FlexoFORM Scanner

User’s Manual

10-003591-01EN [Q7780031] — Rev. 4

January 2020

This instruction manual contains essential information on how to use this Olympus product safely and effectively.
Before using this product, thoroughly review this instruction manual. Use the product as instructed.
Keep this instruction manual in a safe, accessible location.
Olympus Scientific Solutions Americas, 48 Woerd Avenue, Waltham, MA 02453, USA

Copyright © 2018, 2020 by Olympus. All rights reserved. No part of this publication may be
reproduced, translated, or distributed without the express written permission of Olympus.

This document was prepared with particular attention to usage to ensure the accuracy of the
information contained therein, and corresponds to the version of the product manufactured
prior to the date appearing on the title page. There could, however, be some differences
between the manual and the product if the product was modified thereafter.

The information contained in this document is subject to change without notice.

Part number: 10-003591-01EN [Q7780031]

Rev. 4
January 2020

Printed in Canada

All brands are trademarks or registered trademarks of their respective owners and third
party entities.
 10-003591-01EN [Q7780031], Rev. 4, January 2020

Table of Contents

List of Abbreviations ...................................................................................... vii

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

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

Intended Use .......................................................................................................................... 5
Instruction Manual ................................................................................................................ 5
Instrument Compatibility ..................................................................................................... 6
Repair and Modification ....................................................................................................... 6
Presence of Visual Interferences .......................................................................................... 7
Safety Symbols ....................................................................................................................... 7
Safety Signal Words .............................................................................................................. 8
Note Signal Words ................................................................................................................ 9
Safety ....................................................................................................................................... 9
Warnings ................................................................................................................................. 9
Equipment Disposal ............................................................................................................ 10
CE (European Community) ............................................................................................... 10
WEEE Directive .................................................................................................................... 11
China RoHS .......................................................................................................................... 11
Korea Communications Commission (KCC) ................................................................... 12
KC (South Korea Community) .......................................................................................... 12
FCC (USA) Compliance ...................................................................................................... 13
ICES-001 (Canada) Compliance ........................................................................................ 14
Packing and Return Shipping ............................................................................................ 14
Warranty Information ......................................................................................................... 14
Technical Support ................................................................................................................ 15

Introduction ...................................................................................................... 17

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1. Overview ...................................................................................................... 19
1.1 FlexoFORM Case Contents ...................................................................................... 19
1.2 Alternative Components .......................................................................................... 21

2. Setup of Equipment ................................................................................... 23

2.1 Setting Up an Instrument Using a USB Key ......................................................... 23
2.2 Setting Up an Instrument Using the Interface ...................................................... 23
2.2.1 Setup Characteristics ..................................................................................... 24
2.2.2 Setting the Parameters for a Symmetrical Scan ......................................... 24
2.3 Installing the Probe and Wedge .............................................................................. 26
2.4 Connecting the Scanner ............................................................................................ 28

3. Preparation for Inspection ....................................................................... 29

3.1 Drop Precautions ...................................................................................................... 29
3.2 Cleaning the Inspection Surface ............................................................................. 30
3.3 Setting Up the Scan and Index Parameters for an Elbow ................................... 31
3.4 Marking the Scan Lines ............................................................................................ 33

4. Inspection .................................................................................................... 37
4.1 Wetting the Surface and Purging Air Bubbles ...................................................... 37
4.2 Inspecting a Part ........................................................................................................ 38
4.2.1 Inspecting a Part Using Marked Scan Lines ............................................... 38
4.2.2 Inspecting a Part without Marked Scan Lines ........................................... 40
4.3 Correction Factors ..................................................................................................... 41

5. Maintenance and Troubleshooting ........................................................ 45

5.1 Preventive Maintenance ........................................................................................... 45
5.2 Cleaning the Product ................................................................................................ 45
5.3 Changing a Magnetic Wheel ................................................................................... 46
5.4 Cleaning the Magnetic Wheels ............................................................................... 49
5.5 Changing the Encoder .............................................................................................. 49
5.6 Changing the Foam Gasket and the O-ring Seals ................................................ 50
5.7 Changing the Water Tube ........................................................................................ 52
5.8 Changing the Cable Sleeve ...................................................................................... 53
5.9 Troubleshooting ........................................................................................................ 55

6. Specifications .............................................................................................. 57
6.1 General Specifications .............................................................................................. 57
6.2 Wedge Pipe Diameter Ranges ................................................................................. 58
6.3 Flat Wedge Inspection Surfaces .............................................................................. 60
6.4 Cable Connector Pinout ........................................................................................... 60

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6.5 Dimensions ................................................................................................................ 61

7. Spare Parts and Accessories ..................................................................... 65

Appendix A: Setting Up to Inspect a Straight Pipe — Unidirectional or

Bidirectional Scan ...................................................................................... 75

Appendix B: Calculating True Defect Length ............................................ 77

List of Figures ................................................................................................... 79

List of Tables ..................................................................................................... 81

Index ................................................................................................................... 83

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vi Table of Contents
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List of Abbreviations

CLK clock
EFUP Environment-Friendly Use Period
ID identification
IP International (ingress) Protection
OD outside diameter
RH relative humidity
RoHS Restriction of Hazardous Substances
SDHC secure digital high capacity
WEEE Waste Electrical and Electronic Equipment

List of Abbreviations vii

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viii List of Abbreviations

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Labels and Symbols

Safety-related labels and symbols are attached to the instrument at the locations
shown in Figure i-1 on page 1. If any of the labels or symbols are missing or illegible,
please contact Olympus.

Location of scanner rating and address labels

(see Table 1 on page 2) [encoder label not visible between scanner’s
assembled parts]

Figure i-1 Labels location for scanner

Labels and Symbols 1

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Table 1 Content of the rating and address labels

Scanner labels

Encoder label

Item Description

The CE marking is a declaration that this product conforms to

all the applicable directives of the European Community. See
the Declaration of Conformity for details. Contact your Olympus
representative for more information.

The regulatory compliance mark (RCM) label indicates that

the product complies with all applicable standards, and has
been registered with the Australian Communications and
Media Authority (ACMA) for placement on the Australian
market.

Seller and user shall be noticed that this equipment is suitable

for electromagnetic equipment for office work (class A) and it
can be used outside the home.
The MSIP code for the FlexoFORM scanner is the following:
R-R-OYN-FLEXOFORM.
The KC marking is a declaration that this product conforms to
all the applicable standards of South Korea. Contact your
Olympus representative for more information.

2 Labels and Symbols

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Table 1 Content of the rating and address labels (continued)

The warning symbol indicates that the user must read the
user’s manual in order to find out the nature of the potential
hazards and any actions to avoid them.

The China RoHS mark indicates the product’s Environment-

Friendly Use Period (EFUP). The EFUP is defined as the
number of years for which listed controlled substances will not
leak or chemically deteriorate while in the product. The EFUP
for the FlexoFORM scanner has been determined to be
15 years. Note: The Environment-Friendly Use Period (EFUP)
is not meant to be interpreted as the period assuring
functionality and product performance.

The WEEE symbol indicates that the product must not be

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

S/N The serial number.

The direct current symbol.

Labels and Symbols 3

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4 Labels and Symbols

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Important Information — Please Read Before Use

Intended Use

The FlexoFORM scanner is designed to perform nondestructive inspections on

industrial and commercial materials.

Do not use the FlexoFORM scanner for any purpose other than its intended use. It
must never be used to inspect or examine human or animal body parts.

Instruction Manual

This instruction manual contains essential information on how to use this Olympus
product safely and effectively. Before using this product, thoroughly review this
instruction manual. Use the product as instructed.

