Cygnus MINI ROV User manual

Cygnus MINI ROV Mountable
and
Topside Repeater Systems
Operation Manual
and
Accessories List
Doc No. M4-CYGMINI-TSR-M-ENG_Iss 1
August 2014
(Mk4 Cygnus MINI ROV Gauges)

Cygnus MINI ROV Operation Manual
M4-CYGMINI-TSR-M-ENG_Iss 1
Page 2 of 66
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.
Cygnus is an ISO-9001 accredited company.
The scope of our accreditation covers all our products and
services.


M4-CYGMINI-TSR-M-ENG_Iss 1
Cygnus MINI ROV Operation Manual
Page 3 of 66
Contents
1. Introduction......................................................................7
CYGNUS MINI ROV Mountable Ultrasonic Thickness Gauge ...........7
Multiple Echo Measurements ...................................................8
Triple Echo Verification ........................................................8
Cygnus Instruments...............................................................9
2. Gauge Kit Contents .........................................................10
Data Conversion Items .........................................................10
Top Side Repeater (TSR) Remote Display Unit with Video On-
Screen-Display (OSD) ..........................................................12
3. Gauge Preparation ..........................................................13
Fitting the Probe-module ......................................................13
Underwater Cable connection to the Gauge..............................14
Electrical connections to the Gauge ........................................15
Power Supply ...................................................................15
Data Output .....................................................................15
Electrical connections to the Surface.......................................16
Connection to a Computer..................................................16
Connection to the ROV Craft ...............................................16
Custom Connection ...........................................................16
Custom Display Software ...................................................16
Measuring Through a Water Gap ............................................17
4. Displaying the Thickness Measurements.........................18
Data Logging ......................................................................18
Video Overlay .....................................................................18
5. Calibration ......................................................................19
6. Using the TSR Remote Display Unit.................................20
Turning the Unit On .............................................................20
Changing the Displayed Units ................................................20
Setting the Velocity of Sound ................................................20
Calibrating to a Known Thickness using a TSR..........................21
Display Hold Function...........................................................21
Automatic Display Backlight ..................................................21
Video Overlay Facility ...........................................................21
Connecting the Video Signal ...............................................22
Positioning the On-Screen Display (OSD)..............................22
Testing the Link...................................................................23

Cygnus MINI ROV Operation Manual
M4-CYGMINI-TSR-M-ENG_Iss 1
Page 4 of 66
Troubleshooting - Error Messages ..........................................23
7. CygLink Surface Display and Control Kit .........................24
Kit Contents........................................................................24
Connection Diagram.............................................................25
Connector Details and Signals ...............................................25
Installing CygLink ................................................................25
COM Port Numbers ..............................................................26
Setting the COM Port Manually............................................26
Finding your COM Port Number ...........................................26
To Change the COM Port number assigned by Windows®.........26
Running CygLink Application..................................................28
Connecting to the Cygnus MINI ROV Gauge .............................29
Changing Gauge Settings......................................................30
Velocity Table...................................................................30
Calibrating to a Known Thickness using CygLink .......................31
CygLink Surveys and Data Logging.........................................31
Editing the Survey Details ..................................................33
Editing the Survey Group Details .........................................33
Producing a Survey Report Document ..................................34
Logging Measurements Directly in CygLink ..............................35
Linear or Grid Data Logging................................................35
Reference and Minimum Thickness Criteria ...........................35
Pre-Set Measurement Comments List...................................36
Adding Comments or Notes to a Measurement.......................36
CygLink Trouble Shooting .....................................................37
Connection Problems –USB Drivers .....................................37
Wiring Problems ...............................................................38
8. Probes & Membranes ......................................................39
Probe Selection ...................................................................39
Changing the Membrane .......................................................40
Probe Selection & Specifications.............................................41
Mounting the Ultrasonic Probe ...............................................42
9. O-Ring Seals ...................................................................43
Correct fitting of O-ring seals ................................................43
Removing the Nosecone .......................................................44
Replacing the O-Ring Seals ...................................................45
Checking the O-rings............................................................45
10. General Points on Thickness Gauging ..........................47
11. Troubleshooting...........................................................48

