Summary of Contents for Cygnus MINI ROV
- Page 1 Cygnus MINI ROV Mountable Topside Repeater Systems Operation Manual Accessories List Doc No. M4-CYGMINI-TSR-M-ENG_Iss 1 August 2014 (Mk4 Cygnus MINI ROV Gauges)
- Page 2 Cygnus MINI ROV Operation Manual M4-CYGMINI-TSR-M-ENG_Iss 1 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.
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Page 3: Table Of Contents
M4-CYGMINI-TSR-M-ENG_Iss 1 Cygnus MINI ROV Operation Manual 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) ............ - Page 4 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 .........
- Page 5 Recommended cable connection for direct cabling from Cygnus MINI ROV Gauge to surface computer ........63 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 ................
- Page 6 Cygnus MINI ROV Operation Manual M4-CYGMINI-TSR-M-ENG_Iss 1 Index ................66 Page 6 of 66...
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Page 7: Introduction
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. -
Page 8: Multiple Echo Measurements
Cygnus MINI ROV Operation Manual M4-CYGMINI-TSR-M-ENG_Iss 1 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,... -
Page 9: Cygnus Instruments
M4-CYGMINI-TSR-M-ENG_Iss 1 Cygnus MINI ROV Operation Manual 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. -
Page 10: Gauge Kit Contents
Cygnus MINI ROV Operation Manual M4-CYGMINI-TSR-M-ENG_Iss 1 2. Gauge Kit Contents 16/17 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. - Page 11 M4-CYGMINI-TSR-M-ENG_Iss 1 Cygnus MINI ROV Operation Manual 10 x ‘B/D’ O Rings 10 x ‘A’ O Rings Silicone Grease K3 RS-422/485 to RS-232 Converter RS-232 to USB Converter K3 Manual, Documents and Warranty Letter Probe Assembly, including: Spare Membranes and Membrane Key...
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Page 12: Top Side Repeater (Tsr) Remote Display Unit With Video On
Cygnus MINI ROV Operation Manual M4-CYGMINI-TSR-M-ENG_Iss 1 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. -
Page 13: Gauge Preparation
M4-CYGMINI-TSR-M-ENG_Iss 1 Cygnus MINI ROV Operation Manual 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. -
Page 14: Underwater Cable Connection To The Gauge
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: ... -
Page 15: Electrical Connections To The Gauge
M4-CYGMINI-TSR-M-ENG_Iss 1 Cygnus MINI ROV Operation Manual Cygnus MINI ROV Gauge Body Blanking Plug 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 &... -
Page 16: Electrical Connections To The Surface
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. -
Page 17: Measuring Through A Water Gap
M4-CYGMINI-TSR-M-ENG_Iss 1 Cygnus MINI ROV Operation Manual 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. -
Page 18: Displaying The Thickness Measurements
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. -
Page 19: Calibration
M4-CYGMINI-TSR-M-ENG_Iss 1 Cygnus MINI ROV Operation Manual 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. -
Page 20: Using The Tsr Remote Display Unit
M4-CYGMINI-TSR-M-ENG_Iss 1 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... -
Page 21: Calibrating To A Known Thickness Using A Tsr
M4-CYGMINI-TSR-M-ENG_Iss 1 Cygnus MINI ROV Operation Manual Calibrating to a Known Thickness using a TSR The TSR display can be calibrated to a known thickness by using the Gauge to measure a sample of the material that will be measured. This method ensures the velocity of sound is set for the actual material being measured rather than using a “generic”... -
Page 22: Connecting The Video Signal
Cygnus MINI ROV Operation Manual M4-CYGMINI-TSR-M-ENG_Iss 1 video recording of the survey. This provides a thickness measurement that can be linked to a position or place in the video. 28.10 5920 28.10 5920 Connecting the Video Signal The TSR has two BNC sockets on its top panel; Video In and Video Out. -
Page 23: Testing The Link
M4-CYGMINI-TSR-M-ENG_Iss 1 Cygnus MINI ROV Operation Manual 28.10 5920 Press the MENU key to display the MENU Press the DOWN ARROW key to scroll down to OSD X POS Press EDIT to adjust the X screen position Press EXIT to save and exit... -
Page 24: Cyglink Surface Display And Control Kit
2. CygLink Software Installer on USB Flash Drive You will also need an Umbilical cable and connectors to connect the Cygnus MINI ROV Gauge to the top side. Cygnus can supply the complete umbilical cable with connectors fitted, or the customer can make their own umbilical cable using connectors supplied with cable tails/flying leads. -
Page 25: Connection Diagram
See page 63 for wiring details. Installing CygLink CygLink is supplied on a USB Flash Drive or can be downloaded from a web link emailed from Cygnus Instruments. Installation of CygLink follows normal software installation conventions after running the setup.exe program and following instructions. -
Page 26: Com Port Numbers
Cygnus MINI ROV Operation Manual M4-CYGMINI-TSR-M-ENG_Iss 1 COM Port Numbers CygLink should automatically find the COM port number assigned to the USB converter when you click “connect” so you don’t need to search for the port number Windows has assigned. - Page 27 M4-CYGMINI-TSR-M-ENG_Iss 1 Cygnus MINI ROV Operation Manual easily remembered. You may change the number assigned to the port by following these steps: In Device Manager Each version of Windows has a slightly different procedure for opening Device Manager. The most direct route is to press and R keys together, type “devmgmt.msc”...