Keep this instruction manual in a safe, accessible location.

Important Information — Please Read Before Use 5

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Some of the details of components and/or software images in this manual may differ
from your instrument’s components or software display. However, the principles
remain the same.

Instrument Compatibility

The FlexoFORM scanner is compatible with the ancillary equipment listed in Table 2
on page 6. Also see “Spare Parts and Accessories” on page 65 for a list of compatible
accessories.

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

Table 2 Ancillary equipment

Part number Description
Several available models OmniScan series flaw detectors
(contact Olympus for details)
CFU03 [U8780008] Electric water pump and tubing, 120 V and 220 V
WTR-SPRAYER-8L [U8775001] Eight liter manual water pump
OMNI-A-ADP27 [U8780329] LEMO female to DE15 male adaptor for encoder
connector on OmniScan MX flaw detector

Repair and Modification

The FlexoFORM scanner contains user-serviceable parts. See “Maintenance and

Troubleshooting” on page 45 for information about authorized repairs and
maintenance.

6 Important Information — Please Read Before Use

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To prevent human injury and/or equipment damage, do not modify the FlexoFORM
scanner.

Presence of Visual Interferences

Presence of strong electromagnetic interference could generate noise in the signal that
is visually detectable. This interference is temporary and random in comparison with
the signals generated by the physical features of the inspected part, which are
coherent and persistent. This interference depends greatly on the nature, strength,
and proximity of the electromagnetic source and it will only disappear when the
source of the noise is no longer emitting signals.

Safety Symbols

The following safety symbols might appear on the instrument and in the instruction
manual:

General warning symbol

This symbol is used to alert the user to potential hazards. All safety messages that
follow this symbol shall be obeyed to avoid possible harm or material damage.

Finger crushing warning symbol

This symbol is used to alert the user to potential hazards to fingers from crushing
by magnetic wheels. All safety messages that follow this symbol shall be obeyed
to avoid possible harm.

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Magnetic field warning symbol

This symbol is used to alert the user to potentially strong magnetic fields. All
safety messages that follow this symbol shall be obeyed to avoid possible harm.

Safety Signal Words

The following safety signal words might appear in the documentation of the
instrument:

The DANGER signal word indicates an imminently hazardous situation. It calls

attention to a procedure, practice, or the like that if not correctly performed or
adhered to will result in death or serious personal injury. Do not proceed beyond a
DANGER signal word until the indicated conditions are fully understood and met.

The WARNING signal word indicates a potentially hazardous situation. It calls

attention to a procedure, practice, or the like that if not correctly performed or
adhered to could result in death or serious personal injury. Do not proceed beyond a
WARNING signal word until the indicated conditions are fully understood and met.

The CAUTION signal word indicates a potentially hazardous situation. It calls

attention to a procedure, practice, or the like that if not correctly performed or
adhered to may result in minor or moderate personal injury, material damage,
particularly to the product, destruction of part or all of the product, or loss of data. Do
not proceed beyond a CAUTION signal word until the indicated conditions are fully
understood and met.

8 Important Information — Please Read Before Use

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Note Signal Words

The following note signal words could appear in the documentation of the
instrument:

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

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

The TIP signal word calls attention to a type of note that helps you apply the
techniques and procedures described in the manual to your specific needs, or that
provides hints on how to effectively use the capabilities of the product.

Safety

Before turning on the instrument, verify that the correct safety precautions have been
taken (see the following warnings). In addition, note the external markings on the
instrument, which are described under “Safety Symbols.”

Warnings

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

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• Keep this instruction manual in a safe place for further reference.

• Follow the installation and operation procedures.
• It is imperative to respect the safety warnings on the instrument and in this
instruction manual.
• If the equipment is used in a manner not specified by the manufacturer, the
protection provided by the equipment could be impaired.
• Do not install substitute parts or perform any unauthorized modification to the
instrument.
• Service instructions, when applicable, are for trained service personnel. To avoid
the risk of electric shock, do not perform any work on the instrument unless
qualified to do so. For any problem or question regarding this instrument, contact
Olympus or an authorized Olympus representative.
• Do not touch the connectors directly by hand. Otherwise, a malfunction or electric
shock may result.
• Do not allow metallic or foreign objects to enter the device through connectors or
any other openings. Otherwise, a malfunction or electric shock may result.
• Make sure no FlexoFORM scanner components (screws, straps, etc.) have come
loose or are lost in critical equipment being inspected. Thoroughly check your
inspection area before and after an inspection to prevent foreign-object debris
(FOD) that could potentially cause equipment damage, injury, or loss of life.

Equipment Disposal

Before disposing of the FlexoFORM scanner, check your local laws, rules, and
regulations, and follow them accordingly.

CE (European Community)

This device complies with the requirements of directive 2014/30/EU

concerning electromagnetic compatibility, directive 2014/35/EU
concerning low voltage, and directive 2011/65/EU concerning
restriction of hazardous substances (RoHS). The CE marking indicates
compliance with the above directives.

10 Important Information — Please Read Before Use

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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.

China RoHS

China RoHS is the term used by industry generally to describe legislation

implemented by the Ministry of Information Industry (MII) in the People’s Republic
of China for the control of pollution by electronic information products (EIP).

The China RoHS mark indicates the product’s Environment-

Friendly Use Period (EFUP). The EFUP is defined as the number of
years for which listed controlled substances will not leak or
chemically deteriorate while in the product. The EFUP for the
FlexoFORM scanner has been determined to be 15 years.
Note: The Environment-Friendly Use Period (EFUP) is not meant
to be interpreted as the period assuring functionality and product
performance.

“ 中国 RoHS” 是一个工业术语，一般用于描述中华人民共和国信息工业部 （MII）针

对控制电子信息产品 （EIP）的污染所实行的法令。

中国 RoHS 标识是根据 “ 电器电子产品有害物质限制使用管理办

法 ” 以及 “ 电子电气产品有害物质限制使用标识要求 ” 的规定，适
用于在中国销售的电气电子产品上的电气电子产品有害物质限制使
用标识。
注意：电气电子产品有害物质限制使用标识内的数字为在正常的使
电气电子产品
有害物质 用条件下有害物质不会泄漏的年限，不是保证产品功能性的年限。
限制使用标识

Important Information — Please Read Before Use 11

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产品中有害物质的名称及含量
有害物质
部件名称 铅及其 汞及其 镉及其 六价铬及 多溴联苯 多溴
化合物 化合物 化合物 其化合物 二苯醚
(Pb) (Hg) (Cd) (Cr( Ⅵ )) (PBB) (PBDE)
机构部件 × ○ ○ ○ ○ ○
主体 光学部件 × ○ ○ ○ ○ ○
电气部件 × ○ ○ ○ ○ ○
附件 × ○ ○ ○ ○ ○
本表格依据 SJ/T 11364 的规定编制。
○：表示该有害物质在该部件所有均质材料中的含量均在 GB/T26572 规定的限量要求以下。
×：表示该有害物质至少在该部件的某一均质材料中的含量超出 GB/T26572 规定的限量要求。

Korea Communications Commission (KCC)

이 기기는 업무용 환경에서 사용할 목적으로 적합성평가를 받은 기기로서 가정용 환

경에서 사용하는 경우 전파간섭의 우려가 있습니다 .

KC (South Korea Community)

This device complies with the requirements of KN 61000-6-2 and KN 61000-6-4

concerning electromagnetic compatibility. The KC marking indicates compliance with
the above standards.