M4-CYGMINI-TSR-M-ENG_Iss 1
Cygnus MINI ROV Operation Manual
Page 5 of 66
Difficulty obtaining a Reading ................................................48
If Readings are Erratic or Unstable .........................................48
12. The 3 Point Check ........................................................49
13. Care and Servicing.......................................................50
Cleaning the Gauge..............................................................50
Use of O-Rings ....................................................................50
Data-link connector..............................................................50
Environmental.....................................................................51
Repairs ..............................................................................51
Returning the Gauge for Servicing..........................................51
14. Information .................................................................52
Technical Specifications ........................................................52
15. Serial Data Format.......................................................53
Protocol .............................................................................53
Valid Thickness Measurement Packet Arrangement.................53
No Thickness Measurement Packet Arrangement....................53
Status-byte Structure ........................................................54
Data-bytes Arrangement....................................................54
Interpreting the Readings sent from the Gauge .....................55
16. Table of Sound Velocities.............................................56
Reading Conversions .........................................................57
17. Part Number & Accessories List ...................................58
Software ............................................................................58
Underwater Probes with 1 Metre Lead .....................................58
Probe Spares and Membranes................................................59
Knurled Rings .....................................................................60
Cables and Leads.................................................................60
Electronic Bodies Only ..........................................................60
Miscellaneous Spares ...........................................................60
18. Recycling and Disposal (EC Countries).........................62
19. Independent Cable Connection ....................................63
Recommended cable connection for direct cabling from Cygnus
MINI ROV Gauge to surface computer.....................................63
20. ROV-Local Termination Connection..............................64
Recommended cable connection from Cygnus MINI ROV Gauge to
ROV craft ...........................................................................64
Recommended connection at surface, taken from ROV cabling to
computer ...........................................................................65

Cygnus MINI ROV Operation Manual
M4-CYGMINI-TSR-M-ENG_Iss 1
Page 6 of 66
21. Index ...........................................................................66

M4-CYGMINI-TSR-M-ENG_Iss 1
Cygnus MINI ROV Operation Manual
Page 7 of 66
1. Introduction
CYGNUS MINI ROV Mountable Ultrasonic Thickness
Gauge
The Cygnus MINI ROV Mountable Ultrasonic Thickness
Gauge (Cygnus MINI ROV Gauge) is designed for high-reliability
thickness measurement using the Multiple-Echo technique. The
Gauge is a lightweight gauge designed to be mounted on smaller
submersible ROV craft.
Fully-waterproof, the Cygnus MINI ROV Gauge can be used both
underwater and in air and is pressure tested to 500 metres’ water
depth. It is supplied with dedicated PC-software for displaying and
logging thickness readings at the surface.
The Gauge is supplied with one ultrasonic Probe. The Probe type
must be specified at the time of purchase of the Gauge. Probes
are not freely interchangeable –please consult with Cygnus if you
wish to use a different Probe with the Gauge.
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, first time users
should carefully read this manual to familiarise themselves
with the features of the Gauge.

Cygnus MINI ROV Operation Manual
M4-CYGMINI-TSR-M-ENG_Iss 1
Page 8 of 66
Multiple Echo Measurements
The Gauge works on the pulse-echo principle. The Probe transmits
a very short pulse of ultrasound which enters the test piece. The
Probe then acts as a receiver listening for return echoes,
converting them into electrical signals which are processed to
produce timing information that can be used to determine the
material thickness.
The multiple-echo beam travel is depicted above, spread out in
time, to illustrate the timing method. In reality the beam path is
straight and perpendicular to the surface as the ultrasonic energy
reverberates up and down within the metal (shown on the left).
Each time an echo is reflected back down, a small portion of the
energy comes up through the coatings and is detected by the
Probe which acts as a receiver (e1, e2 and e3).
The delay between echoes at the Probe-face (t2 and t3) is exactly
equal to the time taken to pass through the metal twice, therefore
coatings such as paint are ignored and the measurement displayed
is the metal thickness only.
Triple Echo Verification
The Gauge requires 3 equi-spaced return echoes in order to
calculate a thickness measurement value (t2=t3). This method
ensures the Gauge only displays valid thickness values, the three
echoes provide a reliable method of signal verification. This
process is referred to as Triple Echo Verification.
e1
e2
e3
t2
t3
Valid Thickness Measurement only when: t2=t3
Time
Paint, Dirt etc
Metal
0
t1
Probe

