HydroFORM

Manual One-Axis Corrosion Scanner

User’s Manual

DMTA-20017-01EN — Rev. E
August 2016

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 © 2010, 2012, 2014, 2015, 2016 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: DMTA-20017-01EN

Rev. E
August 2016

Printed in Canada

All brands are trademarks or registered trademarks of their respective owners and third
party entities.
 DMTA-20017-01EN, Rev. E, August 2016

Table of Contents

Labels and Symbols ........................................................................................... 1

Important Information — Please Read Before Use ..................................... 5

Intended Use .......................................................................................................................... 5
Instruction Manual ................................................................................................................ 5
Instrument Compatibility ..................................................................................................... 6
Repair and Modification ....................................................................................................... 8
Presence of Visual Interferences .......................................................................................... 8
Safety Symbols ....................................................................................................................... 9
Safety Signal Words ............................................................................................................... 9
Note Signal Words ............................................................................................................... 10
Safety ..................................................................................................................................... 11
Warnings ............................................................................................................................... 11
CE (European Community) ............................................................................................... 12
WEEE Directive .................................................................................................................... 12
EMC Directive Compliance ................................................................................................ 12
Warranty Information ......................................................................................................... 12
Technical Support ................................................................................................................ 13

Introduction ...................................................................................................... 15

1. HydroFORM Scanner Overview and Setup ......................................... 17

1.1 Scanner Components ................................................................................................ 18
1.2 Wheels ........................................................................................................................ 19
1.2.1 Magnetic Wheel Safety .................................................................................. 19
1.2.2 Changing the Wheels .................................................................................... 20
1.3 Replacing the Foam Gasket on the Gasket Plate .................................................. 21

2. Scanner Operation ..................................................................................... 25

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DMTA-20017-01EN, Rev. E, August 2016

2.1 Single-Axis Mode ...................................................................................................... 25

2.2 Raster-Scan Mode ...................................................................................................... 29
2.2.1 Raster-Scan Mode Setup ................................................................................ 32
2.2.2 Inspection ........................................................................................................ 35
2.2.2.1 Positioning the Origin for a C-Scan .................................................. 36
2.2.2.2 Performing a Raster Scan ................................................................... 39
2.2.2.3 Positioning the HydroFORM Scanner at the Next 0,0 Position .... 40

3. Maintenance ................................................................................................ 43
3.1 Replacing the Probe .................................................................................................. 43
3.2 Setting Up the Mini-Wheel ...................................................................................... 45
3.3 Converting the Circulation System in the Probe Chamber ................................ 47
3.4 Cleaning the Unit ...................................................................................................... 52
3.5 Cleaning the Magnetic Wheels ............................................................................... 53

4. Specifications .............................................................................................. 55
4.1 HydroFORM Scanner Specifications ...................................................................... 55
4.2 Probe Specifications .................................................................................................. 56
4.3 Gasket Plate Specifications ...................................................................................... 56
4.4 Connector Reference ................................................................................................. 57

5. Spare Parts and Accessories ..................................................................... 59

5.1 HydroFORM Scanner Spare Parts .......................................................................... 59
5.2 HydroFORM Irrigation Kit ...................................................................................... 62
5.3 MapSCANNER HydroFORM Holder Accessory ................................................ 63
5.4 HydroFORM Lite Holder Accessory ..................................................................... 64

Appendix: ChainSCANNER Preparation ................................................... 67

A.1 Modifying the ChainSCANNER Translation Axis Arm ..................................... 67
A.2 Replacing the Umbilical Cable ................................................................................ 70
A.3 Installing the Umbilical Cable ................................................................................. 72

List of Figures ................................................................................................... 77

List of Tables ..................................................................................................... 79

Index ................................................................................................................... 81

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 DMTA-20017-01EN, Rev. E, August 2016

Labels and Symbols

Safety-related labels and symbols are attached to the HydroFORM scanner at the
locations shown in Figure i-1 on page 1 and Figure i-2 on page 2. If any labels or
symbols are missing or illegible, please contact Olympus. The descriptions of the
symbols are provided in Table 1 on page 2.

Label on the carriage

Label on the
Mini-Wheel encoder.
The encoder is
mounted inside the
Label on the encoder holder (see
probe holder “Setting Up the Mini-
Wheel” on page 45).

Figure i-1 Labels on the HydroFORM scanner

Labels and Symbols 1

DMTA-20017-01EN, Rev. E, August 2016

Model number
Encoder serial
number
Symbols

Figure i-2 Location of the rating label on the Mini-Wheel encoder

Table 1 Content of the rating labels

Probe holder
rating label

Carriage rating
label

2 Labels and Symbols

 DMTA-20017-01EN, Rev. E, August 2016

Table 1 Content of the rating labels (continued)

Mini-Wheel
encoder rating
label

Content

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.

The WEEE symbol indicates that the product must not be

disposed of as unsorted municipal waste, but should be
collected separately.

The direct current symbol.

S/N The serial number.

Labels and Symbols 3

DMTA-20017-01EN, Rev. E, August 2016

4 Labels and Symbols

 DMTA-20017-01EN, Rev. E, August 2016

Important Information — Please Read Before Use

Intended Use

The HydroFORM scanner is a single-axis encoded scanner designed for manual

corrosion inspection on flat surfaces and on pipes with an outside diameter of
four inches or larger.

WARNING
Do not use the HydroFORM 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.

Important Information — Please Read Before Use 5

DMTA-20017-01EN, Rev. E, August 2016

IMPORTANT
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 HydroFORM scanner is compatible with the Olympus ancillary equipment listed
in Table 2 on page 6 and Table 3 on page 8.

CAUTION
Always use equipment and accessories that meet Olympus specifications. Using
incompatible equipment could cause equipment malfunction and/or damage, or
human injury.

Table 2 Ancillary equipment

Part number Description
Kit for adapting the HydroFORM to the
U8775183
ChainSCANNER.
Two encoded axes ChainSCANNER for pipe OD up to
U8750041
38 in.
HydroFORM lite holder to mount the HydroFORM on
U8840177 GLIDER scanner using optional ADIX893 (U8775084)
yoke.
U8775084 Optional yoke for HYDROFORM-A-LITEHOLDER

6 Important Information — Please Read Before Use

 DMTA-20017-01EN, Rev. E, August 2016

Table 2 Ancillary equipment (continued)

Part number Description
Indexer clicker button kit.
Hand held clicker system with LEMO connector
compatible with the OmniScan MX2, SX, and FOCUS PX.
The assembly consists of a handle with one indexer
Q7500011 button as well as a configurable digital input button to
perform remote instrument operations such as Start/Stop
acquisition. The cable has a LEMO female connector
input to connect to a LEMO male connector from an
Olympus encoder or scanner. Cable length is 2.5 m.
U8780008 Electric water pump and tubing; 120 V and 220 V.
Foam-gasket spare part kit.
U8775184
Quantity: 100
Scanner interface adaptor to connect scanners encoder
U8775201 cables with DE-15 connector to OmniScan MX2, SX, and
FOCUS PX with LEMO connector scanner interface.
Scanner interface adaptor to connect scanners encoder
U8780329 cables with LEMO connector to OmniScan MX with
DE-15 connector scanner interface.
0.3 m long adaptor LEMO female to Bendix male linking
U8769010
LEMO encoder cable to FOCUS LT.
0.3 m long adaptor DE-15 female to Bendix male linking
U8767107
DE-15 encoder cable to FOCUS LT.
Many OmniScan and FOCUS instrument models can be
—
used.a

a. Encoder cable adaptor may be required (see Table 8 on page 57).

Important Information — Please Read Before Use 7

DMTA-20017-01EN, Rev. E, August 2016

Table 3 HydroFORM kits — compatibility

Scanner type
Compatibility
MapROVER MapSCANNER ChainSCANNER
Optimum fit HydroFORM-K-AUT HydroFORM-K-SAUT HydroFORM-K-
HydroFORM-K-AUT- ADPCHAIN
30m
Also HydroFORM-K- HydroFORM-K-Manual
compatiblea Manual + plastic wheels HydroFORM-K-
—
HydroFORM-K- ADPCHAIN
ADPCHAIN
a. These kits are fully compatible but include extra parts that are not required.