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FCC (USA) Compliance

This product has been tested and found to comply with the limits for a Class A digital
device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide
reasonable protection against harmful interference when the product is operated in a
commercial environment. This product generates, uses, and can radiate radio
frequency energy, and if not installed and used in accordance with the instruction
manual, might cause harmful interference to radio communications. Operation of this
product in a residential area is likely to cause harmful interference, in which case you
will be required to correct the interference at your own expense.

Changes or modifications not expressly approved by the party responsible for

compliance could void the user’s authority to operate the product.

FCC Supplier’s Declaration of Conformity

Hereby declares that the product,
Product name: FlexoFORM
Model: FlexoFORM-X-XXX, FlexoFORM-XXX, FlexoFORM-XX-XXXXX
Conforms to the following specifications:
FCC Part 15, Subpart B, Section 15.107 and Section 15.109.
Supplementary information:
This device complies with Part 15 of the FCC Rules. Operation is subject to the
following two conditions:
(1) This device may not cause harmful interference.
(2) This device must accept any interference received, including interference
that may cause undesired operation.
Responsible party name:
Olympus Scientific Solutions Americas Corp.

Important Information — Please Read Before Use 13

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Address:
48 Woerd Avenue, Waltham, MA 02453, USA
Phone number:
+1 781-419-3900

ICES-001 (Canada) Compliance

This Class A digital apparatus complies with Canadian ICES-001.

Cet appareil numérique de la classe A est conforme à la norme NMB-001 du Canada.

Packing and Return Shipping

If the FlexoFORM scanner is not returned in its transport case, it could be damaged
during shipping. Olympus reserves the right to void the warranty on instruments
damaged while in transit if they are shipped without their transport case. Prior to
returning any units, contact Customer Service to obtain the required RMA number(s)
and any important shipping information.

Follow the steps below to return your FlexoFORM scanner:

1. Pack the FlexoFORM scanner back into the transport case that it came in using the
original packing materials.
2. Include the RMA in the case, and reference the RMA number in your shipping
documents.
3. Close the transport case and either:
— Secure the transport case with plastic zip ties, or;
— Pack the transport case within another box.

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/.

14 Important Information — Please Read Before Use

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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.

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 15

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Introduction

The FlexoFORM scanner is designed to inspect pipes and pipe elbows. A flexible,
phased array ultrasonic probe is held and shaped by a water wedge that is contoured
to fit the radius of curvature of the surface being inspected. The scanner adjusts to
hold wedges of various sizes for a range of radius of curvatures.

Figure i-2 FlexoFORM scanner

The FlexoFORM scanner is designed to be used with an OmniScan series instrument.

For details on instrument and software operation, refer to the OmniScan MX and MX2
User’s Manual or OmniScan SX User’s Manual, as well as the OmniScan MXU Software
User’s Manual.

Introduction 17
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1. Overview

The FlexoFORM scanner kits can be composed of different components.

1.1 FlexoFORM Case Contents

The FlexoFORM scanner case contents are shown in Figure 1-1 on page 19. Main
components are detailed in Figure 1-2 on page 20.

Spare parts kit (screws,

o-rings, etc.), Allen
(hexagonal) keys, user’s
Spare foam gaskets manual
for wedge

Flexible magnetic Wedge storage

straightedge compartments (5)

Line marking
template tool FlexoFORM scanner
with cable

Figure 1-1 Case contents

Overview 19
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The FlexoFORM scanner has magnetic wheels that must be carefully handled to
prevent the risk of injury and equipment damage from magnetic fields and
inadvertent attractive forces. Before unpacking and handling, observe the magnetic
wheel safety precautions, as outlined in the warning note on page 27.

The case is configured to hold the following parts (for details, see “Spare Parts and
Accessories” on page 65):

• FlexoFORM scanner unit with cable assembly

• Set of water wedges for a range of inspection surface radii (optional)
• Flexible PA probe (FA1)
• Line marking template tool
• Flexible magnetic straightedge
• Spare parts kit including screws and o-ring seals for probe and water connections
• Wedge foam gaskets (spares)
• Printed copy of FlexoFORM Scanner User’s Manual

Thumb wheel
(open and close scanner) Indexing button

Grip Encoder

Grip
Wedge
Probe
Magnetic wheels (4)

Figure 1-2 Scanner components

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1.2 Alternative Components

The FlexoFORM scanner requires dedicated SFA1-FLEXO series wedges and a FA1-
type flexible probe. However, the FA1-type probe can also be used with two other
wedge series designed to scan without a FlexoFORM scanner:

• Small-diameter wedge series (SFA1-SMALL): used to manually scan the

extrados of elbows or pipes with outer diameters from 33 mm (1.3 in.) up to
102 mm (4 in.).
• Automated 2D rastering wedge series (SFA1-AUTO): this wedge series can be
used with the SteerROVER or MapROVER motorized scanner to perform
automated corrosion inspection of pipes with outer diameters of 218 mm
(8.625 in.) and greater in the longitudinal direction.
Both SFA1-SMALL and SFA1-AUTO wedges can be fitted with a Mini-Wheel encoder
from Olympus, using the standard hardware kit provided with the encoder. This
setup can be used to perform encoded, one-line scans (see Figure 1-3 on page 21).

Figure 1-3 Mini-Wheel encoder standard hardware kit

Overview 21
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2. Setup of Equipment

The FlexoFORM scanner and the instrument must be properly connected and set up
to enable inspection.

2.1 Setting Up an Instrument Using a USB Key

You can load a predefined inspection-parameter setup from the supplied USB key
into your OmniScan instrument. Or, if the predefined setups are not suitable for your
requirements, you can create a new setup.

To set up an instrument using a USB key

 Load the setup from the USB key:
a) Use a computer to transfer the setup from the supplied USB key to the
OmniScan instrument’s SDHC memory card.
b) Insert the SDHC card into the OmniScan and then turn it on.
c) Select the setup.

2.2 Setting Up an Instrument Using the Interface

Most common setups can be easily created by following the instructions in the User’s
Manual for your OmniScan instrument. The instructions below are specific to the
FlexoFORM scanner, and should not be considered complete.

Setup of Equipment 23
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2.2.1 Setup Characteristics

To create an instrument setup, make the following selections on your OmniScan
instrument:

• FA1-type probe model

• Depending on the application, one of the following three types of wedges:
— FlexoFORM scanner applications: SFA1-FLEXO
— Automated inspections: SFA1-AUTO
— Small diameter inspections: SFA1-SMALL
• Select Plate in the Specimen Type parameter field (see Figure 2-1 on page 24).
Although the probe has a concave shape, it is important to select Plate, even if you
are inspecting a curved surface.

Figure 2-1 Selecting Plate in the Specimen Type field

2.2.2 Setting the Parameters for a Symmetrical Scan

For pipe elbow inspections, Olympus recommends the symmetrical scan pattern for a
full 360° inspection around the circumference (see Figure 2-2 on page 25). The
OmniScan instrument must be correctly set up to enable this type of inspection. For
details about alternative inspection patterns for straight pipe surfaces, see “Setting Up
to Inspect a Straight Pipe — Unidirectional or Bidirectional Scan” on page 75.

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Scan axis

The initial position of the

Center line scanner must be at the
(zero position) center of each scan line.
on pipe

Index
axis

Figure 2-2 Symmetrical scan pattern for a pipe elbow inspection of 360°

In a symmetrical scan pattern, the indexing button is pressed once after completing a
scan, which stops the acquisition and activates the button’s red LED. Because of its
“smart indexing” function, the FlexoFORM scanner can then freely move along the
index axis to the next scan line without overwriting any acquisition data. When the
scanner is in position at the center of the next scan line (the zero position, or origin),
the indexing button is pressed once again, and the red LED turns off.

