resolution, Velocity of Sound




Single Echo Measurements (SE)
1



Echo-Echo Measurements (EE)
1



Multiple-Echo Measurements (ME) including Deep Coat

1


Measurement Limits




Material List




Calibration 1 & 2 Point




Indoor/Outdoor Display Colours




Measurement Freeze




Auto Probe Detection



A-Scan Display
1
1


Manual Gain Control
1
1


High Temperature Measurement 2
1
1
1

Data Logging (Basic)

-
Data Logging (Advanced)
1
1
1

B-Scan
1


Manual Gates (A & B)
1
1

Fast Update Rate (32Hz)


Measurement Setups

User Access Control

1 Feature can be purchased as an upgrade.
2With suitable high temperature Ex probe when available.

Cygnus 1 Ex Operating Manual
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Upgrading
Purchasing an Update Code
To purchase an Update Code, you will need to provide the serial number of the
gauge, its current variant and feature code.
To find the Variant, Serial Number and Feature Code of the gauge, navigate to
Menu->Setup->Gauge Info. See Menu Group - Setup on page 79.
Entering an Update Code
1.
Access the Menu and scroll down to
the Setup group. Then scroll right
and select Enable Features.
Press the √key to start and enter in
the update code.
2.
Enter the update code exactly as
shown, the format is:
XXXX-XXXX-XXXX-XXXX
3.
If the code is accepted the gauge will
update and require a re-start.