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Page 28: Running Cyglink Application
Cygnus MINI ROV Operation Manual M4-CYGMINI-TSR-M-ENG_Iss 1 On the “Advanced Settings” form you can change the COM Port number. Finish by clicking the “OK” button. Running CygLink Application Once installed, CygLink will place shortcuts in the start menu and on the desktop. -
Page 29: Connecting To The Cygnus Mini Rov Gauge
CygLink Main Screen with No Connection Connecting to the Cygnus MINI ROV Gauge To connect the software to the Cygnus MINI ROV Gauge, assuming the gauge is connected and turned on, from the top menu click Gauge then Connect to Gauge then ROV Gauge. -
Page 30: Changing Gauge Settings
Cygnus MINI ROV Operation Manual M4-CYGMINI-TSR-M-ENG_Iss 1 Changing Gauge Settings To change the gauge settings click Gauge -> Measurement Settings. You can change the Units and Velocity. Measurement Settings Screen Velocity Table You can select the Velocity of Sound from a table of common materials. -
Page 31: Calibrating To A Known Thickness Using Cyglink
M4-CYGMINI-TSR-M-ENG_Iss 1 Cygnus MINI ROV Operation Manual Calibrating to a Known Thickness using CygLink The CygLink display can be calibrated to a known thickness by using the Gauge to measure a sample of the material that will be measured. This method ensures the velocity of sound is set for the actual material being measured rather than using a “generic”... - Page 32 Cygnus MINI ROV Operation Manual M4-CYGMINI-TSR-M-ENG_Iss 1 Right side of CygLink main screen with a Survey Group with 4 Measurements You can Save, Open or create New Surveys from the File menu: Page 32 of 66...
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Page 33: Editing The Survey Details
M4-CYGMINI-TSR-M-ENG_Iss 1 Cygnus MINI ROV Operation Manual Editing the Survey Details The Survey contains all the Groups and is used to save all the data. You can also add details to the Survey itself, that will be printed at the beginning of the PDF report. -
Page 34: Producing A Survey Report Document
Cygnus MINI ROV Operation Manual M4-CYGMINI-TSR-M-ENG_Iss 1 Producing a Survey Report Document A PDF report can be produced containing all the Groups and thickness measurements in the Survey, grouped by each Survey Group. From the File menu select Create Survey Report PDF. -
Page 35: Logging Measurements Directly In Cyglink
M4-CYGMINI-TSR-M-ENG_Iss 1 Cygnus MINI ROV Operation Manual Logging Measurements Directly in CygLink You can use CygLink to log the displayed topside thickness measurements into a Survey so they can be presented in the Survey report. Clicking the Log button next to the thickness measurement. -
Page 36: Pre-Set Measurement Comments List
Cygnus MINI ROV Operation Manual M4-CYGMINI-TSR-M-ENG_Iss 1 The Reference Thickness is the thickness of metal when new. Any measurement recorded below the Minimum Thickness will be highlighted Red on the screen and in the survey report. Pre-Set Measurement Comments List You can add up to 8 short text comments, which can then be used to append to a thickness measurement. -
Page 37: Cyglink Trouble Shooting
The Serial to USB converter used for the Cygnus MINI ROV Gauge is manufactured by KK Systems and uses Prolific drivers. You can search the web for the latest drivers from Prolific (type the following into Google search: “KK SYSTEMS USB232”). -
Page 38: Wiring Problems
USB232 Windows Drivers. Wiring Problems Sometimes the cable between the Cygnus MINI ROV Gauge and the USB converter is damaged, or has been repaired incorrectly. Although there are only 2 data wires they must be connected the correct way around. -
Page 39: Probes & Membranes
The Gauge should only be used with Soft-Faced probes supplied by Cygnus Instruments Cygnus Soft-Faced probes are fitted with a Polyurethane Membrane which provides better contact on rough surfaces and protects the probe face from wear, prolonging the life of the probe. -
Page 40: Changing The Membrane
Cygnus MINI ROV Operation Manual M4-CYGMINI-TSR-M-ENG_Iss 1 Changing the Membrane Unscrew the Knurled Ring from the end of the Probe Use the Locking Ring Key to unscrew the Locking Ring from inside the Knurled Ring. The old membrane can then be removed... -