When the indexing button is released at the center of the next scan line, the position of
encoder 1 is reset to the Origin parameter value (equivalent to Scan > Encoder >
Origin). At the same time, the index value will be incremented by a predefined
distance set in the (encoder 2) Resolution parameter (see “Setting Up the Scan and
Index Parameters for an Elbow” on page 31).

To set the parameters for a symmetrical scan

1. Set the appropriate scan type in the OmniScan MXU software by selecting Scan >
Inspection > Type = Raster Scan.
2. In the OmniScan MXU software, set the scanner’s encoder number (1), type
(Quad), and resolution (12 steps/mm):
a) Select Scan > Encoder > Encoder = 1.
b) Select Scan > Encoder > Type = Quad.
c) Select Scan > Encoder > Resolution = 12.

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3. Set the indexing button’s encoder number (2), type (Clicker + Preset), and
origin (0):
a) Select Scan > Encoder > Encoder = 2.
b) Select Scan > Encoder > Type = Clicker + Preset.
c) Select Scan > Origin = 0.
The resolution value will be set as detailed in “Setting Up the Scan and Index
Parameters for an Elbow” on page 31.
4. Assign the digital input for the indexing button:
a) Select Preferences > Category = DIN.
b) Select Preferences > Select DIN = DIN 3 and set the state:
○ Select DIN3 > Assign DIN = Acquisition State.
○ Select DIN3 > State = On.

2.3 Installing the Probe and Wedge

Because of its design, the flexible phased array probe can be easily damaged if
handled incorrectly. It is not recommended to bring the probe into direct contact with
a part. The probe should only be shaped using an Olympus SFA1 type wedge.
Bending the probe too much could permanently damage it.

The flexible phased array probe slides into one of several available water wedge sizes
(see Figure 2-3 on page 27).

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Insert probe and wedge Press to unlock

Slide probe into wedge. combination into scanner probe and remove it
opening. from wedge.

Figure 2-3 Installing the probe and wedge

To install the probe and wedge

1. Choose the wedge size for the elbow size you are inspecting.
2. Slowly slide the probe fully into the wedge until it locks into place.
As noted above, avoid overbending the probe, which could permanently damage
it.

Before handling the FlexoFORM scanner, observe the following general safety
precautions related to its magnetic wheels (see “Changing a Magnetic Wheel” on
page 46 for complete details on wheel safety):

• The magnetic fields around the wheels may affect pacemakers, watches, and
other sensitive electronic devices, and anyone relying on such devices must keep
a safe distance away from the wheels to avoid the risk of serious injury or death.
• Magnetic wheels present a risk of finger crushing if fingers are placed between
the wheels and a ferromagnetic surface.
• The wheels may suddenly attract ferromagnetic objects or particles in their
vicinity, which can cause injury, equipment damage, or malfunction.

3. Turn the thumb wheel to open the FlexoFORM scanner, and install the assembled
wedge and probe.

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4. Turn the thumb wheel the opposite way to close the scanner, and tighten it
sufficiently to fasten the wedge in place.

2.4 Connecting the Scanner

The probe and scanner encoder cables are connected to the OmniScan instrument,
and—together with the water supply tube—are held in a cable sleeve attached to the
scanner.

To connect the scanner

1. Connect the LEMO encoder cable to the OmniScan instrument (see Figure 2-4 on
page 28).
2. Connect the probe cable to the OmniScan instrument.
3. Connect the water supply to an Olympus couplant feed unit.
For more details on the recommended CFU03 pump connection, refer to the
CFU03/CFU05/CFU-PWZ Couplant Feed Unit User’s Manual.

Note: Water supply

system may vary.
Encoder and OmniScan
cables, and water supply in
cable sleeve connected to
scanner

Water connector

LEMO encoder OmniScan probe

connector connector

Figure 2-4 Scanner connections example

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3. Preparation for Inspection

In addition to the setup detailed in “Setup of Equipment” on page 23, before you
begin inspecting you must also clean the inspection surface and set up the instrument
parameters. It is recommended that you also mark the scan lines.

3.1 Drop Precautions

Be sure to observe the following precautions when handling the FlexoFORM scanner.

To prevent injury and equipment damage when operating the FlexoFORM scanner at
heights 2 meters or higher above ground or floor level, secure it with a lanyard that is
held taut (see attachment point in Figure 3-1 on page 30). Wear appropriate safety
shoes that protect your feet in case you accidentally drop the unit during handling.
Also ensure the inspection surface is free of rust, debris, or obstructions, and is
continuously ferromagnetic so that magnetic wheels remain attached to the surface.

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Figure 3-1 Attachment point for lanyard

Olympus recommends that you keep the wedge securely mounted in the frame while
handling the scanner. This provides increased resistance to accidental impact.

3.2 Cleaning the Inspection Surface

The inspection surface must be free of scaling and other obstructions. A smooth
surface helps maintain the water column and extends the life of the wedge’s foam
gasket that rubs against the surface during inspection.

To avoid the risk of injury, wear appropriate work gloves and safety glasses when
cleaning the inspection surface using scrapers, metal brushes, or other cleaning tools.

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To clean the inspection surface

1. Carefully use an appropriate metal scraper, chisel, or file to remove scaling,
protruding metal, or weld residue on the surface, without affecting the structural
integrity and curvature of the surface.
2. Use a metal brush to remove any remaining loose material on the surface.

3.3 Setting Up the Scan and Index Parameters for an Elbow

Before an inspection, on the OmniScan instrument, you must set the required scan
and index parameters for your elbow size. These are determined by your probe’s
effective beam width, elbow dimensions, and desired scan overlap.

To set up the scan and index parameters for an elbow

1. Measure and record your elbow’s extrados (maximum, outer elbow curve length
on surface; see Figure 3-2 on page 31).

Extra scan length

Extrados
n
igi
Or

Figure 3-2 Extrados — maximum outer elbow curve length

2. Set the scan parameters:

a) Divide the extrados value by two and add your preferred “safety factor,” or
extra scan length value (for example: 500 mm/2 + 10 mm = 260 mm).
b) In the OmniScan MXU software, select Scan > Area > Scan Start =
[EXAMPLE −260.00], and Scan End = [EXAMPLE 260.00] (see Figure 3-3 on
page 32).
c) Set the Index End value equal to or greater than the pipe circumference value.

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Figure 3-3 Example Scan Start and Scan End setting in the OmniScan

3. Set the index parameter (encoder 2 Resolution value):

a) See Table 3 on page 42 to determine the effective beam width on the surface,
and then subtract from it your desired scan overlap value.
Because of the FlexoFORM scanner’s flexible, curved probe—with a radius of
curvature that is concentric to the surface radius of curvature—the effective
beam width on the surface is smaller than the Index Res value calculated by
the OmniScan. The OmniScan Index Res value (at right in Figure 3-3 on
page 32) should therefore not be used, but instead you must obtain a value
using Table 3 on page 42. For more details and alternative calculation, see
“Correction Factors” on page 41.
For example, for a 559 mm (22 in.) OD pipe and a focal law of 4 elements,
Table 3 on page 42 provides an effective beam width value of 58.1 mm on the
surface. If the desired overlap is 2 mm, then the Index Res value can be
calculated as follows:

58.1 mm − 2 mm = 56.00 mm, the nearest integer millimeter value

This is the value you will enter in the encoder 2 Resolution parameter, which
represents the distance between your scan lines.
b) Select Scan > Encoder > Encoder 2 > Resolution = [EXAMPLE 56.00] (see
Figure 3-4 on page 32).