Repair and Modification

The HydroFORM does not contain any user-serviceable parts. Opening the
instrument might void the warranty.

CAUTION
In order to prevent human injury and/or equipment damage, do not disassemble,
modify, or attempt to repair the instrument.

Presence of Visual Interferences

IMPORTANT
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

8 Important Information — Please Read Before Use

 DMTA-20017-01EN, Rev. E, August 2016

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.

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 symbols might appear in the documentation of the instrument:

DANGER

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.

Important Information — Please Read Before Use 9

DMTA-20017-01EN, Rev. E, August 2016

WARNING

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.

CAUTION

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.

Note Signal Words

The following safety symbols could appear in the documentation of the instrument:

IMPORTANT

The IMPORTANT signal word calls attention to a note that provides important
information, or information essential to the completion of a task.

NOTE

The NOTE signal word calls attention to an operating procedure, practice, or the like,
which requires special attention. A note also denotes related parenthetical
information that is useful, but not imperative.

TIP

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
provides hints on how to effectively use the capabilities of the product.

10 Important Information — Please Read Before Use

 DMTA-20017-01EN, Rev. E, August 2016

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

WARNING

General Warnings
• Carefully read the instructions contained in this instruction manual prior to
turning on the instrument.
• 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.

Important Information — Please Read Before Use 11

DMTA-20017-01EN, Rev. E, August 2016

CE (European Community)

This device complies with the requirements of both directive

2004/108/EC concerning electromagnetic compatibility and directive
2006/95/EC concerning low voltage. The CE marking indicates
compliance with the above directives.

WEEE Directive

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.

EMC Directive Compliance

This equipment generates and uses radio-frequency energy and, if not installed and
used properly (that is, in strict accordance with the manufacturer’s instructions), may
cause interference. The HydroFORM has been tested and found to comply with the
limits for an industrial device in accordance with the specifications of the EMC
directive.

Warranty Information

Olympus guarantees your Olympus product to be free from defects in materials and
workmanship for a specific period, and in accordance with conditions specified in the
Olympus Scientific Solutions Americas Inc. Terms and Conditions available at
http://www.olympus-ims.com/en/terms/.

The Olympus warranty only covers equipment that has been used in a proper
manner, as described in this instruction manual, and that has not been subjected to
excessive abuse, attempted unauthorized repair, or modification.

12 Important Information — Please Read Before Use

 DMTA-20017-01EN, Rev. E, August 2016

Inspect materials thoroughly on receipt for evidence of external or internal damage

that might have occurred during shipment. Immediately notify the carrier making the
delivery of any damage, because the carrier is normally liable for damage during
shipment. Retain packing materials, waybills, and other shipping documentation
needed in order to file a damage claim. After notifying the carrier, contact Olympus
for assistance with the damage claim and equipment replacement, if necessary.

This instruction manual explains the proper operation of your Olympus product. The
information contained herein is intended solely as a teaching aid, and shall not be
used in any particular application without independent testing and/or verification by
the operator or the supervisor. Such independent verification of procedures becomes
increasingly important as the criticality of the application increases. For this reason,
Olympus makes no warranty, expressed or implied, that the techniques, examples, or
procedures described herein are consistent with industry standards, nor that they
meet the requirements of any particular application.

Olympus reserves the right to modify any product without incurring the
responsibility for modifying previously manufactured products.

Technical Support

Olympus is firmly committed to providing the highest level of customer service and
product support. If you experience any difficulties when using our product, or if it
fails to operate as described in the documentation, first consult the user’s manual, and
then, if you are still in need of assistance, contact our After-Sales Service. To locate the
nearest service center, visit the Service Centers page at: http://www.olympus-
ims.com.

Important Information — Please Read Before Use 13

DMTA-20017-01EN, Rev. E, August 2016

14 Important Information — Please Read Before Use

 DMTA-20017-01EN, Rev. E, August 2016

Introduction

This manual contains instructions on assembling, installing, and operating the

HydroFORM scanner (see Figure i-3 on page 15).

The HydroFORM scanner is a single-axis encoded scanner designed for manual

corrosion inspection on flat surfaces and on pipes with an outside diameter of
four inches or larger. It can also be mounted on a compatible Olympus scanner in
order to perform dual-axis encoded inspections using the optional adaptation parts:
the ChainSCANNER or MapSCANNER for semiautomated inspections, or the
MapROVER scanner for automated inspections.

The HydroFORM scanner is designed to perform inspection for the detection of wall-
thickness reductions due to corrosion, abrasion, and erosion. It also detects mid-wall
damage such as hydrogen-induced blistering or manufacturing-induced laminations,
and easily differentiates these anomalies from loss of wall thickness.

Figure i-3 The HydroFORM scanner

Introduction 15
DMTA-20017-01EN, Rev. E, August 2016

16 Introduction
 DMTA-20017-01EN, Rev. E, August 2016

1. HydroFORM Scanner Overview and Setup

This chapter provides an overview of the HydroFORM scanner and explains the
general setup of the HydroFORM scanner. These general setup items, which are valid
for both manual and semiautomated modes, apply particularly to the wheels and the
foam gaskets. The contents of a HydroFORM case are shown in Figure 1-1 on page 17.

Documentation

Spare gaskets

Carriage
Accessories

Cable

Figure 1-1 The contents within the HydroFORM case

HydroFORM Scanner Overview and Setup 17

DMTA-20017-01EN, Rev. E, August 2016

1.1 Scanner Components

The HydroFORM scanner is composed of a phased array probe, a carriage with four
wheels, a probe holder, a probe height adjustment knob, a water control valve, an
encoder, an encoder holder, a gasket plate, and consumable foam gaskets (see
Figure 1-2 on page 18 and Figure 1-3 on page 19).

Encoder holder
Phased array probe

Encoder
Probe height
adjustment knob
(on the side of the
Probe holder probe holder)

Carriage
Wheel (4)

Figure 1-2 The manual HydroFORM scanner components

18 Chapter 1
 DMTA-20017-01EN, Rev. E, August 2016

Gasket plate Consumable

foam gasket

Figure 1-3 Bottom view of scanner

1.2 Wheels

The HydroFORM scanner can be fitted with two types of wheels:

• Magnetic, for manual scanning (standard)

• Nonmagnetic (plastic), for semiautomated scanning with the ChainSCANNER
All HydroFORM kits are supplied with magnetic wheels. Non-magnetic (plastic)
wheels are only included with the HYDROFORM-K-ADPCHAIN and the
HYDROFORM-A-ADPCHAIN. When mounted on the ChainSCANNER, the
HydroFORM scanner can be used with a combination of both types of wheels.

1.2.1 Magnetic Wheel Safety

The magnetic attraction forces around magnetic wheels may pose certain safety risks,
depending on use and operating conditions.

HydroFORM Scanner Overview and Setup 19

DMTA-20017-01EN, Rev. E, August 2016

CAUTION
Magnetic-wheel versions of the HydroFORM present a risk of finger crushing if
fingers are placed under the wheels and placed onto a magnetic surface. The magnetic
force has a peak of 9286 Gauss or 0.9286 Tesla at the surface of the wheel. This field
quickly drops off to 274 Gauss or 0.0274 Tesla at a distance of 12 mm away from the
surface. The magnet does not present any navigational interference risk.

WARNING
The HydroFORM’s magnetic wheels can generate a magnetic field strong enough to
affect pacemakers, watches, and other sensitive electronic devices, and anyone
wearing or depending on such devices should keep a safe distance away from the
HydroFORM to avoid the risk of serious injuries or death. This magnetic field can also
demagnetize credit cards, magnetic ID (identification) badges, etc.