Page 41: Probe Selection & Specifications
M4-CYGMINI-TSR-M-ENG_Iss 1 Cygnus MINI ROV Operation Manual Probe Selection & Specifications Crystal Frequency Measurement Application Diameter Range 13 mm 2¼ MHz 3.0 – 250 mm This is the standard probe ½ inch 0.12 – 10 inch – suitable for most... -
Page 42: Mounting The Ultrasonic Probe
Cygnus MINI ROV Operation Manual M4-CYGMINI-TSR-M-ENG_Iss 1 Mounting the Ultrasonic Probe The Ultrasonic Probe is responsible for generating then transmitting and receiving the ultrasonic signal through the material being measured. To ensure the ultrasonic probe has the best chance of detecting the return echoes there are some basic... -
Page 43: O-Ring Seals
M4-CYGMINI-TSR-M-ENG_Iss 1 Cygnus MINI ROV Operation Manual 9. O-Ring Seals Correct fitting of O-ring seals There is one O-ring seal (‘A’) fitted to the nosecone and one O-ring seal (‘B’) fitted to the Gauge body. Gauge (Nosecone-End) O-ring Nosecone O-ring Location... -
Page 44: Removing The Nosecone
Cygnus MINI ROV Operation Manual M4-CYGMINI-TSR-M-ENG_Iss 1 Wrong Incorrect Location of Nosecone ‘A’ O-ring Only use the Torque Bar to undo the nosecone after each submersion. 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’... -
Page 45: Replacing The O-Ring Seals
M4-CYGMINI-TSR-M-ENG_Iss 1 Cygnus MINI ROV Operation Manual Replacing the O-Ring Seals Spare O-rings are included in the kit, the different O-rings are marked A and B. ‘A’ O-rings ‘B’ O-rings Silicone Grease (1 pack of 10) (1 pack of 10) 1. - Page 46 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 9 for contact details). Things to look for when inspecting the O-rings are: Any flats or signs of wear ...
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Page 47: General Points On Thickness Gauging
M4-CYGMINI-TSR-M-ENG_Iss 1 Cygnus MINI ROV Operation Manual 10. General Points on Thickness Gauging On very rough surfaces and especially if both sides are badly corroded, it is often necessary to move the Probe around to locate a back wall reflector. Sometimes a slight rocking movement can help find reflectors which are otherwise impossible. -
Page 48: Troubleshooting
Cygnus MINI ROV Operation Manual M4-CYGMINI-TSR-M-ENG_Iss 1 11. Troubleshooting Difficulty obtaining a Reading If there is 1 single flashing bar on the display – this means the Gauge is not receiving any echoes: Check that the Probe-lead is properly connected to both Probe and Gauge ... -
Page 49: The 3 Point Check
M4-CYGMINI-TSR-M-ENG_Iss 1 Cygnus MINI ROV Operation Manual 12. The 3 Point Check The most frequent reasons found to cause difficulty getting readings are: 1. Is the Probe-membrane fitted correctly? Check that there is a thin layer of oil between the membrane and Probe-face, and with no air-bubbles trapped. -
Page 50: Care And Servicing
Cygnus MINI ROV Operation Manual M4-CYGMINI-TSR-M-ENG_Iss 1 13. Care and Servicing Cleaning the Gauge After each submersion, and while the instrument is still assembled, wash the unit in fresh water and allow to dry To maintain the water-tight integrity of the assembly : the... -
Page 51: Environmental
Cygnus Instruments or by an Authorised Cygnus Service dealer Returning the Gauge for Servicing A full Manufacturer’s Factory Service is available from Cygnus Instruments. The Complete Kit should always be returned for Service or Repair, including all Probes and Leads. -
Page 52: Information
Cygnus MINI ROV Operation Manual M4-CYGMINI-TSR-M-ENG_Iss 1 14. Information Technical Specifications General Attributes Size Gauge Body dimensions, excluding cabling: Length 160mm x Diameter 62mm (6.3 x 2.4 in.) Probe Cable length: 1m (39.4 in.) Weight In Air With Remote Probe 550 grams (19.4 ounce) Power Supply External 7.5 to 30 V DC 150mA Supply... -
Page 53: Serial Data Format
, this section describes the arrangement of the data sent from the Gauge. Note the Cygnus MINI ROV Gauge has a fixed Velocity of Sound value of 6400 m/s, you must re-scale the received thickness value for the velocity of sound required. -
Page 54: Status-Byte Structure