Figure 3-4 Example index Resolution setting in the OmniScan

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It is recommended to scan using an overlap between scan lines, with the Index Res
value set according to the method above. For this, the Linear at 0° mode must be
selected (Focal Law > Configuration > Law Config. = Linear at 0°).

If an overlap is not required, or if you want to use beam angles that differ from 0°, you
need to use Linear mode (Focal Law > Configuration > Law Config. = Linear), and
you must set the encoder 2 Resolution linked to the indexing button [also named
Clicker] (Scan > Encoder > Resolution) to equal the Index Res value. As an example
of an index value setting, Figure 3-3 on page 32 shows an Index Res value that would
be transferred to the Resolution field shown in Figure 3-4 on page 32. However, if you
use this scanning method, the surface actually covered by the ultrasonic beam is
smaller than the Index Res value. This means that some portions of the surface may
not have been covered by the scan. Therefore, Linear at 0° mode is recommended.

3.4 Marking the Scan Lines

Before an inspection, it is recommended that you lay out and mark scan lines to
follow when moving the FlexoFORM scanner over a surface. The steps for
determining the line length and spacing for an elbow are detailed in “Setting Up the
Scan and Index Parameters for an Elbow” on page 31. However, it is also possible to
inspect without scan lines, as detailed in “Inspecting a Part without Marked Scan
Lines” on page 40.

To mark the scan lines

1. Define the required index value (encoder 2 Resolution).
See the example (56 mm/step resolution) procedure in “Setting Up the Scan and
Index Parameters for an Elbow” on page 31.
2. Determine your zero position (the middle, or center, of the scan line), and then
draw your zero line perpendicular to the part’s longitudinal axis, using the
flexible straightedge wrapped around the circumference as a guide (see left
illustration in Figure 3-5 on page 34).
3. Position the flexible magnetic straightedge so that one edge rests flat on the
longest (extrados) section of the elbow or part, and draw your first scan line

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parallel to the part’s longitudinal axis (see right illustration in Figure 3-5 on
page 34).

Mark along
straightedge

Figure 3-5 Marking the zero position (left) and scan (right) lines on an elbow

A template marking tool is provided with the FlexoFORM scanner package to help
you draw scan lines. The supplied tool has markings that help you draw a line a
distance of 48 mm to 58 mm from the previous line.

4. Insert a paint marker (pen) into the hole in the template marking tool, then use the
tool’s markings as a guide to follow the first scan line and draw your next scan
line at the required index distance (see Figure 3-6 on page 35). Draw the
remainder of the scan lines this way around the circumference of the part.

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Hole for paint

marker

Template marking
tool and paint marker
Scan line drawn by
the paint marker

Distance markings
(in millimeters)
Required indexing
distance

Figure 3-6 Drawing the scan lines on an elbow

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4. Inspection

Before starting an inspection, make sure that the scanner and instrument setup and
connections have been completed and your inspection surface has been prepared (see
“Setup of Equipment” on page 23 and “Preparation for Inspection” on page 29).

4.1 Wetting the Surface and Purging Air Bubbles

Before an inspection, you must turn on the supply of water, wet the surface, and clear
air from the water column between the inspection surface and the probe.

To wet the surface and purge air bubbles

1. Wet the surface, for example, by using a cloth soaked with water.
2. Open the water supply, and then position the FlexoFORM scanner on the
inspection surface.
3. Move the scanner back and forth (and sideways, if necessary) over the inspection
surface to help clear air bubbles.
4. Observe the instrument display for bubble indications.
5. If necessary, lift the scanner, wipe any bubbles from the probe using a finger, and
repeat these motions until all bubbles are cleared (see Figure 4-1 on page 38).

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Figure 4-1 An example S-scan display free of bubbles

4.2 Inspecting a Part

Water must be turned on and air bubbles cleared before inspection can be started. You
can inspect a part either with or without marked scan lines.

4.2.1 Inspecting a Part Using Marked Scan Lines

Use the following procedure if you have marked scan lines on your part surface.

To inspect a part using marked scan lines

1. Position the FlexoFORM scanner so that it is aligned with the (first) marked scan
line and the start (zero) position (see Figure 4-2 on page 39).
— Use the wedge’s alignment mark and the encoder wheel to align on the scan
line.
— Use the alignment marks on the sides, between the wheels, to align on the
zero position.

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Alignment mark on Alignment marks between Alignment using

wedge wheels for zero position (on encoder wheel
both sides)

Figure 4-2 Alignment marks

2. On the OmniScan, press the Play key ( ) to set the encoder position to zero.
3. Move the FlexoFORM scanner along the scan line, and observe the instrument
display to make sure that all data has been captured.
The recommended 360° scan pattern for a pipe (or pipe elbow) is shown in
Figure 4-3 on page 40.
4. After completing the first scan line, press the indexing button.
5. Slide the scanner over and align it on the next scan line and on the zero position
line, as detailed in step 1.
6. Press the indexing button again (releasing it from indexing) to restart the
acquisition, increment (increase) the index position, and reset the scan position.

To avoid the risk of overwriting a small portion of your acquisition data, wait at least
one second after having pressed (and released) the button before starting to move the
scanner along the next scan line.

7. Repeat steps 3 to 6 for the remaining scan lines to complete the inspection.

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Scan axis
Keep FlexoFORM scanner
(c) orientation the same and
6. Press 4. Press button, then return it to zero at the
button. move (c) to zero. center of each scan line.
(Go to 3.)

Index axis
1. Align on zero position.
2. Press Play on OmniScan.
Zero position
(line perpendicular
to pipe) 5. Index. 3. Scan (a and b).
(b) (a)

Figure 4-3 Scan pattern for a pipe elbow

4.2.2 Inspecting a Part without Marked Scan Lines

As an alternative to marking scan lines along the full length of your scan, you can
make small starting marks on the pipe on which to align before a scan motion.
However, your scan overlap value must be large enough to compensate for the
scanner tracking error (its deviation from a straight path). For scanning procedure
details, see “To inspect a part using marked scan lines” on page 38, which is similar
except for the starting marks.

To inspect a part without marked scan lines

1. Align the FlexoFORM scanner on the zero position (line around the pipe
circumference) using the alignment marks on the sides, between the wheels.
2. Use a pen to make a mark on the pipe at probe element 1 (see Figure 4-4 on
page 41) and another mark at element 64. (Offset the marks towards the center of
the scanner by an amount that corresponds to the overlap value.)

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64 1

Figure 4-4 Probe element marks on the wedge

3. On the OmniScan, press the Play key ( ) to set the encoder position to zero.
4. Make your scan motion, and observe the instrument display to make sure that all
data has been captured.
5. After completing the first scan, press the indexing button.
6. Slide the scanner over, align it on the next scan zero position, and align the
element 1 mark on the wedge with the element 64 mark on the pipe.
7. Make your next mark at element 64, and then press the indexing button again and
wait at least one second after having pressed the button before moving (to avoid
the risk of overwriting your data).
8. Repeat the above steps 4–7 until you complete all necessary inspection scans.

4.3 Correction Factors

The probe’s concave shape, its distance away from the inspection surface, and the
number of elements in its beam affect the effective probe beam width and observed
defect size in the following ways:

• The effective width covered by the probe beam on the inspection surface is
smaller than the width of the probe’s active aperture.
• The length of a defect (along the index axis) appears to be longer than it is in
reality.
• As the inspection surface radius (pipe diameter) decreases, the above effects
increase in magnitude.
To compensate for these effects, correction factors need to be applied.

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Effective probe beam width

Table 3 on page 42 provides corrected values for probe beam width for a range of pipe
sizes and number of elements in focal laws.

It is also possible to calculate the corrected value using equation (1) on page 43. The
equation’s variables are illustrated in Figure 4-5 on page 43.

