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.


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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
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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

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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
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21. Index ...........................................................................66

M4-CYGMINI-TSR-M-ENG_Iss 1
Cygnus MINI ROV Operation Manual
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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
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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
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Cygnus Instruments
Cygnus Instruments Limited, founded in 1983, pioneered the
development of the Digital Ultrasonic Multiple-Echo Technique
used for measurement through coatings. This has long since been
the standard required to ensure that accurate measurements are
taken without the need to zero the Gauge or remove any coatings
first.
Our philosophy is to work closely our customers to provide high
quality products, engineered to serve heavy industry & harsh
environments. Cygnus Ultrasonic thickness gauges are designed to
be reliable and simple to use. We have an unrivalled reputation in
over 45 countries around the world.
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
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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