Cygnus UW-TSR User manual

Cygnus UNDERWATER
and
Topside Repeater Systems
Operation Manual
and
Accessories List
Doc No. M4-CYG1UW-TSR-M-ENG_Iss11.docx
August 2019
(Mk4 Cygnus UW Gauges)

Cygnus UW-TSR Operation Manual
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Contents
1. Important Notice ..............................................................6
2. Introduction......................................................................7
Cygnus UNDERWATER (UW) Thickness Gauge............................7
Multiple Echo Measurements ...................................................9
Triple Echo Verification ........................................................9
Cygnus Instruments.............................................................11
Gauge Kit Contents..............................................................12
Basic Kit Contents: “Cygnus UNDERWATER Upgradable Kit” .......12
Upgrade Kit ‘A’ – Cygnus Topside Repeater (TSR) Display ..........13
Upgrade Kit ‘B’ – CygLink Software ........................................14
3. Gauge Preparation ..........................................................15
Fitting the Battery Pack ........................................................15
Connecting the Probe and Nosecone .......................................16
Removing the Nosecone.....................................................16
Replacing the O-Ring Seals ...................................................17
Checking the O-rings.........................................................19
Lanyard .............................................................................20
4. Gauge Operation .............................................................21
Gauge Controls ...................................................................21
Turning the Gauge On ..........................................................22
Turning the Gauge Off..........................................................22
Automatic Power Off..........................................................22
Taking a Thickness Measurement ...........................................23
Echo-Strength Indicators ......................................................23
Battery Life.........................................................................25
Low Battery Warning............................................................25
Charging the Batteries..........................................................26
5. Topside Repeater Facility................................................28
6. Using the Topside Repeater Display ................................29
Turning the Unit On .............................................................29
Turning the Unit Off .............................................................30
Changing the Displayed Units ................................................30
Display Hold Function...........................................................30
Automatic Display Backlight ..................................................30
Connecting to the Cygnus UNDERWATER Gauge.......................30
Testing the Link...................................................................31
Troubleshooting - Error Messages ..........................................32

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7. CygLink Surface Display and Control Kit .........................33
Kit Contents........................................................................33
Connection Diagram.............................................................34
Connector Details and Signals ...............................................34
Installing CygLink ................................................................34
Requirements...................................................................34
Upgrading........................................................................35
Installing .........................................................................35
Running CygLink Application..................................................35
Connecting to the Gauge ......................................................35
First time USB Connection..................................................35
COM Port Numbers............................................................35
Connecting the Gauge to CygLink for the First Time ...............36
Connecting to the Gauge Afterwards ....................................36
Disconnecting from the Gauge ............................................37
Manual Connection Settings................................................37
Status Bar ..........................................................................37
Surveys .............................................................................38
Creating a new Survey.......................................................38
Opening an Existing Survey................................................39
Editing the Survey Info ......................................................39
Managing the Survey ...........................................................40
Sorting Survey Records .....................................................40
Viewing Record Information................................................40
Ref and Min Thickness .......................................................41
Protection State................................................................42
Measurement Summary Stats .............................................42
Logging Measurements in CygLink..........................................43
Logging Measurements ......................................................43
Grouping Measurements in Survey Records...........................43
Viewing Thickness Measurements in a Record........................43
Managing Measurements....................................................44
Viewing Measurement Information.......................................45
Adding Comments to Measurements ....................................46
Measurement Comment List ..................................................47
Creating a PDF Survey Report ...............................................48
Exporting a Survey to a CSV File............................................50
CygLink Trouble Shooting .....................................................51
Setting the COM Port Manually............................................51
Finding your COM Port Number ...........................................51

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To Change the COM Port number assigned by Windows®...........52
Opening Device Manager....................................................52
Connection Problems –USB Drivers.....................................55
Wiring Problems ...............................................................55
8. Connecting the UNDERWATER Gauge to the Computer ...56
9. Probes & Membranes ......................................................57
Probe Selection ...................................................................57
Changing the Membrane.......................................................58
Probe Selection & Specifications.............................................59
Probe Frequency Identification...............................................59
10. Gauge Setup ................................................................60
Gauge Menu Diagram...........................................................60
Connecting the Battery during Setup ......................................61
11. Calibrating the Gauge .................................................. 62
Calibrating to a known thickness (Single Point)......................63
Setting the Velocity of Sound..............................................64
Measurement Units ..............................................................65
Resolution Setting ...............................................................66
Automatic Probe Frequency Setting ........................................67
12. General Points on Thickness Gauging ..........................68
13. Troubleshooting...........................................................69
The Gauge will not Switch On ................................................69
Difficulty obtaining a Reading ................................................69
If Readings are Erratic or Unstable .........................................69
14. The 4 Point Check ........................................................71
15. Care and Servicing .......................................................72
Cleaning the Gauge..............................................................72
O-Ring Seals.......................................................................72
Batteries ............................................................................72
Environmental.....................................................................72
Repairs ..............................................................................73
Returning the Gauge for Servicing..........................................73
16. Information .................................................................74
Technical Specifications ........................................................74
17. Topside Repeater Electrical Connections .....................76
Cygnus UNDERWATER Gauge to Topside Repeater Display Unit 76
Cygnus UNDERWATER Gauge to USB-485 to Computer (CygLink)
......................................................................................76

