Cygnus M5-C4P User manual

Cygnus 4+
Multi-Mode Ultrasonic Thickness Gauge
Operating Manual
Covers Gauge Model : M5-C4P
Doc No. M5-CYG4P-M-01_Iss5.doc
17 December 2015

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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 ..............................................................8
2. Introduction......................................................................9
Cygnus 4+Thickness Gauge ....................................................9
Cygnus Instruments.............................................................10
Gauge Kit Contents...............................................................11
Basic Gauge Kit...................................................................11
Kit supplied with Single Element Probe....................................11
Kit supplied with Twin Element Probe......................................11
3. Gauge Preparation..........................................................12
Fitting the Batteries .............................................................12
Connecting the Probe...........................................................13
Fitting the Neck Strap ..........................................................14
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
Measuring Higher Temperatures..........................................19
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
Measurement Screen Views...................................................25
Status Information...............................................................26
Taking Thickness Measurements ............................................27
Zeroing the Probe (twin element probes)..............................27
Taking the Thickness Measurement......................................27
Echo Indicators in Multiple Echo Mode..................................28

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Measurement Stability Indication in SE & EE Modes................29
Measuring Small Diameter Pipe & Tubes..................................30
Display Hold Function...........................................................30
Battery Life.........................................................................31
Battery Level....................................................................31
Low Battery Indication..........................................................32
6. Using the A-Scan Display ................................................33
Single Echo Mode ................................................................33
Measuring Over Corrosion Pits ............................................34
Echo-Echo Mode..................................................................35
Multiple Echo Mode..............................................................36
7. Calibration ......................................................................38
Why should I Calibrate my Thickness Gauge?...........................38
Calibration Options ..............................................................39
Calibrating to a known thickness (Single or 1 Point)..................39
Two Point Calibration ...........................................................41
Ladder Step Wedge...........................................................41
Two Point Calibration Procedure ..........................................42
Probe Zero (twin element probes)..........................................44
Starting a Probe Zero from the Main Menu............................45
Probe Zero Function ..........................................................45
Setting the Velocity of Sound ................................................46
8. Gauge Setup ...................................................................48
Menu Operation...................................................................48
Settings are Saved with the Probe Type ..................................49
Inputting Numeric Values using the Navigation Keys.................50
Inputting Text using the Navigation Keys ................................50
Selecting the Probe Type ......................................................52
Automatic Probe Detection .................................................53
Measurement Units..............................................................54
Resolution Setting ...............................................................54
Limit Functions....................................................................55
Deep Coat Function (multiple echo mode) ...............................58
9. Data Logging...................................................................61
Data Logging Features..........................................................61
Record Types......................................................................62
Reference and Minimum Thicknesses......................................62
Minimum Thickness Limit Alert............................................62
Radial Points.......................................................................62

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Measurement Comments ......................................................63
Loading Measurement Comments from a File ........................64
Grid Records.......................................................................64
Template Records................................................................66
Data Logging Menu..............................................................66
Creating a new Record .........................................................66
Your Choices will be Saved for Next Time .............................68
Using a Template to Create a new Record................................69
User Field Input................................................................69
Reviewing and Editing User Field Choices..............................69
Logging Thickness Measurements...........................................70
Auto-Log Feature..............................................................71
Logging Obstructions and No-Readings.................................72
Changing Measurement Units while Data Logging...................73
Re-taking the Last Measurement............................................73
Stepping Backwards in the Record..........................................74
Adding Radial Points ............................................................75
Adding Measurement Comments............................................77
Closing and Opening a Record ...............................................78
Closing the Record............................................................79
Opening a Record .............................................................79
Protecting a Record..............................................................80
Opening Protected Records.................................................82
Deleting Records .................................................................82
Deleting Individual Records ................................................83
Deleting All Records ..........................................................84
Record Status...................................................................84
10. Data Logging Templates ..............................................86
Templates ..........................................................................86
Integrating with Microsoft Excel ..........................................87
Measurement Points.............................................................87
User Fields .........................................................................88
User Field ‘List’ Type .........................................................88
11. Manual Gain Adjustment..............................................89
Manual Gain Mode ...............................................................89
Turning on Manual Gain.....................................................89
Manual Gain Menu ............................................................90
Adjusting the Gain ............................................................91
Adjusting the Range..........................................................92
Measuring Below the Probes Minimum Thickness Specification .93