CAUTION
Sharp filings or other ferromagnetic objects can be attracted to the magnetic wheels,
which can cause equipment malfunction or injuries. It is important to keep the wheels
clean (see “Cleaning the Magnetic Wheels” on page 53).

1.2.2 Changing the Wheels

WARNING
To avoid injuries or equipment damage when handling magnetic wheels, take note of
the magnetic attraction forces around the wheels, and observe the safety notes
outlined in “Magnetic Wheel Safety” on page 19.

20 Chapter 1
 DMTA-20017-01EN, Rev. E, August 2016

To change the wheels

1. Remove the wheels that are installed on the scanner:
a) Hold the wheel being removed with one hand.
b) Remove the screw on the opposite end of the shaft with a hexagonal key (see
Figure 1-4 on page 21).

Figure 1-4 Changing the HydroFORM scanner wheels

c) Pull the wheel away from the shaft.

2. Install the new wheels on the scanner, and then reinstall the screws.

When installing wheels, always insert the non-threaded side toward the scanner
frame.

1.3 Replacing the Foam Gasket on the Gasket Plate

To obtain an adequate seal between the HydroFORM’s water chamber and the surface
being inspected, the scanner is equipped with a foam gasket with an abrasion-
resistant layer. The foam is a consumable item, and wears out over time with use. The
life expectancy of the foam gasket is dependent upon the inspected surface condition.

HydroFORM Scanner Overview and Setup 21

DMTA-20017-01EN, Rev. E, August 2016

The rougher the surface, the faster the foam gasket will wear out. The HydroFORM
comes with 100 foam gaskets included in the kit. The kit also includes four standard
gasket plates and one gasket plate for thick material. However, in order to reduce
downtime, the plates can be fitted in advance with new foam gaskets. These gaskets
can be quickly changed during the inspection if necessary (see Figure 1-5 on page 22).
For the gasket-plate specifications, see “Gasket Plate Specifications” on page 56.

Figure 1-5 Gasket plates for standard (right) and thick materials (left)

To replace a foam gasket

1. Loosen the four thumb screws located on the top of the probe holder (see
Figure 1-6 on page 22).

Probe holder

Gasket plate

Figure 1-6 Removing the thumb screws

2. Remove the gasket plate (see Figure 1-6 on page 22).

3. Use the scraper provided to remove the old foam and adhesive layer from the
gasket plate (see Figure 1-7 on page 23).

22 Chapter 1
 DMTA-20017-01EN, Rev. E, August 2016

Figure 1-7 Removing the old foam

Never perform this operation when the gasket plate is mounted on the HydroFORM
scanner, because doing so could damage the phased array probe.

4. If necessary, use a cloth to remove any adhesive residue remaining on the gasket
plate.
5. Peel the protective backing from the new foam adhesive pad (see Figure 1-8 on
page 23).

Figure 1-8 Peeling the protective backing from the adhesive strip

6. Install the new foam pad onto the gasket plate (see Figure 1-9 on page 24).

HydroFORM Scanner Overview and Setup 23

DMTA-20017-01EN, Rev. E, August 2016

Figure 1-9 New foam installed on the gasket plate

7. Place the gasket plate under the probe-holder assembly with the corners properly
aligned (see Figure 1-10 on page 24).

Align the corners.

Figure 1-10 Installing the gasket plate on the probe holder

The corner chamfers are not symmetrical to ensure that the gasket plate and the probe
holder match each other when installed in the correct orientation.

8. Tighten the four thumb screws.

9. Reinstall the probe-holder assembly into the carriage.

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 DMTA-20017-01EN, Rev. E, August 2016

2. Scanner Operation

The HydroFORM scanner can be operated as follows:

• By itself as a stand-alone unit in single-axis mode

• In conjunction with another scanner to perform semiautomated or automated
raster scanning using two encoded axes

2.1 Single-Axis Mode

In the single-axis scan configuration, the position is acquired using the encoder
integrated in the HydroFORM scanner. When mounted on the HydroFORM scanner,
the integrated encoder has a resolution of 8 steps/mm, and that value must be entered
into the instrument parameters under Scan > Encoder > Resolution for encoder #1.
The beam width is 61 mm (2.4 in.).

To obtain a more precise position, it is recommended that you calibrate the encoder in
the acquisition instrument before performing an inspection.

To merge multiple one-line scans together into one data file, the probe can be indexed
manually in the instrument software, or indexed using a clicker (Olympus
P/N: U8775015).

Scanner Operation 25
DMTA-20017-01EN, Rev. E, August 2016

To prepare the system for single-axis mode

 To perform a manual, encoded one-line scan, connect the Mini-Wheel encoder
cable to the LEMO 6-pin encoder cable extension, and then connect the LEMO
16-pin connector to the instrument (see Figure 2-1 on page 26).

Instrument-side Scanner-side
LEMO 16-pin LEMO 6-pin connector
connector

Figure 2-1 The encoder cable extension

The following procedure should be carried out with the scanner positioned on the
surface being inspected.

Before using the HydroFORM scanner, ensure that the probe is correctly installed.
Element number 1 must be adequately positioned for the C-scan. The first and the last
element numbers are engraved on the top of the probe (see Figure 2-2 on page 27). For
the probe replacement procedure, see “Maintenance” on page 43.

26 Chapter 2
 DMTA-20017-01EN, Rev. E, August 2016

Element number 1 Element number 64

Figure 2-2 The probe element numbers

To adjust the probe holder height and fill the water chamber
1. Place the HydroFORM scanner on top of the pipe.
2. Loosen the probe height adjustment knob.
3. Open the water control valve (see Figure 2-3 on page 27).

Water control valve

Probe height
adjustment knob

Figure 2-3 The water control valve

Scanner Operation 27
DMTA-20017-01EN, Rev. E, August 2016

4. Apply slight pressure to the probe holder.

You should be able to hear the bubbles exiting.
5. Tighten the probe height adjustment knob.
6. To help clear the remaining bubbles, move the HydroFORM scanner back and
forth over the pipe.
7. Make sure that the S-scan signal is free of bubbles (see Figure 2-4 on page 28).

Figure 2-4 The S-scan display

If the flow is too high, turbulence could occur, which would compromise the signal
integrity.

• To achieve the desired results, you may need to repeat the above procedure until
the signal is good.
• After each attempt, lift the HydroFORM scanner and empty the water chamber.
• Bubbles may form on the surface of the probe. To remove any bubbles, wipe the
active area of the probe with your finger.

28 Chapter 2
 DMTA-20017-01EN, Rev. E, August 2016

• Removing bubbles is easier when the encoder module is further down (on the low
side), because the evacuation holes are positioned on the opposite side.
• After initially flooding the water chamber and clearing the bubbles, reduce the
water supply to a light flow during scanning.
The surface condition of the pipe determines how much water is required.
The best results and fastest scan speed are achieved using an electric pump
providing constant pressure.

8. Move the scanner back to the origin (0,0) prior to starting the acquisition.

2.2 Raster-Scan Mode

The HydroFORM scanner can be used in conjunction with scanners that have two
encoded axes to perform raster scans for corrosion monitoring (see Figure 2-5 on
page 29, Figure 2-6 on page 30, and Figure 2-7 on page 30). Such a combination is well
suited for rapid inspection of medium- to large-surfaces using 2-axis encoded data
acquisition.

Figure 2-5 The MapROVER scanner

Scanner Operation 29
DMTA-20017-01EN, Rev. E, August 2016

Figure 2-6 The MapSCANNER

Figure 2-7 The ChainSCANNER

For automated corrosion inspection, Olympus recommends the MapROVER scanner.

For semiautomated inspection, the MapSCANNER or the ChainSCANNER are
recommended. The ChainSCANNER is used as an example in the manual sections
that follow. However, similar manipulations apply to the MapSCANNER and the
MapROVER scanners.