M4-CYGMINI-TSR-M-ENG_Iss 1
Cygnus MINI ROV Operation Manual
Page 9 of 66
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.
CYGNUS Instruments Ltd.
Cygnus House, 30 Prince of Wales Road,
Dorchester, Dorset, DT1 1PW England.
Tel: [phone]
Fax: [phone]
www.cygnus-instruments.com
[email protected]
CYGNUS Instruments Inc.
CYGNUS Singapore (S) Pty. 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
[email protected]
[email protected]

Cygnus MINI ROV Operation Manual
M4-CYGMINI-TSR-M-ENG_Iss 1
Page 10 of 66
2. Gauge Kit Contents
1. Cygnus MINI ROV Gauge Body
2. Nose Cone Torque Bar
3. Operation Manual & CygLink Software on USB Flash Drive
(Not Shown)
4. Bottle of Membrane Couplant
5. Carry Case
6. Test Lead
7. 9 Way D-Type Connector
8. Impulse Plug to Fly Leads
9. Impulse Blanking Plug
16/17

M4-CYGMINI-TSR-M-ENG_Iss 1
Cygnus MINI ROV Operation Manual
Page 11 of 66
10. 10 x ‘B/D’ O Rings
11. 10 x ‘A’ O Rings
12. Silicone Grease
13. K3 RS-422/485 to RS-232 Converter
14. RS-232 to USB Converter
15. K3 Manual, Documents and Warranty Letter
16. Probe Assembly, including:
17. Spare Membranes and Membrane Key
18. Sample Test Block
Data Conversion Items
Connection to USB is an RS232-to-USB Adaptor, as included in the
main kit contents. This USB-to-Serial Adaptor is used together
with the RS422-to-RS232 Converter as shown:
1. RS-232 to USB Converter Module & Cable
2. ‘K3’ RS-422/485 to RS-232 Converter Module
3. Connection from ROV subsea link
1
2
3

Cygnus MINI ROV Operation Manual
M4-CYGMINI-TSR-M-ENG_Iss 1
Page 12 of 66
Top Side Repeater (TSR) Remote Display Unit with
Video On-Screen-Display (OSD)
The Cygnus TSR Display unit with OSD is an Optional Accessory to
the main Gauge Kit.
It is supplied with:
1. Protective silicone sleeve
2. 12V DC power supply UK/EU/US
3. BNC to BNC cable x 2
4. BNC Jack to Phono plug
5. BNC Plug to Phono socket
6. 9-way D to Lemo link lead

M4-CYGMINI-TSR-M-ENG_Iss 1
Cygnus MINI ROV Operation Manual
Page 13 of 66
3. Gauge Preparation
The Gauge is supplied ready to use, once the probe-module has
been attached to it. All that is required is to make the necessary
electrical connections between the Gauge and the ROV Craft and
the chosen topside display.
There are no controls or display on the gauge. Calibration is
performed at the surface using the top side display.
Fitting the Probe-module
The “Probe-module”consists of a nosecone, an integral length of
underwater coaxial cable and the probe itself. It is attached by
screwing the nosecone section on to the end of the Gauge body,
hand tight.
Do not use the nosecone Torque Bar to tighten the nosecone.
See page 44.
There is an O-ring seal (‘A’) fitted to the nosecone and another
(‘B’) fitted to the Gauge body. Cover both O-rings with a light
coating of Silicone grease and fit strictly as shown:
Nosecone O-ring Location
Gauge O-ring Location
B
A

