Cygnus Cygnus 4 User manual

Cygnus 4
Multiple Echo Ultrasonic Thickness Gauge
Operating Manual
Covers Gauge Model : M5-C4
Doc No. M5-CYG4-M-01_Iss6.doc
18 October 2016

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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-to-
use 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 ..............................................................6
2. Introduction......................................................................7
Cygnus 4 Thickness Gauge......................................................7
Cygnus Instruments...............................................................8
Regional Offices ....................................................................8
Gauge Kit Contents.................................................................9
3. Gauge Preparation..........................................................10
Fitting the Batteries .............................................................10
Connecting the Probe...........................................................11
Fitting the Neck Strap ..........................................................11
4. Selecting the Right Probe................................................13
Measuring Metals.................................................................13
Measurement Modes Explained and Compared .........................14
Multiple Echo Mode (Mode 3)..............................................14
Measuring Non-Steels ..........................................................14
Measuring Non-Metals..........................................................14
Single Element Probes and Protective Membranes.....................15
Summary of Cygnus Probes ..................................................18
Single Element probes.......................................................18
The ‘Probe Type’ Code .......................................................19
5. Gauge Operation.............................................................20
Gauge Controls ...................................................................20
Turning the Gauge On..........................................................21
Turning the Gauge Off..........................................................21
Automatic Power Off..........................................................21
Status Information...............................................................22
Taking Thickness Measurements ............................................22
Taking the Thickness Measurement......................................23
Echo Indicators in Multiple Echo Mode..................................23
Display Hold Function...........................................................24
Battery Life.........................................................................25
Battery Level....................................................................25
Low Battery Indication..........................................................26
6. Calibration ......................................................................27
Why should I Calibrate my Thickness Gauge?...........................27
Calibration Options ..............................................................28
Calibrating to a known thickness (Single or 1 Point)..................28

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Setting the Velocity of Sound ................................................30
7. Gauge Setup ...................................................................32
Menu Operation...................................................................32
Settings are Saved with the Probe Type ..................................33
Changing Numeric Values using the Navigation Keys.................34
Selecting the Probe Type ......................................................35
Automatic Probe Detection .................................................36
Measurement Units..............................................................37
Resolution Setting ...............................................................37
Limit Functions....................................................................38
Deep Coat Function..............................................................41
8. Setup Menu.....................................................................44
Vibrate Feature ...................................................................44
Brightness Setting ...............................................................44
Power Off Setting ................................................................45
Set Time and Set Date .........................................................45
9. General Points On Thickness Gauging.............................47
10. Troubleshooting...........................................................48
The Gauge will not Switch On................................................48
Difficulty obtaining a Reading ................................................48
If Readings are Erratic or Unstable .........................................48
Tips for Optimising Battery Life..............................................48
11. Updating your Gauge ...................................................50
Update Software..................................................................50
Gauge Firmware Files...........................................................50
12. Care and Servicing.......................................................51
Cleaning the Gauge..............................................................51
Batteries ............................................................................51
Environmental.....................................................................51
Repairs ..............................................................................51
Returning the Gauge for Servicing..........................................52
13. Information .................................................................53
Technical Specifications........................................................53
Table of Sound Velocities......................................................56
Reading Conversions .........................................................57
14. EU Declaration of Conformity.......................................58
15. Recycling and Disposal (EC Countries).........................59
16. Warranty Information..................................................60

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17. Index...........................................................................61

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1. Important Notice
The 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 4 Thickness Gauge
The Cygnus 4 Ultrasonic Thickness Gauge is a rugged,
handheld, battery-powered instrument designed for high-reliability
multiple echo thickness measurements in harsh environments
using ultrasound.
The gauge can be used with a choice of Ultrasonic Probes, selected
to suit the material and thickness range to be measured.
The gauge measures material thickness using the Multiple Echo
technique giving quick, reliable measurements through surface
coatings which are ignored.
Measurements can be displayed in either Metric (mm) or in
Imperial (inch) units. The gauge has an side mounted sunlight
readable LCD 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 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.
Regional Offices
CYGNUS Instruments Ltd.
Cygnus House Dorchester
DT1 1PW England
Tel: [phone]
Fax: [phone]
www.cygnus-instruments.com
[e-mail]
CYGNUS Instruments Inc.
PO Box 6417 Annapolis
MD 21401 USA
Tel: [phone]
Fax: [phone]
www.cygnusinstruments.com
[e-mail]
CYGNUS Instruments Middle
East
P.O.Box 127267
Jebel Ali Free Zone (JAFZA)
Dubai UAE
Tel. [phone]
CYGNUS Singapore (S) Pte.
Ltd.
63 Jalan Pemimpin #05-01,
Pemimpin Industrial Building.
577219 Singapore.
Tel : [phone]
Fax : [phone]
www.cygnus-instruments.sg
[e-mail]

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Gauge Kit Contents
1. Cygnus 4 Gauge
2. Operating Manual (in side pouch)
3. Neck Strap (in side pouch)
4. Ultrasonic Probe
5. Moulded Probe Cable (in side pouch)
6. Accessory Pouch, containing;
3 x AA Batteries
Blue Couplant Gel.
15mm (or ½”) Steel Test Block
Spare Membranes
Membrane Key
Membrane Couplant

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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 and
you are ready to take 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
cable will not stiffen after exposure to ultraviolet light.
The connector uses original Lemo connectors for reliability.
Depending on the type of probe supplied the probe end will have
either a BNC or single Lemo 00 connector.
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 fitted to the gauge. These
wire loops are made from coated stainless steel.

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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.

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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.
The probe type is displayed at the top of the measurement screen
in the status area.
Probe Type set to S2C.
Measuring Metals
Material 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
The S2C probe is suitable for most applications.
When measuring in Multiple Echo mode the coating will be
ignored and just the metal thickness measured.

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Measurement Modes Explained and Compared
Multiple Echo Mode (Mode 3)
Multiple Echo measurement mode is by far the most reliable and
easy 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, 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 no measurement is possible.
Measuring Non-Steels
The gauge will measure the following non-steels;
•Aluminium alloys
•Copper and Brass alloys
•Titanium
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
The gauge is not suitable for measuring non-metals. Typically
these materials cannot be measured with this gauge model;
•Plastics
•Concrete

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•Wood
•Thermal insulation materials
•Foams
•Composites
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, 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.
Single Element Probe Membrane Parts.
Probe Body
Locking Ring
Polyurethane Membrane
Knurled Ring

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Single Element Probe Membrane Locking Key

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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
Single Element probes
Probe
Type Size Frequency Range in Steel Typical Uses
S2C
13mm
2.25 MHz
3 to 250 mm
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
S3C
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

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The ‘Probe Type’ Code
S
2
C
Single or Twin
Crystal Frequency in MHz
Size
A6mm
B8mm
C13mm
D19mm

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5. Gauge Operation
Gauge Controls
End view of gauge
Front view of gauge
Probe
Connection
Power
Key
Select
Keys
Menu
Key
Navigation
Keys