Cygnus MINI ROV Operation Manual M4-CYGMINI-TSR-M-ENG_Iss 1 Status-byte Structure Name Details Gauge Type =1 (always) Resolution 1 = High Resolution 0 = Low resolution Units 0 = Metric mm 1 = Imperial Inch Reading Range 1 = High Range 0 = Low Range... -
Page 55: Interpreting The Readings Sent From The Gauge
M4-CYGMINI-TSR-M-ENG_Iss 1 Cygnus MINI ROV Operation Manual Interpreting the Readings sent from the Gauge Decimal Point Decimal Point position is implied from the position combination of Range, Resolution, and Units bits in the Status byte of each Reading [see table above]... -
Page 56: Table Of Sound Velocities
Cygnus MINI ROV Operation Manual M4-CYGMINI-TSR-M-ENG_Iss 1 16. Table of Sound Velocities Velocities will vary according to the precise grade and processing conditions of the material being measured. This table is included as a guide only. Wherever possible, the Gauge should always be calibrated on the material under test. -
Page 57: Reading Conversions
M4-CYGMINI-TSR-M-ENG_Iss 1 Cygnus MINI ROV Operation Manual Velocity of Sound (V) Conversion Material Factor (f) in/us F51 Duplex Steel 0.956 – 5715 - 5750 0.225 – 0.2264 UNS S31803 0.971 Core Ten Steel 5920 0.2331 1.00 EN12223 S355-J0 3320 0.1307 0.561... -
Page 58: Part Number & Accessories List
Cygnus MINI ROV Operation Manual M4-CYGMINI-TSR-M-ENG_Iss 1 17. Part Number & Accessories List Gauges Part No. Description 001-7144/4 MINI ROV 500m ROV UTG Kit with 2.25MHz 13mm Probe 001-9944/4 MINI ROV 500m UTG Kit, without Probe Surface/Topside Display Part No. Description... -
Page 59: Probe Spares And Membranes
M4-CYGMINI-TSR-M-ENG_Iss 1 Cygnus MINI ROV Operation Manual Probe Spares and Membranes Polyurethane Membranes are for normal use on surface temperatures up to 75°C. Teflon Membranes are for use on surface temperatures up to 150°C Part No. Description 001-3702 Pack of 20 Polyurethane Membranes for 6mm (¼”) Probes... -
Page 60: Knurled Rings
001-0432 Test Cable Impulse with DC Power for Mk3/4 ROV Gauges Electronic Bodies Only Part No. Description 001-7190/4 Cygnus MINI ROV Mountable UTG Gauge Body 001-7181/4 Cygnus Topside Repeater (Instrument Body) Miscellaneous Spares Part No. Description 001-4850 Steel Test Block 15 mm 001-4851 Steel Test Block 1/2"... - Page 61 ‘K3’ 003-0422 RS232 to USB Serial interface cable 001-3712 ‘O’ Ring Pack for Cygnus MINI ROV Mountable Gauge Kit contents: 20 x ‘O’-ring type A and 20 x ‘O’ Ring type B 001-4813-ROV Pelican Carry Case for Cygnus MINI ROV Gauge...
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Page 62: Recycling And Disposal (Ec Countries)
Cygnus MINI ROV Operation Manual M4-CYGMINI-TSR-M-ENG_Iss 1 18. Recycling and Disposal (EC Countries) The WEEE Directive (Waste Electrical and Electronic Equipment 2002/96.EC) has been put into place to ensure that products are recycled using best available treatment, recovery and recycling techniques to ensure human health and high environmental protection. -
Page 63: Independent Cable Connection
19. Independent Cable Connection Recommended cable connection for direct cabling from Cygnus MINI ROV Gauge to surface computer Cable-termination: for long cables it may help to fit a 120 Ω resistor, in series with a 1nF capacitor, between the TX+ and TX- connections inside the 9-way D-type plug. -
Page 64: Rov-Local Termination Connection
Cygnus MINI ROV Operation Manual M4-CYGMINI-TSR-M-ENG_Iss 1 20. ROV-Local Termination Connection Recommended cable connection from Cygnus MINI ROV Gauge to ROV craft Page 64 of 66... -
Page 65: Recommended Connection At Surface, Taken From Rov Cabling To Computer
ROV cabling to computer Alternatively - if you intend to convert the serial data sent from the Cygnus MINI ROV Gauge using your own electronics and/or software : the TX+ / TX- data-pair may be connected directly to any RS-422 compatible receiving equipment. - Page 66 Cygnus MINI ROV Operation Manual M4-CYGMINI-TSR-M-ENG_Iss 1 21. Index Accessories Replacing, 44 Cables and Leads, 60 Power Supply, 15 Electronic Bodies, 60 Probes Knurled Rings, 60 Knurled Ring, 40 Membrane Couplant, 60 Locking Ring Key, 40 Miscellaneous Spares, 60 Membrane Couplant, 40...
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