Table 3 Effective beam width on surface (mm)

Pipe OD Law aperture

(in.) 3 elem. 4 elem. 5 elem. 6 elem. 7 elem. 8 elem.
1.315 39.5 38.8 38.2 37.5 36.9 36.2
1.66 42.6 41.9 41.2 40.5 39.8 39.1
1.9 44.3 43.6 42.8 42.1 41.4 40.7
2.375 46.9 46.1 45.3 44.6 43.8 43
2.875 48.8 48 47.2 46.4 45.6 44.8
3.5 50.6 49.8 49 48.1 47.3 46.5
4 51.7 50.9 50 49.2 48.3 47.5
4.5 52.6 51.8 50.9 50 49.2 48.3
6.625 55 54.1 53.2 52.3 51.4 50.5
8.625 56.3 55.4 54.5 53.6 52.6 51.7
10.75 57.2 56.3 55.3 54.4 53.4 52.5
12.75 57.8 56.8 55.9 54.9 54 53
16 58.4 57.4 56.5 55.5 54.6 53.6
22 59.1 58.1 57.1 56.2 55.2 54.2
26 59.4 58.4 57.4 56.4 55.5 54.5
30 59.6 58.6 57.6 56.6 55.7 54.7
34 59.7 58.8 57.8 56.8 55.8 54.8
38 59.9 58.9 57.9 56.9 55.9 55
42 60 59 58 57 56 55.1
48 60.1 59.1 28.1 57.1 56.2 55.2
Flat 61 60 59 58 57 56

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A A = Active aperture length

B B = Beam coverage width on the surface
h = Water column height (9 mm for SFA1-
FLEXO and SFA1-AUTO wedge series, and
11 mm for SFA1-SMALL wedge series)
Ro = Outside radius

Figure 4-5 Variables for calculating probe beam width on the surface

Ro A
B = -------------------
- (1)
( Ro + h )

Defect length correction (only along index axis)

Table 4 on page 44 provides correction factors (multiplication factors) that must be
applied to the measured defect length from inspection data along the index axis. The
table provides multiplication factors for a range of defect depths in typical inspection
applications.

For example, if a defect is measured to be 10 mm long along the index axis, 6 mm

below the surface on a 114 mm (4.5 in.) pipe, the multiplication factor is 0.77 and the
true defect length = 10 mm × 0.77 = 7.7 mm.

For inspection applications that fall outside the range of the table, the true defect
length can be calculated as shown in “Calculating True Defect Length” on page 77.

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Table 4 Multiplication factors for defect length correction along index axis
Pipe OD Defect depth
(in.) 2 mm 3 mm 4 mm 5 mm 6 mm 7 mm 8 mm 9 mm 10 mm
1.3 0.57 0.53 0.49 0.45 0.41 0.37 0.33 0.29 0.25
1.66 0.63 0.60 0.57 0.53 0.50 0.47 0.43 0.40 0.37
1.9 0.67 0.64 0.61 0.58 0.55 0.52 0.49 0.46 0.43
2.375 0.72 0.69 0.67 0.64 0.62 0.59 0.56 0.54 0.51
2.875 0.76 0.73 0.71 0.69 0.67 0.65 0.63 0.60 0.58
3.5 0.79 0.77 0.76 0.74 0.72 0.70 0.68 0.66 0.64
4 0.81 0.80 0.78 0.76 0.75 0.73 0.71 0.70 0.68
4.5 0.83 0.82 0.80 0.79 0.77 0.76 0.74 0.73 0.71
6.625 0.88 0.87 0.86 0.85 0.84 0.83 0.82 0.81 0.80
8.625 0.91 0.90 0.89 0.88 0.87 0.86 0.86 0.85 0.84
10.75 0.92 0.92 0.91 0.90 0.90 0.89 0.88 0.88 0.87
12.75 0.94 0.93 0.92 0.92 0.91 0.91 0.90 0.89 0.89
16 0.95 0.94 0.94 0.93 0.93 0.92 0.92 0.91 0.91
22 0.96 0.96 0.95 0.95 0.95 0.94 0.94 0.94 0.93
26 0.97 0.96 0.96 0.96 0.96 0.95 0.95 0.95 0.94
30 0.97 0.97 0.97 0.96 0.96 0.96 0.96 0.95 0.95
34 0.97 0.97 0.97 0.97 0.97 0.96 0.96 0.96 0.96
38 0.98 0.98 0.97 0.97 0.97 0.97 0.97 0.96 0.96
42 0.98 0.98 0.98 0.97 0.97 0.97 0.97 0.97 0.96
48 0.98 0.98 0.98 0.98 0.98 0.97 0.97 0.97 0.97
Flat 1 1 1 1 1 1 1 1 1

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5. Maintenance and Troubleshooting

This chapter outlines procedures for basic maintenance to keep the product in good
physical and working condition, as well as routine part changes. Basic
troubleshooting advice is also provided.

5.1 Preventive Maintenance

Because there are few moving parts, the FlexoFORM scanner does not require much
preventive maintenance. Only regular inspection of the scanner is recommended to
ensure that it is functioning correctly. If necessary, clean the scanner or clean and/or
change the wheels, as outlined below. Monitor the condition of the foam gasket and
the water seals and replace as needed, as outlined below.

5.2 Cleaning the Product

The FlexoFORM scanner’s external surfaces may be cleaned when needed.

To clean the product

1. Turn off the equipment connected to the scanner.
2. Disconnect all cables.
3. If necessary, clean the scanner and encoder wheels using adhesive tape
(recommended) or a cloth, according to the precautions and steps in “Cleaning
the Magnetic Wheels” on page 49.

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Although the scanner can be rinsed with water, do not rinse the PA probe connector if
it is disconnected. Water in the connector may cause equipment malfunction, damage,
electric shock, or injury.

4. If dirt or foreign particles have accumulated on the scanner surface or in its

mechanism, gently rinse it with water to wash dirt away until the scanner opens
and closes smoothly with the thumb wheel.
5. To bring the external surface back to its original finish, clean it with a soft cloth.
6. To get rid of persistent stains, use a damp cloth and a soft soapy solution. Do not
use abrasive products or powerful solvents that might damage the finish.
7. Make sure that the connectors are dry before reconnecting them. If they are not
dry, either dry them off using compressed air, or wait until they dry on their own.

5.3 Changing a Magnetic Wheel

Depending on use, it may be necessary to periodically change the magnetic wheels.

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

The magnetic wheels have a magnetic field strength of approximately 0.99 milligauss
at a distance of 2.1 m (7 ft) away from the wheels. This is well below the 2 milligauss
limit at which a product would be considered to be a magnetic material requiring
special handling during shipment by air. This means that the FlexoFORM scanner can
be shipped by air without restrictions.

Magnetic wheels present a risk of finger crushing if fingers are placed between the
wheels and a ferromagnetic surface.

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The 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 wheels to
avoid the risk of serious injury or death. This magnetic field can also demagnetize
credit cards, magnetic ID (identification) badges, etc.

Sharp filings or other ferromagnetic objects can be attracted to the magnetic wheels,
which can cause equipment malfunction or injury. It is important to keep the wheels
clean (see “Cleaning the Magnetic Wheels” on page 49).

Be careful while using tools around magnetic wheels and while holding or moving
the wheels. Tools, wheels, or other ferromagnetic objects in the vicinity may suddenly
move and forcefully be attracted to each other, which could potentially cause injury or
equipment damage. Be sure to allow sufficient free space around equipment and tools
to prevent sudden attractive forces between them.