To use the HydroFORM scanner in the 2-axis semiautomated mode, the Olympus
ChainSCANNER (CHAINSCAN-XY38) or a similar model with XY capability is
required. The HydroFORM adaptation kit includes all of the hardware required to
adapt the instrument to a standard Olympus ChainSCANNER (see Figure 2-8 on
page 31). Those parts are included in the HydroFORM-K-ADPCHAIN package, and
can also be bought separately by ordering the HydroFORM-A-ADPCHAIN.

30 Chapter 2
 DMTA-20017-01EN, Rev. E, August 2016

The adaptation kit includes:

• A crank handle
• An encoder junction with LEMO 6-pin connector (see Figure 2-9 on page 32)
• A spring-loaded arm
• Four plastic wheels
• Necessary parts enabling the ChainSCANNER to inspect flat surfaces

Probe-holder bar Plastic wheels

mount for flat
surfaces

Reversed spring-
loaded arm

Crank handle
Brake system for
flat surface

Figure 2-8 The adaptation kit parts

Scanner Operation 31
DMTA-20017-01EN, Rev. E, August 2016

Figure 2-9 The encoder junction

2.2.1 Raster-Scan Mode Setup

This section explains how to connect the HydroFORM scanner to the
ChainSCANNER.

To connect the HydroFORM scanner to the ChainSCANNER

1. Consult the ChainSCANNER User’s Manual to determine the required number of
short links and long links needed for the diameter of the pipe to be inspected, and
then connect the links following the instructions in the manual.
2. Ensure that the adjustment screw is set so that when the scanner is clamped to the
pipe, it fits closely and does not move freely.
3. Make sure that you use a small link equipped with dovetails to secure the
umbilical strain relief (see Figure 2-10 on page 33). For installation with umbilical
strain relief, see “Installing the Umbilical Cable” on page 72.

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Small link equipped with dovetails

Strain relief

Figure 2-10 The umbilical strain relief

4. Install the HydroFORM scanner on the index arm as shown in Figure 2-11 on
page 34. The probe height adjustment knob should be on the far side of the
ChainSCANNER.

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DMTA-20017-01EN, Rev. E, August 2016

Index axis

Scan axis
Probe height
adjustment knob

64 1

Probe element numbers

Figure 2-11 The HydroFORM scanner installed on the index arm

• Olympus recommends that you install the probe so that element 1 is closest to the
ChainSCANNER. To change the probe orientation, see “Replacing the Probe” on
page 43.
• The umbilical cable should be set up with some slack to provide a full range of
motion on the index arm.

The HydroFORM scanner assembly is attached to the ChainSCANNER using a

spring-loaded arm with three possible positions (see Figure 2-12 on page 35):

• Locked-up (to release pressure on the HydroFORM and help manipulations)

• Down (ready for lock-up)
• Free moving

You must pull and turn the latch knob to pass from one position to another.

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Spring-loaded
arm and latch
knob

Figure 2-12 The spring-loaded arm

When acquiring data, the spring-loaded arm should be in the free-moving position.

Acquiring data while the arm is in a locked-up position results in poor data quality.

2.2.2 Inspection
To perform an inspection and retain a proper reference position for the part, special
actions must be carried out beforehand to ensure that there are no remaining
uninspected areas.

The general procedure below describes the steps to perform an inspection. Several of
the steps in this general procedure are subprocedures, all of which are referenced
herein and described in the subsections to this section.

Scanner Operation 35
DMTA-20017-01EN, Rev. E, August 2016

To perform an inspection
1. Position the origin for a C-scan.
For more information, see “Positioning the Origin for a C-Scan” on page 36.
2. Perform a raster scan.
For more information, see “Performing a Raster Scan” on page 39.
3. Position the HydroFORM scanner at the next 0,0 position, at a distance of 305 mm
(12 in.) from the current 0,0 position.
For more information, see “Positioning the HydroFORM Scanner at the Next 0,0
Position” on page 40.
4. Repeat steps 2 and 3 above as many times as required, until the inspection on the
pipe has been completed.

2.2.2.1 Positioning the Origin for a C-Scan

For multiple acquisitions, the ChainSCANNER must be repositioned every 305 mm
(12 in.). The magnetic template is used to set the origin (0,0), and to maintain the
correct reference position between successive scanner positionings (every 305 mm
[12 in.]).

Using the default aperture of four elements positions the origin (0,0) [focal law 1]
2 mm away from the first-element position line when using a standard probe with
1 mm pitch (see Figure 2-13 on page 37).

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0,0

Figure 2-13 The origin on the probe

To position the origin for a C-scan

1. Connect the LEMO encoder cable extension to the back of the ChainSCANNER
module, and then connect the connector to the instrument.
2. Identify the location of the origin on the surface to be inspected (see Figure 2-14
on page 37).

0,0

Probe height adjustment knob

Figure 2-14 The origin (0,0) on the surface

Scanner Operation 37
DMTA-20017-01EN, Rev. E, August 2016

3. Place the center of the magnetic template cross on the location of the origin (see
Figure 2-15 on page 38).

Figure 2-15 The center of the template cross

4. Using a pen, mark the positive directions from the origin (see Figure 2-16 on
page 38).

Template cross

Figure 2-16 Marking the positive directions

5. Move the ChainSCANNER over the magnetic template until the HydroFORM
scanner is approximately aligned with the template marks (see Figure 2-17 on
page 39), and then latch the ChainSCANNER onto the pipe.
6. If you have not already done so, raise the probe holder in the carriage using the
probe height adjustment knob until the gasket is just off the surface.
7. Using the ChainSCANNER, move the HydroFORM scanner again, until it is
precisely aligned with the template marks (see Figure 2-17 on page 39).

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Figure 2-17 Aligning the HydroFORM scanner with the template marks

8. Reset the encoders on the instrument to 0,0.

9. Move the HydroFORM scanner, and then remove the template.
10. Return the HydroFORM scanner back to the origin (0,0) using the instrument
encoder reading.
11. Adjust the probe-holder height and fill the water chamber (see “To adjust the
probe holder height and fill the water chamber” on page 27.

2.2.2.2 Performing a Raster Scan

Before performing a raster scan, the water chamber must be filled properly (see
“Single-Axis Mode” on page 25), and the HydroFORM scanner must have been
located at the origin (0,0) [see “Positioning the Origin for a C-Scan” on page 36].

Scanner Operation 39
DMTA-20017-01EN, Rev. E, August 2016

To perform a raster scan

1. Start the acquisition on the instrument.

Before acquiring data, make sure the spring-loaded arm of the HydroFORM scanner
is in the free-moving position.

2. Rotate the scanner around the pipe for a complete cycle. Look at the data to make
sure that it is in the proper direction and that there is no lost data.
3. With the crank handle, index the Y-position until the Y-axis position increases by
61 mm (2.4 in.) minus the required overlap after a complete rotation.
4. Scan around the pipe in the opposite direction. Rotate the scanner around the
pipe for a complete cycle.
5. Repeat steps 2 to 4, until the y-axis position on the scanner has covered the entire
length of 305 mm (12 in.) on the index arm of the ChainSCANNER.
6. If another raster scan has to be done, the end position of the current scan has to be
marked, and then the scanner must be moved to the next position (see
“Positioning the HydroFORM Scanner at the Next 0,0 Position” on page 40)

2.2.2.3 Positioning the HydroFORM Scanner at the Next 0,0 Position

Once the scanner has covered the entire length of 305 mm (12 in.) on the index arm of
the ChainSCANNER, the HydroFORM must be relocated to the next 0,0 position.

To position the HydroFORM scanner at the next 0,0 position

1. Using the probe height adjustment knob, raise the probe holder in the carriage
until the gasket is just off the surface.
2. Place the template under the HydroFORM scanner, making sure that it is aligned
correctly. (The template must be correctly positioned before the HydroFORM
begins moving. See Figure 2-18 on page 41.)

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Figure 2-18 Template under the HydroFORM and correctly aligned

3. Return the HydroFORM scanner to 0,0 using the instrument encoder reading.
4. Using a pen, mark the center of the template cross.
This marking represents the ending position of your last scan (see Figure 2-19 on
page 41).