Cygnus MINI ROV Operation Manual
M4-CYGMINI-TSR-M-ENG_Iss 1
Page 14 of 66
It is important to ensure that the O-Rings are properly
located. Incorrect fitting of O-rings, as shown below, will
result in the instrument leaking.
Incorrect Location of Nosecone ‘A’ O-ring
Both O-Rings must be replaced after every job or submersion.
See page 45.
Underwater Cable connection to the Gauge
The Cygnus MINI ROV Gauge is provided with a fully-waterproof
external (“Impulse”) cable connection. To maintain the integrity of
the electrical operation and watertight-seal it is essential that
these precautions are observed:
Cable connection should only ever be made in dry, ambient
conditions at the surface.
Connections must never be made, or broken, underwater
Both the male underwater cable Connector and the Blanking-
plug should have Silicone grease smeared on the pins before
inserting into the female socket-connector on the Gauge
The male plug-connector should be pushed fully into the female
socket-connector, and then the rubber retaining-loop should be
pushed into the groove on the male-connector to complete the
fully-waterproof connection
Wrong

M4-CYGMINI-TSR-M-ENG_Iss 1
Cygnus MINI ROV Operation Manual
Page 15 of 66
A Blanking-plug is supplied for use: For safety we recommend
that the Blanking Plug is fitted at all times when there is no
cable attached to the Gauge body
Electrical connections to the Gauge
See pages 63, 64 & 65 for schematic connection details.
Power Supply
The Gauge requires a DC supply voltage between 7.5 and 30 volts.
There is an internal 1 amp fuse and crowbar circuit to protect the
instrument from over-voltage surges. The supply input is also
protected against accidental reverse polarity connection.
There is no ON/OFF switch. The Gauge will operate continuously
whilst power is connected. There will be an initial delay of about 2
seconds, and then the instrument will begin continuously
transmitting thickness-measurement data.
A “Test-Cable”is supplied in the main Gauge Kit, which can be
used to verify the Gauge operation. If you are using the Test-
Cable, connect Red to positive and Black to negative.
Data Output
The Gauge outputs its status and thickness measurements as RS-
422 serial data. The RS-422 output option can transmit the serial
data up to 1200 m (4,000 ft) along a twisted pair cable. The serial
Cygnus MINI ROV
Gauge Body
Blanking
Plug

Cygnus MINI ROV Operation Manual
M4-CYGMINI-TSR-M-ENG_Iss 1
Page 16 of 66
output drivers have ESD protection to ±15 kV. See Serial Data
Format on Page 53.
Electrical connections to the Surface
Connection to a Computer
A single “umbilical” cable can connect the Gauge to the surface,
independent of the ROV craft’s own cabling. See page 63. This has
a maximum length of 1000 metres. This cable can be supplied, on
request, by Cygnus.
As shown on page 10, assemble the data conversion items:
9-way D-connector (on the umbilical cable) to the K3 interface
adapter (at the end marked RS422)
the other end of the K3 (marked RS232) can either connect to a
free RS-232 serial port on your computer or to the Serial-to-
USB adaptor, which can connect to a spare USB port on your
computer.
Connection to the ROV Craft
In this method the connection from the Gauge is taken to the ROV
craft itself and is merged with the ROV’s own cabling to connect to
the surface. See pages 64 and 65.
Power for the Gauge can be taken from the ROV’s own power
supply, if suitable.
It is essential that the data connections from the Gauge are
maintained throughout as twisted-pair.
If the distance from the Gauge to the surface is greater than
1000 metres the Data-output from the Gauge must be
electronically buffered within the ROV.
Custom Connection
If you intend to convert the serial data sent from the Cygnus MINI
ROV Gauge using your own electronics: the TX+ / TX- data-pair
may be connected directly to any RS-422 compatible receiving
equipment.
Custom Display Software
For Users who wish to develop their own display software: the
format of the data sent from the Gauge is detailed in Serial Data
Format, page 53.