The FlexoFORM scanner’s replacement magnetic wheels are supplied as a set of two.
The two wheels in a set have opposing polarity when installed. This provides a
repulsive force between wheels that makes it easier to install them. However, wheels
must be carefully handled and held to prevent accidental ejection, as outlined in the
procedure below. It is recommended to replace the two wheels as a set on each side of
the scanner.

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To change a magnetic wheel

To avoid injury or equipment damage, be sure to carefully hold and restrict the
movement of magnetic wheels when disassembling or assembling. The magnetic
repulsive force between wheels may cause a wheel to suddenly eject if it is
disassembled or assembled without an adequate hold.

1. Use a 3 mm Allen key to hold the shaft and a 2 mm Allen key to remove the screw
on the wheel you want to replace (see Figure 5-1 on page 48).
2. Partially push out the shaft from the inside, then carefully pull out the shaft while
holding the wheel to counteract the magnetic repulsive force, and then pull out
the wheel with its bearings.
3. Similarly (see steps 1 and 2), remove the wheel next to it on the same side of the
scanner.
4. Install the first new wheel with its bearings, and tighten the screw.
5. Install the second new wheel by carefully pushing against it to counteract the
magnetic repulsive force from the other wheel, and tighten the screw.
6. Repeat for the set of wheels on the other side of the scanner, if needed.

Shaft partially pushed out

1. Hold shaft with 3 mm

Allen key while loosening
screw.

2. Hold wheel, then pull out

shaft while holding wheel.

3. Repeat steps 1 and 2 to remove wheel set.

Figure 5-1 Changing a wheel

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5.4 Cleaning the Magnetic Wheels

The scanner and encoder’s magnetic wheels can attract sharp filings or other
ferromagnetic objects or particles. The wheels need periodic cleaning to avoid
accumulation of any particles that can cause injury or equipment malfunction. The
cleaning frequency depends on your operating conditions.

Required materials:

• Work gloves
• Adhesive tape (recommended for best cleaning)
• Clean cloth (alternative, if adhesive tape is unavailable or inappropriate)

To avoid injury or equipment damage when handling magnetic wheels, take note of
the magnetic attraction forces around the wheels, and observe the safety notes
outlined in “Changing a Magnetic Wheel” on page 46.

To clean the magnetic wheels

1. Put on your work gloves.
2. Apply clean adhesive tape to the wheel, then pull the tape off to remove particles,
and, if necessary, repeat until all particles have been removed. (This is the
recommended wheel cleaning method.)
OR
If adhesive tape is unavailable, hold a clean cloth against the wheel, then turn it to
remove particles (use the cloth to grab particles), and, if necessary, repeat with a
clean section of cloth until all particles have been removed.
3. Repeat above step 2 for each wheel that needs cleaning.

5.5 Changing the Encoder

The encoder (with wheel) can be removed as a single unit.

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To change the encoder

1. Use a 1.5 mm Allen key to remove the four screws on the encoder (see Figure 5-2
on page 50).
2. Remove the encoder.
3. Install the new encoder:
 Apply a small drop of Loctite 425 thread locker to each of the four screws,
position the encoder, and insert and tighten the screws.
Olympus recommends Loctite 425 thread locker because it will not damage
plastic parts in the vicinity if inadvertently spilled.

Figure 5-2 Changing the encoder

5.6 Changing the Foam Gasket and the O-ring Seals

The foam gasket on the wedge (which maintains the water column) must be changed
periodically, depending on inspection conditions and surface roughness. The o-ring
seals on the probe and on the water tube connection also may need replacement if
they are worn or damaged.

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To change the foam gasket

1. Pull off the old gasket, and, if necessary, carefully clean the mounting surface (see
Figure 5-3 on page 51).
2. Choose the gasket model that is compatible with the wedge diameter.
3. Peel the backing off the adhesive on the new gasket.
4. Align the adhesive side of the gasket with the mounting surface, and then press it
against the surface to install it.

Clean mounting surface Peel off the backing Align and press new gasket onto
after removing old gasket. on new gasket. mounting surface.

Figure 5-3 Changing the foam gasket

To change the o-ring seal between the probe and wedge

1. Use an appropriate tool such as a small flathead screwdriver to carefully lift and
pull off the old o-ring seal without damaging the mounting surface on the wedge
(see Figure 5-4 on page 52).
2. Install the new o-ring seal.

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Figure 5-4 Changing the probe’s o-ring seal on the wedge

To change the o-ring seal on the water connection

1. Use an appropriate tool such as a small flathead screwdriver to carefully lift and
pull off the old o-ring seal without damaging the mounting surface (see
Figure 5-5 on page 52).
2. Install the new o-ring seal.

Figure 5-5 Changing the o-ring seal for the water connection

5.7 Changing the Water Tube

The water tube on the scanner can be changed if it is damaged.

To change the water tube

1. Remove the screw that fixes the water connector to the scanner (see Figure 5-6 on
page 53).
2. Pull the connector off the water tube.
3. Pull back the cable sleeve to access the tube, disconnect it from the union
connector, and pull it out of the scanner.

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4. Feed the new tube through its channel on the scanner until it reaches the water
connector.
5. Push the tube onto the fitting, install the connector, and then tighten its screw.
6. Cut the tube to the required length, connect it to the union connector, and then
close the cable sleeve.

Union
connector

Water
connector on
scanner

Figure 5-6 Changing the tube (shown disassembled)

5.8 Changing the Cable Sleeve

To change the cable sleeve, you must partially disassemble the scanner on one side,
including two magnetic wheels (see Figure 5-7 on page 55).

To avoid injury or equipment damage when handling the magnetic wheels, take note
of the magnetic attraction forces around the wheels, and observe the safety notes
outlined in “Changing a Magnetic Wheel” on page 46.

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To change the cable sleeve

1. Carefully remove the two wheels on the sleeve side according to the procedure
detailed in “Changing a Magnetic Wheel” on page 46. Be aware of magnetic
forces that can suddenly attract or repulse parts.
2. Remove the screws that hold the scanner end piece, and pull it away.
3. Remove the screws on the bracket and pull the sleeve out of the end piece.
4. Follow the steps in reverse order to reinstall the (new) sleeve, and securely tighten
all screws.

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1.

2.

3.

Figure 5-7 Disassembly steps for changing the cable sleeve

5.9 Troubleshooting

Table 5 on page 56 lists some problems that may arise, possible causes, and suggested
solutions.

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Table 5 Troubleshooting guide

Problem Possible cause Solution

Start-up message “No The acquisition Make sure that the acquisition
module detected”. module is incorrectly module is correctly attached to
connected. the base unit on the
instrument.

Software crashes. Wrong software was Shut down the instrument and
loaded. restart with correct software.

No C-scan displayed. There is no encoder Check encoder connections

connection. between FlexoFORM scanner
and instrument.

Black lines on C-scan. Scanning is too fast. Reduce scanning speed.

Scanner does not open Mechanism contains Gently rinse the scanner with
and close easily during dirt or foreign water to wash dirt away until
wedge change. particles. the mechanism opens and
closes smoothly with the
thumb wheel.

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6. Specifications

6.1 General Specifications

The general specifications for the FlexoFORM scanner are listed in Table 6 on page 57.