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18. Serial Data Format....................................................... 77
Protocol...........................................................................77
19. Table of Sound Velocities............................................. 80
Reading Conversions .........................................................81
20. Accessories List ...........................................................82
Cygnus UNDERWATER Probes with 1 metre Lead......................82
Probe Spares and Membranes................................................82
Cables and Leads.................................................................83
Electronic Bodies Only ..........................................................83
Batteries and Chargers .........................................................84
Miscellaneous Spares ...........................................................84
Carry Case .........................................................................84
21. Topside Repeater Upgrade Options..............................85
Add Option A or B to a Cygnus UNDERWATER Gauge with Impulse
Socket ...............................................................................85
22. Recycling and Disposal (EC Countries).........................87
23. Warranty Information..................................................88
24. Pressure Test Statement..............................................89
25. Index ...........................................................................90

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1. Important Notice
This 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 UNDERWATER (UW) Thickness Gauge
The Cygnus UNDERWATER Thickness Gauge is a rugged,
handheld, battery-powered instrument designed for high-reliability
ultrasonic thickness measurement using the multiple-echo
technique.
The Cygnus UNDERWATER Thickness Gauge is a fully waterproof
unit designed for use by professional divers. It is pressure rated
and tested to a depth of 300 metres (984 ft). The gauge is
powered by a rechargeable NiMH battery pack.
Measurements can be displayed in Metric (mm) or Imperial (inch)
units; measurement resolution can be selected for either 0.1 mm
or 0.05 mm, (0.005 inch or 0.002 inch). The Gauge has a side–
mounted red LED display which can easily be read in low-light
situations.
Crystal-controlled Calibration provides stability and accuracy. The
gauge can easily be calibrated to a known thickness or to a known
Velocity of Sound. Velocity of Sound is displayed in either m/s or
in/μs, depending on the current selection for Measurement Units.
The Top-Side Repeater (TSR) facility allows the thickness
measurements to be relayed from the Gauge up to the surface
where they can be observed and recorded. The TSR equipment is
either included with a new Gauge or can be added to the kit later
1
as an accessory.
The Gauge is able to operate accurately in adverse environmental
conditions.
The Gauge is a solid-state electronic instrument which, under
normal operating conditions, will give many years of active
service.
1
To connect the TSR the Cygnus UW gauge must have an integral Impulse Connector fitted.

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Although designed for ease of operation first time users should
carefully read this manual to familiarise themselves with the
features of the Gauge

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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 (e1, e2 and e3) and is
detected by the Probe which acts as a receiver.
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
e1
e2
e3
t2
t3
Valid Thickness Measurement only when: t2=t3
Time
Paint, Dirt etc
Metal
0
t1
Probe

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echoes provide a reliable method of signal verification. This
process is referred to as Triple Echo Verification.

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CYGNUS Singapore (S) Pty. Ltd.
63 Jalan Pemimpin #05-01,
Pemimpin Industrial Building.
577219 Singapore.
Tel : (+65) 6252 5909
Fax : (+65) 6251 1318
www.cygnus-instruments.sg
Cygnus UAE
Cygnus Instruments Middle East
P.O. Box 127267
Jebel Ali Free Zone (JAFZA)
Dubai
UAE
Website: www.cygnus-instruments.com
Telephone: +971 50 3459305
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 Inc.
Phillips Hwy Commerce Park
6900 Phillips Hwy, Suite 8
Jacksonville, FL 32216
Tel: 00 1 410 267 9771
Fax: 00 1 410 268 2013
www.cygnusinstruments.com
CYGNUS Instruments Ltd.
Cygnus House, 30 Prince of Wales Road,
Dorchester, Dorset, DT1 1PW England.
Website: www.cygnus-instruments.com
Tel: 00 44 (0) 1305 265533
Fax: 00 44 (0) 1305 269960

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2
5
7
1
4
6
3
Gauge Kit Contents
Basic Kit Contents: “Cygnus UNDERWATER
Upgradable Kit”
1. Cygnus UNDERWATER Gauge Body
2. Lanyard & Molykote & Tommy Bar
3. Two Rechargeable NiMH Battery Packs
4. Battery Charger and Leads
5. Probe for Cygnus UNDERWATER, supplied as nosecone
assembly with 1 m cable
6. Membrane Couplant
7. Accessories: Spare O-Rings, Spare Membranes, Membrane
Locking Ring Key, 15 mm (½”) Test block, Torque (“Tommy”)
bar & Calibration Jumper Lead
The Operating Manual and Documentation is attached in the lid of
the case.