M4-CYGMINI-TSR-M-ENG_Iss 1
Cygnus MINI ROV Operation Manual
Page 17 of 66
Measuring Through a Water Gap
In ROV applications the water can be considered to be a coating.
Thus it is possible to measure steel thickness through a small
water gap between the probe and the material under inspection.
As the Velocity of Sound for seawater is approximately 1500m/s
this equates to a maximum seawater gap of 2.25mm.

Cygnus MINI ROV Operation Manual
M4-CYGMINI-TSR-M-ENG_Iss 1
Page 18 of 66
4. Displaying the Thickness Measurements
The Gauge transmits thickness measurement data to the surface
as serial data. To display the thickness value and provide a means
of calibration, two options are provided:
1. Using a Cygnus Top-Side Repeater (TSR) unit
2. Using a computer with CygLink software
It is also possible for a third party application to read the serial
data and process the thickness measurement data. For more
information on the Serial Data Format, to enable use of your own
software, see page 53.
Data Logging
The CygLink software also provides the facility to Data Log the
thickness measurements as they are taken and to generate a
report document for the survey.
Video Overlay
The optional TSR unit has a Video Overlay or On-Screen Display
facility where the thickness measurements can be superimposed
on to a video signal feed before the monitor and/or video recorder.
The video overlay will work with PAL or NTSC video signals.

M4-CYGMINI-TSR-M-ENG_Iss 1
Cygnus MINI ROV Operation Manual
Page 19 of 66
5. Calibration
The Gauge is supplied tested and calibrated to BS EN 15317:2007.
The Gauge will have been calibrated to measure thickness through
steel (grade S355JO).
Either a 15mm or ½” test block is supplied with the kit so the
Gauge can be quickly checked for correct operation. Note, this test
block is not intended to be used for calibration of the Gauge and
may not indicate an exact 15.00 mm.
The best way to calibrate the Gauge is to calibrate using a
Known Thickness of a sample piece of the material you intend
to measure. This method determines the velocity of sound
for the material sample, which will always be more accurate
than using a ‘general’ velocity value.
For calibration instructions using CygLink see Calibrating to a
Known Thickness using CygLink on page 31, or with the TSR see
Calibrating to a Known Thickness using a TSR on page 21.
If there is no test sample available the Gauge can be calibrated by
setting the Velocity of Sound directly. A table on page 56 lists
common materials and their velocity of sound values. For
instructions on setting the velocity of sound using CygLink see
page 30, or with the TSR see page 20.
A third method is to leave the Gauge set to its factory-preset value
for Steel [5920 m/s or 0.2332 in/us], and then use a Conversion
Factor from the table of velocities on page 56.

Cygnus MINI ROV Operation Manual
M4-CYGMINI-TSR-M-ENG_Iss 1
Page 20 of 66
6. Using the TSR Remote Display Unit
The Cygnus Top Side Repeater (TSR) is a small handheld display
unit that can display the thickness measurement values from the
Gauge on its LCD display. It provides the ability to calibrate the
Gauge’s output to suit the material or to a specific velocity of
sound. A video overlay facility is also included, which allows the
thickness measurements to be superimposed on to a video signal
before the monitor or video recording device.
Turning the Unit On
1.
Press the red ON key
2.
The Cygnus Logo screen appears
3.
If not connected to a Gauge the display shows “NO
CONNECTION”
This is normal –it just means no data has being
received yet
Changing the Displayed Units
1.
Press the MENU key to display the MENU
2.
Press the DOWN ARROW key to scroll down to
UNITS the current units are displayed
3.
Press the EDIT key to toggle between mm and Inch
Setting the Velocity of Sound
The velocity of sound value is displayed at the top of the screen in
either m/s or inch/us.
1.
Press the MENU key to display the MENU
2.
The VELOCITY menu option should be selected at the
top
3.
Press the EDIT key to adjust the velocity of sound value
Press the OK key to save and exit