Template cross

Figure 2-19 Marking the positive directions

Scanner Operation 41
DMTA-20017-01EN, Rev. E, August 2016

5. Remove the template, and then make a mark 61 mm (2.4 in.) away from the
inspected area in the longitudinal axis. This will be the next 0,0 position.
6. Unlatch the ChainSCANNER.
7. Place the template so that the new mark is positioned in the center of the cross.
8. Perform steps 5 to 11 of procedure “To position the origin for a C-scan” on
page 37 to relocate the HydroFORM scanner to the next origin (0,0) position.
9. Repeat steps 2 and 3 of the procedure in “Inspection” on page 35, as many times
as required, until the inspection on the pipe has been completed.

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3. Maintenance

This chapter provides information about HydroFORM scanner maintenance.

3.1 Replacing the Probe

Use the following procedure to replace or reposition the probe.

To replace the probe

1. Remove the four screws that secure the probe to the probe holder (see Figure 3-1
on page 43).

Figure 3-1 The probe retaining screws

2. Lift the probe using a flat screw driver (see Figure 3-2 on page 44 and Figure 3-3
on page 44).

Maintenance 43
DMTA-20017-01EN, Rev. E, August 2016

DO NOT pull on the probe cable. Doing so could damage the phased array probe.

Figure 3-2 Lifting the probe

Figure 3-3 The probe removed

3. Perform this procedure in the reverse order to replace or reposition the probe in
the probe holder.

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When the probe is being replaced, it is important to re-install the gasket

underneath the probe top lip.

Use isopropyl alcohol and a soft cloth to clean the surface of the probe.

3.2 Setting Up the Mini-Wheel

The Mini-Wheel encoder traction can be optimized by lifting or lowering the Mini-
Wheel from/onto the drive wheel.

To adjust the Mini-Wheel compression

1. Turn the adjustment screw clockwise to prevent the wheel of the Mini-Wheel
encoder from slipping (see Figure 3-4 on page 45).

Figure 3-4 The Mini-Wheel compression adjustment screw

2. If the HydroFORM scanner wheels are difficult to rotate, turn the adjustment
screw counterclockwise.
3. Verify that the Mini-Wheel encoder does not slip after the above adjustment is
made. To proceed, apply slight pressure on the Mini-Wheel with one finger while

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DMTA-20017-01EN, Rev. E, August 2016

trying to turn the HydroFORM scanner wheel. The scanner wheel and the
encoder wheel should turn in tandem (see Figure 3-5 on page 46).

Lightly hold the Mini-

Wheel with a finger.
Drive wheel

Mini-Wheel

Figure 3-5 Testing the Mini-Wheel compression adjustment

You must redo the encoder calibration in the acquisition instrument each time you
adjust the Mini-Wheel compression. If the compression is set too high, the Mini-
Wheel bearings can wear out prematurely.

To remove the Mini-Wheel

1. Remove the two screws at the top of the encoder (see Figure 3-6 on page 47).

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Screw

Screw

Key

Figure 3-6 Removing the screws

2. Remove the two screws that secure the key to the Mini-Wheel (see Figure 3-6 on
page 47 and Figure 3-7 on page 47).

Key

Figure 3-7 The Mini-Wheel removed

3.3 Converting the Circulation System in the Probe Chamber

The water chamber can be converted so that passages that are normally blocked off
are opened to allow for fluid circulation in the probe chamber. The fluid circulation
around the probe can be used to cool or warm the probe during inspection under
extreme conditions.

To convert the circulation system in the probe chamber

1. Pull the probe holder out of the HydroFORM carriage (see Figure 3-8 on page 48).

Maintenance 47
DMTA-20017-01EN, Rev. E, August 2016

Figure 3-8 Probe holder removed

2. Remove the gasket plate by loosening the 4 thumb screws on the opposite end of
the probe holder (see Figure 3-9 on page 48).

Figure 3-9 Removing the gasket plate

3. Remove the 6 screws on the inner plate (see Figure 3-10 on page 49).

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Figure 3-10 Removing the screws on the inner plate

4. Carefully pull away the inner plate, and then remove the inner gasket, taking care
not to tear the gasket (see Figure 3-11 on page 49).

Figure 3-11 Inner plate and gasket removed

5. Remove the two set screws using a 1.5 mm Allen key (see Figure 3-12 on page 50).
This opens the water passages so that the fluid can circulate around the probe.

Maintenance 49
DMTA-20017-01EN, Rev. E, August 2016

Figure 3-12 Removing the set screws to open the water passages

6. Loosen the two screws on the side plate just enough to free the plate from the
main body (see Figure 3-13 on page 50), while leaving the O-rings around the
circumference of the screws.

Figure 3-13 Loosening the screws on the side plate

7. Remove the side plate, leaving the screws and O-rings attached (see Figure 3-14
on page 51).

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Figure 3-14 The side plate removed

8. Reverse the orientation of the side plate, and then reinstall it (see Figure 3-15 on
page 51).
The small round gaskets align with the small holes, blocking the standard water
exit.

Slot is reversed.

Figure 3-15 The side plate reinstalled

9. Replace all remaining components in the reverse order, except for the set screws,
which should be set aside for later use.

Maintenance 51
DMTA-20017-01EN, Rev. E, August 2016

Make sure the bottom plates are correctly oriented. The corner chamfers are not
symmetrical to ensure that the gasket plate and the probe holder match each other
when installed in the correct orientation (see Figure 3-16 on page 52).

The water now exits

from this hole.

Figure 3-16 The plates correctly aligned (chamfers match)

To clear the water circulation holes, use a thin metal wire or compressed air.

3.4 Cleaning the Unit

The HydroFORM external surfaces can be cleaned when needed. This section
provides the procedure for the appropriate cleaning of the product.

To clean the unit

1. Ensure the unit is turned off by removing the source of power.
2. Disconnect all cables.

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3. To bring the instrument back to its original finish, clean the housing with a soft
cloth.
4. To remove persistent stains, use a damp cloth with a soft, soapy solution. Do not
use abrasive products or powerful solvents that could damage the finish.
5. Wait until the instrument dries completely before connecting the cables.

To clear the water circulation holes, use a thin metal wire or compressed air.

3.5 Cleaning the Magnetic Wheels

The magnetic wheels can attract sharp filings or other ferromagnetic objects. The
wheels need periodic cleaning to avoid accumulation of any foreign objects that can
cause injuries or equipment malfunction. The cleaning frequency depends on your
operating conditions.

Required materials:

• Work gloves
• Clean cloth

WARNING
To avoid injuries or equipment damage when handling magnetic wheels, take note of
the magnetic attraction forces around the wheels, and observe the safety notes
outlined in “Magnetic Wheel Safety” on page 19.

To clean the magnetic wheels

1. Put on your work gloves.
2. While turning the wheel, hold the clean cloth against it to remove particles.
3. Repeat the above step for each wheel.

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4. Specifications

This chapter lists the HydroFORM scanner and probe specifications. For the
ChainSCANNER specifications, refer to the ChainSCANNER User’s Manual.

4.1 HydroFORM Scanner Specifications

Table 4 on page 55 lists the system specifications.

Table 4 System specifications

Parameter Value
Scan speed 100 mm/s (4 in./s)
Effective beam width 61 mm (2.4 in.)
Acquisition resolution 1 mm × 1 mm
Encoder resolution (manual) 8 steps/mm
Coverage (index direction) with
300 mm
ChainSCANNER
Vertical clearance (with
100 mm (4 in.)
ChainSCANNER)
Maximum surface temperature 90 °C (194 °F)
Encoder voltage 5V
Encoder current 25 mA maximum
0–1.5 kHz (maximum displacement velocity
Encoder frequency
of 100 mm/s [4 in./s])

Table 5 on page 56 lists the operating environment specifications.

