Olympus FlexoFORM User manual

10-003591-01EN [Q7780031] — Rev. 4
January 2020
FlexoFORM Scanner
User’s Manual
This instruction manual contains essential information on how to use this Olympus product safely and effectively.
Before using this product, thoroughly review this instruction manual. Use the product as instructed.
Keep this instruction manual in a safe, accessible location.

Olympus Scientific Solutions Americas, 48 Woerd Avenue, Waltham, MA 02453, USA
Copyright © 2018, 2020 by Olympus. All rights reserved. No part of this publication may be
reproduced, translated, or distributed without the express written permission of Olympus.
This document was prepared with particular attention to usage to ensure the accuracy of the
information contained therein, and corresponds to the version of the product manufactured
prior to the date appearing on the title page. There could, however, be some differences
between the manual and the product if the product was modified thereafter.
The information contained in this document is subject to change without notice.
Part number: 10-003591-01EN [Q7780031]
Rev. 4
January 2020
Printed in Canada
All brands are trademarks or registered trademarks of their respective owners and third
party entities.

Table of Contents iii
10-003591-01EN [Q7780031], Rev. 4, January 2020
Table of Contents
List of Abbreviations ...................................................................................... vii
Labels and Symbols ........................................................................................... 1
Important Information — Please Read Before Use ..................................... 5
Intended Use .......................................................................................................................... 5
Instruction Manual ................................................................................................................ 5
Instrument Compatibility ..................................................................................................... 6
Repair and Modification ....................................................................................................... 6
Presence of Visual Interferences .......................................................................................... 7
Safety Symbols ....................................................................................................................... 7
Safety Signal Words .............................................................................................................. 8
Note Signal Words ................................................................................................................ 9
Safety ....................................................................................................................................... 9
Warnings ................................................................................................................................. 9
Equipment Disposal ............................................................................................................ 10
CE (European Community) ............................................................................................... 10
WEEE Directive .................................................................................................................... 11
China RoHS .......................................................................................................................... 11
Korea Communications Commission (KCC) ................................................................... 12
KC (South Korea Community) .......................................................................................... 12
FCC (USA) Compliance ...................................................................................................... 13
ICES-001 (Canada) Compliance ........................................................................................ 14
Packing and Return Shipping ............................................................................................ 14
Warranty Information ......................................................................................................... 14
Technical Support ................................................................................................................ 15
Introduction ...................................................................................................... 17

Table of Contentsiv
10-003591-01EN [Q7780031], Rev. 4, January 2020
1. Overview ...................................................................................................... 19
1.1 FlexoFORM Case Contents ...................................................................................... 19
1.2 Alternative Components .......................................................................................... 21
2. Setup of Equipment ................................................................................... 23
2.1 Setting Up an Instrument Using a USB Key ......................................................... 23
2.2 Setting Up an Instrument Using the Interface ...................................................... 23
2.2.1 Setup Characteristics ..................................................................................... 24
2.2.2 Setting the Parameters for a Symmetrical Scan ......................................... 24
2.3 Installing the Probe and Wedge .............................................................................. 26
2.4 Connecting the Scanner ............................................................................................ 28
3. Preparation for Inspection ....................................................................... 29
3.1 Drop Precautions ...................................................................................................... 29
3.2 Cleaning the Inspection Surface ............................................................................. 30
3.3 Setting Up the Scan and Index Parameters for an Elbow ................................... 31
3.4 Marking the Scan Lines ............................................................................................ 33
4. Inspection .................................................................................................... 37
4.1 Wetting the Surface and Purging Air Bubbles ...................................................... 37
4.2 Inspecting a Part ........................................................................................................ 38
4.2.1 Inspecting a Part Using Marked Scan Lines ............................................... 38
4.2.2 Inspecting a Part without Marked Scan Lines ........................................... 40
4.3 Correction Factors ..................................................................................................... 41
5. Maintenance and Troubleshooting ........................................................ 45
5.1 Preventive Maintenance ........................................................................................... 45
5.2 Cleaning the Product ................................................................................................ 45
5.3 Changing a Magnetic Wheel ................................................................................... 46
5.4 Cleaning the Magnetic Wheels ............................................................................... 49
5.5 Changing the Encoder .............................................................................................. 49
5.6 Changing the Foam Gasket and the O-ring Seals ................................................ 50
5.7 Changing the Water Tube ........................................................................................ 52
5.8 Changing the Cable Sleeve ...................................................................................... 53
5.9 Troubleshooting ........................................................................................................ 55
6. Specifications .............................................................................................. 57
6.1 General Specifications .............................................................................................. 57
6.2 Wedge Pipe Diameter Ranges ................................................................................. 58
6.3 Flat Wedge Inspection Surfaces .............................................................................. 60
6.4 Cable Connector Pinout ........................................................................................... 60