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Upgrade Kit ‘A’–Cygnus Topside Repeater (TSR)
Display
In addition to the main kit the following items are included:
1. Cygnus Topside Repeater Display unit
2. Umbilical cable:
a. Impulse connector for Gauge connection
b. Lemo connection for Topside Repeater Display unit
1
a
b
2

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Upgrade Kit ‘B’–CygLink Software
In addition to the main kit the following items are included:
1. CygLink Software & Driver Installation CD or USB flash drive
2. Umbilical cable
3. USB-485 Converter
2
1
3

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3. Gauge Preparation
The battery packs are supplied uncharged therefore both will
require a full charge before use (see ‘Charging the Batteries’on
page 26).
Once the batteries have been charged the Gauge is ready for use.
Just fit a battery pack, screw on the nosecone/probe assembly,
turn on the power and you are ready to take thickness
measurements.
Fitting the Battery Pack
The Gauge is supplied with two rechargeable NiMH battery packs
which are screwed onto the gauge body by hand. Do not over-
tighten the battery packs –hand tight is sufficient.
When the battery pack is correctly fitted there should be no gap
between the battery pack and gauge body.
Correctly Fitted
Incorrectly Fitted
When changing the battery it is advisable to check the O-
rings (page 19) and if necessary fit two new O-ring seals to
the gauge body. See ‘Replacing the O-Ring Seals’ on page
17.
Gap

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Connecting the Probe and Nosecone
The Probe is connected to the nosecone via a length of underwater
coaxial cable, the nosecone then screws on to the end of the
Gauge body.
When screwing the nosecone onto the Gauge body tighten only by
hand, ensuring there is no gap between the nosecone and Gauge.
DO NOT use the Tommy Bar to tighten the nosecone.
Correctly Fitted
Incorrectly Fitted
Removing the Nosecone
The nosecone can be difficult to remove when the O-rings have
been compressed so a Tommy Bar is supplied with the kit to allow
extra leverage to be applied to ‘break’ the seal. Fit the Tommy Bar
into the hole in the nosecone then unscrew using the Tommy Bar
as a lever.
Gap
Tommy Bar

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Replacing the O-Ring Seals
There are four O-ring seals fitted to the Gauge body, two for the
battery and two for the nosecone. Spare O-rings are included in
the kit, the different O-rings are marked A, B, C & D (B and D are
the same).
‘A’ O-rings
(1 pack of 10)
‘B/D’ O-rings
(2 packs of 10)
‘C’ O-rings
(1 pack of 10)
1. Remove the old O-rings and destroy them
Do not use a sharp instrument to remove the O-rings as
damage to the sealing area may occur
2. Clean the O-ring locations removing all grease and dirt
3. Pre-lubricate the new O-rings with Molykote grease
4. Gently fit the new O-rings into position
C
D

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Battery-End O-ring Location
Molykote Grease
Nosecone O-ring Location
Gauge (Nosecone-End) O-ring
Location
Correct Location of O-rings
Be careful not to fit the ‘A’ O-ring in the wrong position, this is
a common mistake that will cause incorrect gauge operation.
B
A
Wrong

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Incorrect Location of Nosecone ‘A’ O-ring
Checking the O-rings
To ensure the gauge remains water-tight these O-rings must be
checked each time you remove the battery pack or nosecone. It is
recommended to replace the O-rings if in any doubt as to their
condition or age.
Replace the O-rings at the start of a new job
Replace the O-rings after every 2-3 dives
Check the O-rings whenever you remove the battery
Check the O-rings whenever you remove the nosecone
Always lubricate the O-rings with Molykote
Do not use old or damaged O-rings
Never use the Gauge without any O-rings fitted
Spare O-rings are included in the Kit and can be ordered from
Cygnus Instruments (see page 11 for contact details).
Things to look for when inspecting the O-rings are:
•Any flats or signs of wear
•Any signs of pinching or trapping
•Any sand or dirt in the Molykote grease
•Any cuts or cracks

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Lanyard
A lanyard is supplied with the kit for attaching the assembled
gauge to a diver’s belt. The small screw-locking gate should be
attached to the battery pack D-ring; the other two larger
carabiners can then be attached to a belt. One has a screw-gate
for secure attachment to a belt, the other a snap-gate for quick
repositioning of the gauge during use.
Lanyard Attachments
Secure
attachment
to belt
On/off
attachment
to belt
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