Specifications 55
DMTA-20017-01EN, Rev. E, August 2016

Table 5 Operating environment specifications

Parameter Value
Operating temperature 5 °C to 50 °C (41 °F to 122 °F)
Storage temperature ‒30 °C to 60 °C (‒22 °F to 140 °F)
Relative humidity (RH) Max. 85 % RH noncondensing
Wet location Yes
Altitude Up to 2000 m
Outdoor use Yes
Pollution level 1
IP rating Waterproof (designed to meet IP65)

4.2 Probe Specifications

Table 6 on page 56 lists the probe specifications.

Table 6 Probe specifications

Parameter Value
Olympus number 7.5L64-64X7-I4-P-7.5-OM
Part number U8330955
Frequency 7.5 MHz
Number of elements 64
Pitch 1.0 mm
Elevation 7 mm
Cable length 7.5 m
Connector type OmniScan

4.3 Gasket Plate Specifications

Table 7 on page 57 lists the minimum surface diameters and the maximum water
column for each gasket plate model.

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 DMTA-20017-01EN, Rev. E, August 2016

Table 7 Gasket plate specifications

Gasket Position of repeat
Minimum surface Minimum surface Maximum
plate interface echo
OD ID water columna
model (in steel)
Short 100 mm (4 in.) 406 mm (16 in.) 14 mm (0.55 in.) 70 mm (2.76 in.)
Tall 305 mm (12 in.) 254 mm (10 in.) 24 mm (0.95 in.) 125 mm (4.92 in.)

a. The water column varies according to the pressure applied on the foam gasket. High pres-
sure and low surface OD will result in a shorter water column.

4.4 Connector Reference

HydroFORM scanners sold after July 2013 come standard with the LEMO connector
which is compatible with the OmniScan MX2 and SX instruments. For use with a
different instrument, an optional adaptor is required (see Table 8 on page 57).

Table 8 Required encoder cable adaptor

Instrument
Scanner
connector OmniScan MX2, TomoScan
OmniScan MX
SX, and FOCUS PX FOCUS LT
LEMO (from July
P/N: U8780329 — P/N: U8769010
2013 onward)
DE15 (Prior to
— P/N: U8775201 P/N: U8767107
July 2013)

Figure 4-1 on page 58 contains the pinout for the LEMO connector used on the
OmniScan MX2 and SX models.

Specifications 57
DMTA-20017-01EN, Rev. E, August 2016

+5 V Red +5 V
GND White Pair 1 GND
PHA-1 Brown PHB-1
PHB-1 White Pair 2 PHA-1
PHB-2 Black PHA-2
PHA-2 White Pair 3 PHB-2
Shield & drain wire
Case Case

Figure 4-1 LEMO connector pinout diagram for EWIX1413 cable

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5. Spare Parts and Accessories

This chapter provides information about the spare parts kits and accessories that are
available for the HydroFORM scanner.

5.1 HydroFORM Scanner Spare Parts

An exploded view and a list of spare parts and spare part kits for the HydroFORM
scanner are provided in Figure 5-1 on page 60 and Table 9 on page 61.

Some of the parts of the HydroFORM scanner or included in its spare part kits can
also be ordered individually. For more information, see “HydroFORM Irrigation Kit”
on page 62 and “HydroFORM Irrigation Kit” on page 62.

Spare Parts and Accessories 59

DMTA-20017-01EN, Rev. E, August 2016

Probe not shown.

For information on probe
specifications see Table 6
on page 56.

Probe holder frame

(item 14) shown
upside-down here to
reveal the screws
(item 9) underneath.

Figure 5-1 Exploded view of the HydroFORM scanner

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Table 9 HydroFORM scanner spare parts

Drawing
Qtya Part number Description
number
1 4 U8775189 One urethane wheel for Rotix pipe
scanner
One magnetic wheel for the
U8779383
HydroFORM or ChainSCANNER
2 4 Q8300533 Bearing ID-6 mm OD-13 mm W-5 mm
rubber seal
3 4 Q8300536 Spacer ID-6 mm OD-8 mm W-.25 mm
4 4 Q8300538 Spacer ID-6 mm OD-10 mm W-0.9 mm
stainless steel
5 4 Q8300534 External retaining ring 7/32
6 2 Q8300051 Wheel shaft
7 1 Q8300889 Slotted buggy frame
8 1 Q8300888 Pulley
9 8 U8908545 M3 × 3 mm hex stainless steel screw set
10 1 U8779680 Encoder support box kit without
encoder
U8775219 Encoder and support box kit
11 4 Q8300878 M2.5 × 3 mm hex stainless steel screw
set
12 2 Q8300876 M4 × 8 mm Phillips flathead stainless
steel
13 1 Q8300884 Strain relief plate
14 1 Q8300210 Probe holder frame
15 1 U8830328 Height adjustment knob kit
16 1 U8830324 1/16 in. probe gasket
17 2 U8902678 1/8. in. tube to 10-32 brass barb fitting
18 4 Q8300207 Flat washer M4 O.D. 12 mm
19 4 Q8300208 Fixture knob kit
20 4 Q8300877 Stainless steel head screw M4 × 10 mm
button
21 8 U8906398 M3 × 8 mm Phillips flathead stainless
steel screw

Spare Parts and Accessories 61

DMTA-20017-01EN, Rev. E, August 2016

Table 9 HydroFORM scanner spare parts (continued)

Drawing
Qtya Part number Description
number
22 1 Q8300886 Water diverter
23 2 Q8300875 Black o-ring
24 2 Q8300887 Gasket
25 1 U8779670 Frame gasket
26 1 Q8300885 Water distribution plate
27 1 U8830418 Gasket plate
28 100 U8775184 Kit of 100 foam gaskets, 1/4 in. spare
part
— 1 U8330955 Phased array probe (7.5L64-64X7-I4-P-
7.5-OM)
See Table 6 on page 56 for probe
specifications.
— — HydroFORM buggy including frame
and magnetic wheels only.
U8775325
Important note: Does not include
encoder, water column, or PA probe.
— 1 Q8300206 HydroFORM irrigation kit
(See “HydroFORM Irrigation Kit” on
page 62.)
— 1 U8775306 6.5 m long encoder cable with LEMO
connector compatible with the
OmniScan MX2, SX and the FOCUS PX

a. This number represents the typical quantity initially included with your scanner
package.

5.2 HydroFORM Irrigation Kit

An exploded view and a list of spare parts for the HydroFORM scanner’s irrigation
kit (Q8300206) are provided in Figure 5-2 on page 63 and Table 10 on page 63.

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1 1

3 1

Figure 5-2 Exploded view of the irrigation kit (Q8300206)

Table 10 Irrigation kit (Q8300206) spare parts

Drawing Part
Description
number number
1 U8902320 Plastic tubing
2 U8902321 Y barb fitting PR PU-4
3 U8908626 Valve QH-QS-6
4 U8902319 Push-in reducing QS-8-6

5.3 MapSCANNER HydroFORM Holder Accessory

To use the HydroFORM with the MapSCANNER, a specifically designed holder

needs to be used (see Figure 5-3 on page 64). This holder (P/N: Q7750091) is a
standard inclusion of the HydroFORM-K-SAUT package.

Spare Parts and Accessories 63

DMTA-20017-01EN, Rev. E, August 2016

Figure 5-3 HydroFORM holder for use on MapSCANNER

5.4 HydroFORM Lite Holder Accessory

The HydroFORM Lite holder is an optional holder that can replace the standard
carriage (see Figure 5-4 on page 65). The HydroFORM Lite holder has a smaller form
factor and is lighter in order to help integration to some scanners, such as the
GLIDER. The HydroFORM Lite holder uses carbides sliders instead of wheels. To
mount the HydroFORM lite to the GLIDER Scanner, an optional yoke is also required
(P/N: U8775084).

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Figure 5-4 The HydroFORM Lite holder

Spare Parts and Accessories 65

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Appendix: ChainSCANNER Preparation

This section explains how to prepare the ChainSCANNER for corrosion inspection
with the HydroFORM scanner. The HydroFORM adaptation kit includes all of the
hardware required to adapt the instrument to a standard Olympus ChainSCANNER
The necessary parts are included in the HydroFORM-K-ADPCHAIN package (see
Figure A-15 on page 75) and can also be bought separately by ordering the
HydroFORM-A-ADPCHAIN.