Table of Contents v
10-003591-01EN [Q7780031], Rev. 4, January 2020
6.5 Dimensions ................................................................................................................ 61
7. Spare Parts and Accessories ..................................................................... 65
Appendix A: Setting Up to Inspect a Straight Pipe — Unidirectional or
Bidirectional Scan ...................................................................................... 75
Appendix B: Calculating True Defect Length ............................................ 77
List of Figures ................................................................................................... 79
List of Tables ..................................................................................................... 81
Index ................................................................................................................... 83

Table of Contentsvi
10-003591-01EN [Q7780031], Rev. 4, January 2020

10-003591-01EN [Q7780031], Rev. 4, January 2020
List of Abbreviations vii
List of Abbreviations
CLK clock
EFUP Environment-Friendly Use Period
ID identification
IP International (ingress) Protection
OD outside diameter
RH relative humidity
RoHS Restriction of Hazardous Substances
SDHC secure digital high capacity
WEEE Waste Electrical and Electronic Equipment

10-003591-01EN [Q7780031], Rev. 4, January 2020
List of Abbreviationsviii

10-003591-01EN [Q7780031], Rev. 4, January 2020
Labels and Symbols 1
Labels and Symbols
Safety-related labels and symbols are attached to the instrument at the locations
shown in Figure i-1 on page 1. If any of the labels or symbols are missing or illegible,
please contact Olympus.
Figure i-1 Labels location for scanner
Location of scanner rating and address labels
(see Table 1 on page 2) [encoder label not visible between scanner’s
assembled parts]

10-003591-01EN [Q7780031], Rev. 4, January 2020
Labels and Symbols2
Table 1 Content of the rating and address labels
Item Description
The CE marking is a declaration that this product conforms to
all the applicable directives of the European Community. See
the Declaration of Conformity for details. Contact your Olympus
representative for more information.
The regulatory compliance mark (RCM) label indicates that
the product complies with all applicable standards, and has
been registered with the Australian Communications and
Media Authority (ACMA) for placement on the Australian
market.
Seller and user shall be noticed that this equipment is suitable
for electromagnetic equipment for office work (class A) and it
can be used outside the home.
The MSIP code for the FlexoFORM scanner is the following:
R-R-OYN-FLEXOFORM.
The KC marking is a declaration that this product conforms to
all the applicable standards of South Korea. Contact your
Olympus representative for more information.
Scanner labels
Encoder label

10-003591-01EN [Q7780031], Rev. 4, January 2020
Labels and Symbols 3
The warning symbol indicates that the user must read the
user’s manual in order to find out the nature of the potential
hazards and any actions to avoid them.
The China RoHS mark indicates the product’s Environment-
Friendly Use Period (EFUP). The EFUP is defined as the
number of years for which listed controlled substances will not
leak or chemically deteriorate while in the product. The EFUP
for the FlexoFORM scanner has been determined to be
15 years. Note: The Environment-Friendly Use Period (EFUP)
is not meant to be interpreted as the period assuring
functionality and product performance.
The WEEE symbol indicates that the product must not be
disposed of as unsorted municipal waste, but should be
collected separately.
S/N The serial number.
The direct current symbol.
Table 1 Content of the rating and address labels (continued)

10-003591-01EN [Q7780031], Rev. 4, January 2020
Labels and Symbols4

10-003591-01EN [Q7780031], Rev. 4, January 2020
Important Information — Please Read Before Use 5
Important Information — Please Read Before Use
Intended Use
The FlexoFORM scanner is designed to perform nondestructive inspections on
industrial and commercial materials.
Do not use the FlexoFORM scanner for any purpose other than its intended use. It
must never be used to inspect or examine human or animal body parts.
Instruction Manual
This instruction manual contains essential information on how to use this Olympus
product safely and effectively. Before using this product, thoroughly review this
instruction manual. Use the product as instructed.
Keep this instruction manual in a safe, accessible location.
WARNING

