Cygnus M5-C2P User manual

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

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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 2+Thickness Gauge ....................................................7
Cygnus Instruments...............................................................8
Gauge Kit Contents.................................................................9
Basic Gauge Kit.....................................................................9
Kit supplied with Single Element Probe......................................9
Kit supplied with Twin Element Probe........................................9
3. Gauge Preparation..........................................................10
Fitting the Batteries .............................................................10
Connecting the Probe...........................................................11
Fitting the Hand Strap or Belt Clip..........................................12
Fitting the Neck Strap ..........................................................13
4. Selecting the Right Probe................................................15
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 the Gauge On..........................................................24
Turning the Gauge Off..........................................................24
Automatic Power Off..........................................................24
‘No Probe’ Message..............................................................24
Taking Thickness Measurements ............................................25
Zeroing the Probe (twin element probes)..............................25
Taking the Thickness Measurement......................................25
Echo Indicators in Multiple Echo Mode..................................26

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Measurement Stability Indication in SE & EE Modes................26
Measuring Small Diameter Pipe & Tubes..................................27
Battery Life.........................................................................28
Battery Level ......................................................................28
Low Battery Warning............................................................28
6. Calibration ......................................................................29
Why should I Calibrate my Thickness Gauge?...........................29
Calibration Options ..............................................................30
Calibrating to a known thickness (Single or 1 Point)..................30
Two Point Calibration ...........................................................32
Ladder Step Wedge...........................................................32
Two Point Calibration Procedure ..........................................32
Probe Zero (twin element probes)..........................................34
Starting a Probe Zero from the Main 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..............................................................50
The Gauge will not Switch On................................................50
Difficulty obtaining a Reading ................................................50
If Readings are Erratic or Unstable .........................................50
Tips for Optimising Battery Life..............................................50
10. Updating your Gauge....................................................52
Update Software..................................................................52
Gauge Firmware Files...........................................................52
11. Care and Servicing .......................................................53
Cleaning the Gauge..............................................................53
Batteries ............................................................................53
Environmental.....................................................................53

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Storage..............................................................................53
Repairs ..............................................................................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

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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 2+Thickness Gauge
The Cygnus 2+Ultrasonic Thickness Gauge is a rugged,
handheld, battery-powered instrument designed for high-reliability
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 can measure material thickness using three methods;
Single Echo, Echo-Echo or Multiple Echo. Echo-Echo and Multiple
Echo allow measurements through 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 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 2 Gauge
2. Operating Manual (in side pouch)
3. Neck Strap (in side pouch)
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 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 (if ordered)

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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. 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 only be plugged in
one-way around.
Depending on the type
of probe supplied the
probe end will have
either a twin Lemo 00,
BNC or single Lemo 00
connector.

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To release the connector
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

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Optional Krusell® belt clip
attachment parts.
There are four 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.

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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, see
Selecting the Probe Type on page 40.
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
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
Moderate
2.5 mm+
(0.1”+)
T2C
Single Echo
The table above shows that to be able to measure coated and un-
coated 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 Echo-
Echo Mode to ignore thin paint coatings. However this
method does not have the ability to verify measurements
and without an 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
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 (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 no measurement is 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 incorrectly metal
thickness measurement . If the surface coating is very thin paint
(0.2mm / 0.01”) 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 element)
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.
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.
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 verify the
measurement makes sense (the Single Echo measurement should
always be slightly thicker due to the coating thickness).
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.

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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 mounded parts can generally be measured
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;
•Concrete
•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.

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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

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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.