A.1 Modifying the ChainSCANNER Translation Axis Arm

The ChainSCANNER translation axis arm must be modified by adding the handle
included in the adaptation kit into place on the end of the large knob assembly.

To modify the ChainSCANNER translation axis arm

1. Remove and discard the slide assembly located at the end of the translation axis
arm of the ChainSCANNER (see Figure A-1 on page 68).

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DMTA-20017-01EN, Rev. E, August 2016

Figure A-1 Removing the end slide assembly

2. Loosen the two screws on the large knob assembly (see Figure A-2 on page 68),
and then move the mechanism to the end of the arm.

Figure A-2 Loosening the screws of the large knob assembly

3. Precisely align the large knob assembly with the tip of the translation arm and
lead screw (see Figure A-3 on page 69), and then tighten the two screws (see
Figure A-4 on page 69).

68 Appendix
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Ensure that the lead screw is aligned with the end of the translation arm. Otherwise,
you will need to align the Y-axis encoder assembly with the end of the lead screw in
order to carry out this step.

Aligning arm and lead screw Correct

Incorrect Incorrect

Figure A-3 Aligning the arm with the lead screw

Figure A-4 Tightening the screws of the large knob assembly

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4. Install and screw the handle included in the adaptation kit into place on the end
of the large knob assembly (see Figure A-5 on page 70).

Figure A-5 Installing the handle on the large knob assembly

A.2 Replacing the Umbilical Cable

The original LEMO 6-pin cable and encoder junction must be replaced with the
supplied encoder LEMO 16-pin connector and junction equipped with an integrated
LEMO connector.

The supplied umbilical cable is equipped with an integrated LEMO connector,

allowing for quick connection of the two-axis ChainSCANNER to the integrated
single-axis Mini-Wheel encoder.

To replace the umbilical cable

1. Remove the cover from the main ChainSCANNER module (see Figure A-6 on
page 71).

70 Appendix
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Figure A-6 Removing the cover from the main module

2. Pull on the connector (see Figure A-7 on page 71) to disconnect the Y-axis encoder
from the encoder junction.

Figure A-7 Disconnecting the Y-axis encoder module

3. Turn the main module upside down, and then loosen the knob (see Figure A-8 on
page 72) to release the encoder junction.

You do not need to completely remove the knob.

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DMTA-20017-01EN, Rev. E, August 2016

Figure A-8 Loosening the knob that secures the encoder junction

4. Remove and store the original encoder junction, and then install the supplied
encoder junction equipped with an integrated LEMO connector (see Figure A-9
on page 72).

Figure A-9 Installing the encoder junction with its integrated LEMO connector

5. Reinstall the plastic cover for the main module, which was removed in step 1.

A.3 Installing the Umbilical Cable

The umbilical cable must be assembled and installed on the ChainSCANNER.

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To install the umbilical cable

1. Slide the annular part of the strain relief over the cable sheath, as shown in
Figure A-10 on page 73.

Figure A-10 Sliding annular part of the relief connector over the cable sheath

2. Split the cable sheath over a short portion (see Figure A-11 on page 73).
3. Insert the threaded portion of the strain relief into the internal section of the cable
sheath (see Figure A-11 on page 73).

Internal section Threads

Figure A-11 Inserting the threaded portion of the strain relief into the cable sheath

4. Put the cable sheath sections back together.

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DMTA-20017-01EN, Rev. E, August 2016

5. Align and assemble the threaded and annular parts of the strain relief (see
Figure A-12 on page 74).

Figure A-12 Assembling the strain relief connector

6. Connect the LEMO connector of the umbilical cable to the main module of the
ChainSCANNER (see Figure A-13 on page 74).

Figure A-13 Connecting the umbilical cable to the ChainSCANNER

74 Appendix
 DMTA-20017-01EN, Rev. E, August 2016

7. Secure the umbilical cable to the ChainSCANNER using the thumb screw (see
Figure A-14 on page 75).

Figure A-14 Securing the umbilical cable to the ChainSCANNER

The procedure is now complete (see Figure A-15 on page 75).

Figure A-15 The HYDROFORM-K-ADPCHAIN installed

ChainSCANNER Preparation 75
DMTA-20017-01EN, Rev. E, August 2016

76 Appendix
 DMTA-20017-01EN, Rev. E, August 2016

List of Figures

Figure i-1 Labels on the HydroFORM scanner ................................................................. 1

Figure i-2 Location of the rating label on the Mini-Wheel encoder ............................... 2
Figure i-3 The HydroFORM scanner ................................................................................ 15
Figure 1-1 The contents within the HydroFORM case ................................................... 17
Figure 1-2 The manual HydroFORM scanner components ........................................... 18
Figure 1-3 Bottom view of scanner .................................................................................... 19
Figure 1-4 Changing the HydroFORM scanner wheels .................................................. 21
Figure 1-5 Gasket plates for standard (right) and thick materials (left) ........................ 22
Figure 1-6 Removing the thumb screws ........................................................................... 22
Figure 1-7 Removing the old foam .................................................................................... 23
Figure 1-8 Peeling the protective backing from the adhesive strip ............................... 23
Figure 1-9 New foam installed on the gasket plate ......................................................... 24
Figure 1-10 Installing the gasket plate on the probe holder ............................................. 24
Figure 2-1 The encoder cable extension ............................................................................ 26
Figure 2-2 The probe element numbers ............................................................................ 27
Figure 2-3 The water control valve .................................................................................... 27
Figure 2-4 The S-scan display ............................................................................................. 28
Figure 2-5 The MapROVER scanner .................................................................................. 29
Figure 2-6 The MapSCANNER .......................................................................................... 30
Figure 2-7 The ChainSCANNER ........................................................................................ 30
Figure 2-8 The adaptation kit parts .................................................................................... 31
Figure 2-9 The encoder junction ......................................................................................... 32
Figure 2-10 The umbilical strain relief ................................................................................. 33
Figure 2-11 The HydroFORM scanner installed on the index arm ................................. 34
Figure 2-12 The spring-loaded arm ..................................................................................... 35
Figure 2-13 The origin on the probe .................................................................................... 37
Figure 2-14 The origin (0,0) on the surface ......................................................................... 37
Figure 2-15 The center of the template cross ...................................................................... 38
Figure 2-16 Marking the positive directions ....................................................................... 38
Figure 2-17 Aligning the HydroFORM scanner with the template marks .................... 39