10-003591-01EN [Q7780031], Rev. 4, January 2020
Important Information — Please Read Before Use6
Some of the details of components and/or software images in this manual may differ
from your instrument’s components or software display. However, the principles
remain the same.
Instrument Compatibility
The FlexoFORM scanner is compatible with the ancillary equipment listed in Table 2
on page 6. Also see “Spare Parts and Accessories” on page 65 for a list of compatible
accessories.
Always use equipment and accessories that meet Olympus specifications. Using
incompatible equipment could cause equipment malfunction and/or damage or
human injury.
Repair and Modification
The FlexoFORM scanner contains user-serviceable parts. See “Maintenance and
Troubleshooting” on page 45 for information about authorized repairs and
maintenance.
Table 2 Ancillary equipment
Part number Description
Several available models
(contact Olympus for details)
OmniScan series flaw detectors
CFU03 [U8780008] Electric water pump and tubing, 120 V and 220 V
WTR-SPRAYER-8L [U8775001] Eight liter manual water pump
OMNI-A-ADP27 [U8780329] LEMO female to DE15 male adaptor for encoder
connector on OmniScan MX flaw detector
IMPORTANT
CAUTION

10-003591-01EN [Q7780031], Rev. 4, January 2020
Important Information — Please Read Before Use 7
To prevent human injury and/or equipment damage, do not modify the FlexoFORM
scanner.
Presence of Visual Interferences
Presence of strong electromagnetic interference could generate noise in the signal that
is visually detectable. This interference is temporary and random in comparison with
the signals generated by the physical features of the inspected part, which are
coherent and persistent. This interference depends greatly on the nature, strength,
and proximity of the electromagnetic source and it will only disappear when the
source of the noise is no longer emitting signals.
Safety Symbols
The following safety symbols might appear on the instrument and in the instruction
manual:
General warning symbol
This symbol is used to alert the user to potential hazards. All safety messages that
follow this symbol shall be obeyed to avoid possible harm or material damage.
Finger crushing warning symbol
This symbol is used to alert the user to potential hazards to fingers from crushing
by magnetic wheels. All safety messages that follow this symbol shall be obeyed
to avoid possible harm.
CAUTION
IMPORTANT

10-003591-01EN [Q7780031], Rev. 4, January 2020
Important Information — Please Read Before Use8
Magnetic field warning symbol
This symbol is used to alert the user to potentially strong magnetic fields. All
safety messages that follow this symbol shall be obeyed to avoid possible harm.
Safety Signal Words
The following safety signal words might appear in the documentation of the
instrument:
The DANGER signal word indicates an imminently hazardous situation. It calls
attention to a procedure, practice, or the like that if not correctly performed or
adhered to will result in death or serious personal injury. Do not proceed beyond a
DANGER signal word until the indicated conditions are fully understood and met.
The WARNING signal word indicates a potentially hazardous situation. It calls
attention to a procedure, practice, or the like that if not correctly performed or
adhered to could result in death or serious personal injury. Do not proceed beyond a
WARNING signal word until the indicated conditions are fully understood and met.
The CAUTION signal word indicates a potentially hazardous situation. It calls
attention to a procedure, practice, or the like that if not correctly performed or
adhered to may result in minor or moderate personal injury, material damage,
particularly to the product, destruction of part or all of the product, or loss of data. Do
not proceed beyond a CAUTION signal word until the indicated conditions are fully
understood and met.
DANGER
WARNING
CAUTION

10-003591-01EN [Q7780031], Rev. 4, January 2020
Important Information — Please Read Before Use 9
Note Signal Words
The following note signal words could appear in the documentation of the
instrument:
The IMPORTANT signal word calls attention to a note that provides information that
is important or essential to the completion of a task.
The NOTE signal word calls attention to an operating procedure, practice, or the like,
that requires special attention. A note also denotes related parenthetical information
that is useful, but not imperative.
The TIP signal word calls attention to a type of note that helps you apply the
techniques and procedures described in the manual to your specific needs, or that
provides hints on how to effectively use the capabilities of the product.
Safety
Before turning on the instrument, verify that the correct safety precautions have been
taken (see the following warnings). In addition, note the external markings on the
instrument, which are described under “Safety Symbols.”
Warnings
General Warnings
• Carefully read the instructions contained in this instruction manual prior to
turning on the instrument.
IMPORTANT
NOTE
TIP
WARNING