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12. Setup Menu..................................................................94
A-Scan Range .....................................................................94
Automatic........................................................................94
Manual............................................................................94
Vibrate Feature ...................................................................94
Brightness Setting ...............................................................94
Power Off Setting ................................................................95
Auto-Log............................................................................95
Comments..........................................................................95
Set Time and Set Date .........................................................96
Set Time and Set Date .........................................................96
13. General Points On Thickness Gauging..........................97
14. Troubleshooting...........................................................98
The Gauge will not Switch On................................................98
Difficulty obtaining a Reading ................................................98
If Readings are Erratic or Unstable .........................................98
Tips for Optimising Battery Life..............................................98
15. Updating your Gauge .................................................100
Update Software................................................................ 100
Gauge Firmware Files......................................................... 100
16. Care and Servicing.....................................................101
Cleaning the Gauge............................................................ 101
Batteries ..........................................................................101
Environmental...................................................................101
Repairs ............................................................................101
Returning the Gauge for Servicing........................................ 102
17. CygLink Computer Software ......................................103
Installing CygLink.............................................................. 104
Requirements.................................................................104
Upgrading......................................................................104
Installing.......................................................................104
Connecting to the Gauge .................................................... 105
First time USB Connection................................................ 105
Connecting the Gauge to CygLink for the First Time ............. 106
Connecting to the Gauge Afterwards..................................107
Disconnecting from the Gauge .......................................... 107
Manual Connection Settings.............................................. 107
Status Bar........................................................................ 107
Surveys ...........................................................................108

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Creating a new Survey..................................................... 108
Opening an Existing Survey..............................................109
Editing the Survey Info.................................................... 109
Managing the Survey ......................................................... 109
Sorting Survey Records ................................................... 109
Viewing Record Information.............................................. 110
Ref and Min Thickness ..................................................... 111
Protection State.............................................................. 112
Measurement Summary Stats........................................... 112
Data Logger Records.......................................................... 112
Transferring Records from the Gauge................................. 112
Viewing Thickness Measurements in a Record...................... 114
Managing Measurements.................................................. 114
Viewing Measurement Information..................................... 115
Adding Comments to Measurements .................................. 116
Viewing an A-Scan Graph................................................. 117
Deleting all Records from the Gauge ..................................118
Measurement Comment List................................................ 119
Material Velocity List.......................................................... 120
Creating a PDF Survey Report .............................................121
Exporting a Survey to a CSV File.......................................... 122
Templates ........................................................................123
Creating New Templates ..................................................123
Editing Templates ........................................................... 124
Sending Templates to the Gauge.......................................127
Deleting Templates from the Gauge...................................128
Other Features..................................................................128
Setting the Time and Date on the Gauge ............................128
COM Port Numbers ............................................................ 128
Finding your COM Port Number .........................................128
18. Information ...............................................................130
Technical Specifications...................................................... 130
Table of Sound Velocities.................................................... 134
Reading Conversions ....................................................... 135
19. EU Declaration of Conformity.....................................136
20. Recycling and Disposal (EC Countries).......................137
21. Warranty Information................................................138
22. Index.........................................................................139

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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
thickness measurements in harsh environments using ultrasound.
It features a colour LCD display which can be easily read in most
light situations including sunlight.
The gauge can be used with a choice of Ultrasonic Probes, selected
to suit the material and thickness range to be measured.
The gauge can measure material thickness using three methods;
Single Echo, Echo-Echo or Multiple Echo. Echo-Echo and Multiple
Echo allow measurements through surface coatings which are
ignored. An A-Scan display provides the user with information that
can be used to visually verify the thickness measurement which
can displayed in Metric (mm) or Imperial (inch) units.
A Data Logging function can save thickness measurements and A-
Scans in to a record file which can then be transferred to a
computer for analysis and report generation.
The gauge can easily be calibrated to a known thickness or to a
known Velocity of Sound.
The gauge is able to operate accurately over a wide range of
ambient temperatures and is environmentally sealed to IP67 for
use in wet conditions.
The gauge is a solid-state electronic instrument which, under
normal operating conditions, will give many years of active
service.
Although designed for ease of operation the first time user
should carefully read this manual to familiarise themselves
with the features of the Gauge.

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Cygnus Instruments
Cygnus Instruments Limited, founded in 1983, were pioneers in
the development of the Digital Ultrasonic Multiple-Echo Technique
used for measurement through coatings. This has long been the
standard required to ensure that accurate measurements are
taken without the need to first zero the gauge or remove any
coatings.
Our philosophy is to work closely with each of our customers to
provide a range of products specifically for each application.
Cygnus Ultrasonic Thickness Gauges are designed to be simple to
use and to withstand the harsh environments that they are
intended for. We have built up an enviable reputation with our
customers in over 45 countries around the world.
Cygnus House, 30 Prince of Wales Road,
Dorchester, Dorset DT1 1PW England.
Tel: [phone] Fax: [phone]
www.cygnus-instruments.com [e-mail]
CYGNUS Instruments Inc. CYGNUS Singapore (S) Pte. Ltd.
1993 Moreland Parkway, Suite 202.
Annapolis, Maryland 21401, USA.
63 Jalan Pemimpin #05-01,
Pemimpin Industrial Building.
577219 Singapore.
Tel: [phone] Tel : [phone]
Fax: [phone] Fax : [phone]
www.cygnusinstruments.com www.cygnus-instruments.sg
[e-mail] [e-mail]

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Gauge Kit Contents
Basic Gauge Kit
1. Cygnus 4+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, 4 Step.