List of Figures 77
DMTA-20017-01EN, Rev. E, August 2016

Figure 2-18 Template under the HydroFORM and correctly aligned ............................. 41
Figure 2-19 Marking the positive directions ....................................................................... 41
Figure 3-1 The probe retaining screws .............................................................................. 43
Figure 3-2 Lifting the probe ................................................................................................ 44
Figure 3-3 The probe removed ............................................................................................ 44
Figure 3-4 The Mini-Wheel compression adjustment screw .......................................... 45
Figure 3-5 Testing the Mini-Wheel compression adjustment ......................................... 46
Figure 3-6 Removing the screws ........................................................................................ 47
Figure 3-7 The Mini-Wheel removed ................................................................................. 47
Figure 3-8 Probe holder removed ....................................................................................... 48
Figure 3-9 Removing the gasket plate ............................................................................... 48
Figure 3-10 Removing the screws on the inner plate ........................................................ 49
Figure 3-11 Inner plate and gasket removed ...................................................................... 49
Figure 3-12 Removing the set screws to open the water passages .................................. 50
Figure 3-13 Loosening the screws on the side plate .......................................................... 50
Figure 3-14 The side plate removed ..................................................................................... 51
Figure 3-15 The side plate reinstalled .................................................................................. 51
Figure 3-16 The plates correctly aligned (chamfers match) .............................................. 52
Figure 4-1 LEMO connector pinout diagram for EWIX1413 cable ................................ 58
Figure 5-1 Exploded view of the HydroFORM scanner ................................................. 60
Figure 5-2 Exploded view of the irrigation kit (Q8300206) ............................................ 63
Figure 5-3 HydroFORM holder for use on MapSCANNER .......................................... 64
Figure 5-4 The HydroFORM Lite holder ........................................................................... 65
Figure A-1 Removing the end slide assembly ................................................................... 68
Figure A-2 Loosening the screws of the large knob assembly ........................................ 68
Figure A-3 Aligning the arm with the lead screw ............................................................ 69
Figure A-4 Tightening the screws of the large knob assembly ....................................... 69
Figure A-5 Installing the handle on the large knob assembly ........................................ 70
Figure A-6 Removing the cover from the main module .................................................. 71
Figure A-7 Disconnecting the Y-axis encoder module ..................................................... 71
Figure A-8 Loosening the knob that secures the encoder junction ................................ 72
Figure A-9 Installing the encoder junction with its integrated LEMO connector ........ 72
Figure A-10 Sliding annular part of the relief connector over the cable sheath ............. 73
Figure A-11 Inserting the threaded portion of the strain relief into the cable sheath ... 73
Figure A-12 Assembling the strain relief connector ........................................................... 74
Figure A-13 Connecting the umbilical cable to the ChainSCANNER ............................. 74
Figure A-14 Securing the umbilical cable to the ChainSCANNER .................................. 75
Figure A-15 The HYDROFORM-K-ADPCHAIN installed ................................................ 75

78 List of Figures
 DMTA-20017-01EN, Rev. E, August 2016

List of Tables

Table 1 Content of the rating labels .................................................................................... 2

Table 2 Ancillary equipment ............................................................................................... 6
Table 3 HydroFORM kits — compatibility ....................................................................... 8
Table 4 System specifications ............................................................................................ 55
Table 5 Operating environment specifications ............................................................... 56
Table 6 Probe specifications .............................................................................................. 56
Table 7 Gasket plate specifications ................................................................................... 57
Table 8 Required encoder cable adaptor ......................................................................... 57
Table 9 HydroFORM scanner spare parts ....................................................................... 61
Table 10 Irrigation kit (Q8300206) spare parts .................................................................. 63

List of Tables 79
DMTA-20017-01EN, Rev. E, August 2016

80 List of Tables
 DMTA-20017-01EN, Rev. E, August 2016

Index

A CE marking 3
accessory, HydroFORM Lite holder 64 ChainSCANNER
adaptation kit content, ChainSCANNER 31 adaptation 67
adaptors, LEMO/DE-15 connector 57 HydroFORM connection 32
adjusting modification 67
Mini-Wheel compression 45 changing wheels 21
probe holder height 27 cleaning
ancillary equipment 6, 8 magnetic wheels 53
arms probe surface 45
index 34 unit 52
positions (spring-loaded) 34 compatibility, equipment 6
spring-loaded 35 compliance
translation axis 67 EMC directive 12
Australia, RCM compliance 3 RCM (Australia) 3
components, HydroFORM 17, 18, 19
B connector adaptors, LEMO/DE-15 57
bubbles, water 28 connectors, scanner interface pinout 57
contents, HydroFORM case 17
C
C-scan origin positioning
cable pulling caution 44 initial position 37
calibration, encoder 25 next position 40
carriage rating label
location 1 D
symbols 2 DANGER signal word 9
case contents, HydroFORM 17 DE-15/LEMO connector adaptors 57
CAUTION signal word 10 description, HydroFORM 15, 17
cautions direct current symbol 3
finger crushing 20
E
gasket plate, foam removal 23
instrument compatibility 6 EMC directive compliance 12
modification prohibited 8 encoder calibration 25, 46
probe cable pulling 44 environment specifications 56
CE (European Community) 12 equipment, ancillary 6, 8
European Community (CE) 12

Index 81
DMTA-20017-01EN, Rev. E, August 2016

F manual, instruction 5
filling water chamber 27 Mini-Wheel
foam gasket replacement 22 compression adjustment 45
rating label
G location 1
gasket plates symbols 3
foam removal 22, 23 replacement 46
orientation 24 setup 45
specifications 56 modes
general setup 17 preparation, single-axis mode 26
semi-automated
H
equipment 30
holder accessory, HydroFORM Lite 64 setup 32
I single axis 25
modification, instrument 8
important information 5
multiple one-line scans, merging 25
IMPORTANT signal word 10
index arm 34 N
inspection setup 35 NOTE signal word 10
instruction manual 5 notes, information
interference, visual 8 signal words 10
introduction 15
irrigation kit spare parts 62 O
Olympus technical support 13
K
one-line scans, merging multiple 25
kit content, adaptation to ChainSCANNER 31 origin positioning
L initial 37
next position 40
labels, rating
overview, HydroFORM 17
carriage
location 1 P
symbols 2 pacemaker warning 20
Mini-Wheel encoder parts, spare
location 1 irrigation kit 62
symbols 3 scanner 59
probe holder phantom spots 8
location 1 pinouts, OmniScan MX2 scanner interface con-
symbols 2 nector 57
lead screw alignment 69 positioning the origin
LEMO/DE-15 connector adaptors 57 initial 37
M next position 40
positions, spring-loaded arm 34
magnetic template 37
precautions, safety 11
magnetic wheel safety 19
preparation
maintenance
inspection 35
magnetic wheel cleaning 53
single-axis mode 26
unit cleaning 52

82 Index
 DMTA-20017-01EN, Rev. E, August 2016

probe holder scanner, Chain See ChainSCANNER

caution, probe cable pulling 44 scans, merging multiple one-line 25
height adjustment 27 semi-automated mode 30
rating label serial number 3
location 1 setup
symbols 2 HydroFORM, general 17
probes Mini-Wheel 45
element position 34 semi-automated mode 32
proper installation 26 sheath, umbilical cable 72
replacement 43 signal words
specification table 56 information notes 10
procedures See specific procedure entries IMPORTANT 10
NOTE 10
R
TIP 10
raster scan safety 9
inspection procedure 40 CAUTION 10
water chamber filling 39 DANGER 9
rating labels WARNING 10
carriage single-axis mode 25
location 1 spare parts
symbols 2 availability 59
Mini-Wheel encoder exploded view 60
location 1 irrigation kit 62
symbols 3 scanner 59
probe holder specifications
location 1 gasket plates 56
symbols 2 HydroFORM 55
RCM mark 3 probe 56
repair, instrument 8 spring-loaded arm
replacing available positions 34
foam gasket 22 inspection position 35
Mini-Wheel 46 latch knob 35
probe 43 support information, technical 13
umbilical cable 70 symbols
wheels 21 CE 3
S direct current 3
RCM (Australia) 3
safety
safety 9
instrument compatibility 6
WEEE 3
magnetic wheels 19
misuse of instrument 5 T
precautions 11 tables
signal words 9 ancillary equipment 6, 8
symbols 9 gasket plate
scanner interface, connector pinout 57 foam removal 22, 23
scanner spare parts 59 specifications 56

Index 83
DMTA-20017-01EN, Rev. E, August 2016

HydroFORM specifications 55 finger crushing 9

probe specifications 56 general 9
technical support 13 magnetic field 9
template usage 37 warnings
TIP signal word 10 general 11
translation axis arm magnetic field 20
alignment with lead screw 69 misuse of instrument 5
modification 67 pacemaker 20
warranty information 12
U
waste electrical and electronic equipment 12
umbilical cable water chamber See water-circulation system
installation 72 water control valve 27
knob 71 water flow turbulence 28
motion allowance 34 water-circulation system
replacement 70 bubbles 28
sheath assembly 72 clearing, water-circulation holes 52, 53
unit cleaning 52 converting 47
use, intended 5 water chamber filling 27, 39
V water-circulation plate orientation 52
WEEE directive 12
valve, water control 27
symbol 3
W wheels
WARNING signal word 10 replacement 21
warning symbols types 19

84 Index