10-003591-01EN [Q7780031], Rev. 4, January 2020
Important Information — Please Read Before Use10
• Keep this instruction manual in a safe place for further reference.
• Follow the installation and operation procedures.
• It is imperative to respect the safety warnings on the instrument and in this
instruction manual.
• If the equipment is used in a manner not specified by the manufacturer, the
protection provided by the equipment could be impaired.
• Do not install substitute parts or perform any unauthorized modification to the
instrument.
• Service instructions, when applicable, are for trained service personnel. To avoid
the risk of electric shock, do not perform any work on the instrument unless
qualified to do so. For any problem or question regarding this instrument, contact
Olympus or an authorized Olympus representative.
• Do not touch the connectors directly by hand. Otherwise, a malfunction or electric
shock may result.
• Do not allow metallic or foreign objects to enter the device through connectors or
any other openings. Otherwise, a malfunction or electric shock may result.
• Make sure no FlexoFORM scanner components (screws, straps, etc.) have come
loose or are lost in critical equipment being inspected. Thoroughly check your
inspection area before and after an inspection to prevent foreign-object debris
(FOD) that could potentially cause equipment damage, injury, or loss of life.
Equipment Disposal
Before disposing of the FlexoFORM scanner, check your local laws, rules, and
regulations, and follow them accordingly.
CE (European Community)
This device complies with the requirements of directive 2014/30/EU
concerning electromagnetic compatibility, directive 2014/35/EU
concerning low voltage, and directive 2011/65/EU concerning
restriction of hazardous substances (RoHS). The CE marking indicates
compliance with the above directives.

10-003591-01EN [Q7780031], Rev. 4, January 2020
Important Information — Please Read Before Use 11
WEEE Directive
China RoHS
China RoHS is the term used by industry generally to describe legislation
implemented by the Ministry of Information Industry (MII) in the People’s Republic
of China for the control of pollution by electronic information products (EIP).
“中国 RoHS” 是一个工业术语，一般用于描述中华人民共和国信息工业部 （MII）针
对控制电子信息产品 （EIP）的污染所实行的法令。
In accordance with European Directive 2012/19/EU on Waste Electrical
and Electronic Equipment (WEEE), this symbol indicates that the
product must not be disposed of as unsorted municipal waste, but
should be collected separately. Refer to your local Olympus distributor
for return and/or collection systems available in your country.
The China RoHS mark indicates the product’s Environment-
Friendly Use Period (EFUP). The EFUP is defined as the number of
years for which listed controlled substances will not leak or
chemically deteriorate while in the product. The EFUP for the
FlexoFORM scanner has been determined to be 15 years.
Note: The Environment-Friendly Use Period (EFUP) is not meant
to be interpreted as the period assuring functionality and product
performance.
电气电子产品
有害物质
限制使用标识
中国 RoHS 标识是根据 “电器电子产品有害物质限制使用管理办
法”以及 “电子电气产品有害物质限制使用标识要求 ”的规定，适
用于在中国销售的电气电子产品上的电气电子产品有害物质限制使
用标识。
注意：电气电子产品有害物质限制使用标识内的数字为在正常的使
用条件下有害物质不会泄漏的年限，不是保证产品功能性的年限。

10-003591-01EN [Q7780031], Rev. 4, January 2020
Important Information — Please Read Before Use12
Korea Communications Commission (KCC)
이 기기는 업무용 환경에서 사용할 목적으로 적합성평가를 받은 기기로서 가정용 환
경에서 사용하는 경우 전파간섭의 우려가 있습니다 .
KC (South Korea Community)
This device complies with the requirements of KN 61000-6-2 and KN 61000-6-4
concerning electromagnetic compatibility. The KC marking indicates compliance with
the above standards.
产品中有害物质的名称及含量
有害物质
部件名称 铅及其
化合物
汞及其
化合物
镉及其
化合物
六价铬及
其化合物
多溴联苯 多溴
二苯醚
(Pb) (Hg) (Cd) (Cr( Ⅵ)) (PBB) (PBDE)
机构部件 ×○○○○○
主体 光学部件 ×○○○○○
电气部件 ×○○○○○
附件 ×○○○○○
本表格依据 SJ/T 11364 的规定编制。
○：表示该有害物质在该部件所有均质材料中的含量均在 GB/T26572 规定的限量要求以下。
×：表示该有害物质至少在该部件的某一均质材料中的含量超出 GB/T26572 规定的限量要求。