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3. Gauge Preparation
The gauge is supplied ready to use out of the box. Just insert the
batteries, connect the probe to the gauge, turn on the power,
calibrate and you are ready to begin taking thickness
measurements.
Fitting the Batteries
The gauge requires 3 x AA/LR6/UM3 Batteries. Cygnus supplies
and recommends Duracell Alkaline batteries. The batteries are
located behind a cover on the rear of gauge. The hand strap can
be separated by a push-button buckle to gain access to the battery
cover. The battery cover is removed by pressing in with your
thumb the at the base to release the clip.
Press the bottom of the
battery cover to release
the retaining clip and lift
up the battery cover.
The batteries are located
underneath.
The gauge is protected
against electrical damage
from incorrect battery
insertion.
The battery compartment
itself is sealed to contain
any battery fluids that
may leak out.
The gauge can be fitted with NiCad or NiMH rechargeable
batteries but this may alter the specified operating time.

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To avoid damage from leaking batteries always remove the
batteries if the gauge will be unused for any length of time.
If the batteries run flat they may leak acid into the battery
compartment and damage the electrical contacts. This would
not be covered by the warranty.
Connecting the Probe
The Cygnus probe lead uses a custom made cable that offers
superior flexibility and resistance to oils and ultraviolet light. The
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
Depending on the type of probe supplied the probe end will have
either a BNC or single Lemo 00 connector.
The connector is
orientated with a ‘pip’
and can only be plugged
in one-way around.
To release the connector
simply pull back on the
connector body. DO NOT
pull the cable.

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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.
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 52.
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
1 mm+
T7A
Single Echo
Steels
Non
Non to
Heavy
2 mm+
T5B
Single Echo
Cast
Iron
Non
Non to
Moderate
3 mm+
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 observing the A-Scan display it is possible to get
incorrect measurements.
Measurement Modes Explained and Compared
Multiple Echo Mode (ME) (Mode 3)
Multiple Echo measurement mode is by far the most reliable and
quickest method for thickness measurements, because it works by
looking for three matched echoes it can verify the thickness
measurement is valid. This method has been used in all Cygnus
gauges since the late 1970s.
Multiple echo mode will ignore surface coatings (Through Coating
mode), there is no need to remove the paint to take a
measurement.
Also because it uses a single element (or single crystal) probe
there are no errors due to the V-path of the ultrasound beam
found in all twin element probes. This makes it simple to calibrate
– two point calibrations are not required.
However because it requires three echoes to take a measurement,
in heavily corroded steels there is often an insufficient number of
echoes so measurements may not be possible.
Single Echo Mode (SE) (Mode 2)
Single Echo measurement mode is most useful on heavily corroded
metals where Multiple Echo fails. Because it only needs the first
return echo to take a measurement it performs well on virtually all
steel conditions.
However single echo mode will not ignore any surface coatings, so
if you measure through a coating it will give an incorrectly metal
thickness measurement . If the surface coating is very thin
(0.2mm / 0.01”) paint you can make an allowance for this error,
but thicker coatings introduce too much error to be practical.

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Single echo measurements use a twin element (twin crystal)
probe, because there are two elements angled to a focal point
there is a v-path error introduced. However this v-path error is
mostly corrected by the gauge, and furthermore by performing a
two point calibration.
Twin element probes require “zeroing” at regular intervals,
especially if the ambient temperature is changing.
To overcome some of the drawbacks of Single Echo measurements
the gauge has an A-Scan display that can be used to visually
verify the thickness measurements are sensible and therefore
reliable. See section Using the A-Scan Display on page 33.
Echo-Echo Mode (EE) (Mode 3)
Echo-Echo mode uses a twin element probe, but measures
between the first two echoes. This method is intended to ignore
any thin surface coatings whilst still using a twin element probe.
Echo-echo mode is not able to verify its measurements unlike
Multiple echo mode, therefore it is liable to give incorrect readings.
But as the Cygnus 4+gauge has an A-Scan display you can use
this to visually decide if the measurement given is correct.
Echo-echo mode must therefore be used with caution, and only on
thin paint surface coatings (less than 0.5mm). 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

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measured, or the standard velocity of sound for that material
would be entered into the gauge.
Measuring Non-Metals
You can measure certain types of plastics with the gauge using a
twin element probe and the gauge set to Single Echo
measurement mode. Generally the harder the plastic the better,
soft materials like rubber or TPEs tend to absorb too much
ultrasound so only thin samples can be measured.
Engineering plastics like Acetal, Tufset (Polyurethane), Nylon and
High-density polyethylene (HDPE) can be measured successfully.
Rotationally Moulded parts can generally be measured
successfully.
•You must use Single Echo mode to measure plastics.
•You must generally use a low frequency probe (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

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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.
Single Element Probe Membrane Locking Key
Measuring Higher Temperatures
The polyurethane membranes fitted to the single element probes
are suitable for measuring surface temperatures up to 75°C. For
measuring higher temperatures Teflon Membranes are available
and suitable for surface temperatures up to 150°C. Contact
Cygnus instruments to order Teflon membranes.
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.