Table 6 General specifications

Parameter Value
General
Dimensions (L × W × H) 26 cm × 10 cm × 10 cm
Weight 1.53 kg
Inspection surface From 114 mm (4.5 in.) minimum diameter up to a flat surface
curvature
Probe Type: FA1
64 elements, flexible
Cable length: 5 m
Center frequency: 7.5 MHz
Part number: Q3301201
Wedges Type: SFA1-Flexo — multiple models for a range of inspection
surface radii (see Table 7 on page 59 and Table 12 on page 71).
Alternative wedges for inspections without a FlexoFORM scanner
are described in “Alternative Components” on page 21, and listed
in Table 13 on page 72 and Table 14 on page 73.
Minimum clearance Required free access distance over inspection surface:
• 85 mm for 114 mm (4.5 in.) pipe
• 91 mm for 203 mm (8 in.) pipe
• 98 mm for 1219 mm (48 in.) pipe

Specifications 57
10-003591-01EN [Q7780031], Rev. 4, January 2020

Table 6 General specifications (continued)

Parameter Value
Magnetic field strength 0.99 milligauss at a distance of 2.1 m (7 ft) from the wheels (below
of wheels the 2 milligauss limit at which restrictions would be imposed on
air shipment)
Encoder Recommended scanning speed: variable, dependent on OmniScan
instrument and application setup used.
Type: Quadrature
Resolution: 12 steps/mm ±0.15 steps/mm
Wet locations: Water resistant, IP55
Pinout: See Figure 6-1 on page 61
Voltage: 5 VDC
Maximum current: 100 mA
CLK frequency: 1 MHz
Environment
Outdoor use Yes
Altitude Up to 2000 m
Operating temperature 0 °C to 45 °C
Maximum inspection 100 °C (with water flow turned on)
surface temperature
Storage temperature −20 °C to 60 °C
Relative humidity (RH) N/A (water resistant; see IP rating below)
Pollution level 2
IP rating IP55

6.2 Wedge Pipe Diameter Ranges

The FlexoFORM scanner’s wedges have predefined curvatures according to the

Nominal Pipe Size (NPS) standard. Although it is recommended to use a wedge that
matches the exact diameter of the inspected pipe, each wedge has a narrow range of
pipe diameters on which it can be used. Table 7 on page 59 provides the range of
coverage for each standard wedge diameter.

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Table 7 Range of pipe diameters covered by each wedge

OD (in.) Min. OD (in.) Max. OD (in.)

4.5 4.4 4.5

5.563 5.4 5.6

6.625 6.4 6.8

8.625 8.3 8.8

10.75 10.3 11.1

11.75 11.1 12.1

12.75 12.1 13.3

14 13.1 14.6

16 14.9 16.8

18 16.6 18.9

20 18.4 21.1

22 20.1 23.4

24 21.7 25.7

26 23.3 28

28 24.9 30.3

30 26.4 32.7

32 28 35.1

34 29.5 37.4

36 31.3 39.6

38 32.5 42.4

42 35.4 47.4

48 39.6 55.1

Flat 200 Flat

Specifications 59
10-003591-01EN [Q7780031], Rev. 4, January 2020

6.3 Flat Wedge Inspection Surfaces

When fitted with a flat wedge, the FlexoFORM scanner can be used to perform these
inspections on the following parts:

• Flat plates
• Circumferential inspection of pipes:
— With 48 in. and up outside diameters
— With 20 in. and up inside diameters
• Longitudinal inspection of pipes:
— With 200 in. and up outside diameters

The FlexoFORM scanner cannot be used to perform longitudinal inspection of pipes

on the inside surface.

6.4 Cable Connector Pinout

The connector pinout for the scanner interface cable is shown in Figure 6-1 on
page 61.

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OmniScan FlexoFORM scanner

instrument
Housing Shield + drain Housing
Brown DIN3
Yellow PHA-2
Green PHA-1
Orange PHB-1
Black GND
Red 5 V IN
Solder-side view
Solder-side view FGG.0T.305.CLAC50Z
FGG.1K.316.CLAC50Z

Figure 6-1 LEMO connector pinout diagram (5 pin to 16 pin)

6.5 Dimensions

The FlexoFORM scanner dimensions are shown in Figure 6-2 on page 62.

Specifications 61
10-003591-01EN [Q7780031], Rev. 4, January 2020

98.2 mm
(3.87 in.)

260.6 mm
(10.26 in.)

100 mm
(3.94
100 in.)

193 mm
(7.6 in.)

93.1 mm
(3.66 in.)

101.6 mm
(4.00 in.)

52.5 mm 28.7 mm
(2.07 in.) (1.13 in.)
38.9 mm
(1.53 in.)

Figure 6-2 Scanner dimensions

The SFA1-SMALL wedge series dimensions and clearances are shown in Figure 6-3
on page 63, Figure 6-4 on page 64, and in Table 8 on page 64.

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Length

Circumferential
clearance

Height clearance

Probe side clearance Water side clearance

Pipe diameter

Figure 6-3 SFA1-SMALL wedge clearances

Specifications 63
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Width

Figure 6-4 SFA1-SMALL wedge width

Table 8 SFA1-SMALL wedge series dimensions and clearances

Pipe
diameter 1.315 1.66 1.9 2.375 2.875 3.5 4 4.5
(in. OD)

Length (mm) 108.421 117.594 122.098 128.089 131.261 133.042 133.592 111.737

Circumfer- 160.537 170.563 176.208 185.836 195.147 206.707 216.223 226.052

ential clear-
ance (mm)

Height 38.5 38.5 38.5 38.5 38.5 38.5 38.5 38.5

clearance
(mm)

Water side 28.995 30.964 31.383 30.502 27.312 21.645 16.374 10.726
clearance
(mm)

Probe side 46.025 44.47 42.455 37.261 30.919 22.498 15.618 8.711
clearance
(mm)

Width (mm) 95 95 95 95 95 95 95 95

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7. Spare Parts and Accessories

An exploded view of the FlexoFORM scanner is shown in Figure 7-1 on page 65. A list
of standard spare parts is provided in Table 9 on page 66. Accessories and spare part
kits are listed in Table 11 on page 70 to Table 14 on page 73.

14
15

16

17

18
20

19

11
12
9
10
7 8
21

1
5
4

2 3

22
5 5 24

6 5

36

32 34 35 25
31

33
27
5
28
23
30
26

29

Figure 7-1 Scanner exploded view

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Table 9 Spare parts

Part order Marketing
Item Qty Description
number number
1 Q8301415 1 Frame handle, side N/A
2 Q8301416 1 Cable attachment, safety lanyard, 152 mm (6 in.) N/A
3 Q8301417 1 Cable sleeve, 5 m N/A
4 Q8301418 1 Lock plate for cable sleeve N/A
5 U8908544 11 Screw, M3 × 10 mm, hex socket cap, stainless N/A
6 Q8301419 1 Main frame, fixed N/A
7 Q8301422 1 Thumb wheel N/A
8 Q8301423 1 Washer, flat, 8.0 mm N/A
9 Q8301424 1 Cotter pin, 3 mm × 6 mm, stainless steel N/A
10 Q8301425 1 Screw, M3 × 35 mm, hex head, stainless N/A
11 Q8301429 1 Name plate N/A
12 Q8301430 1 Shaft, threaded N/A
13 Q8301432 1 Wiper ring N/A
14 Q8301433 1 Encoder, FlexoFORM N/A
15 Q8301481 1 Encoder base, front N/A
16 Q8301482 1 Encoder base, back N/A
17 Q8301426 4 Lock washer, internal tooth, M2 N/A
18 N/Aa 4 Screw, M2 × 6 mm, hex head, stainless N/A
19 Q8301431 1 Encoder wheel N/A
20 U8909086 2 Bearing, flanged, 8 mm ID × 12 mm OD × 3.5 mm W, N/A
stainless
21 Q8301434 1 Adjustable right-side frame without wheels N/A
22 Q8301435 1 Screw, M6, custom N/A
23 Multiple 1 Wedge (see models listed in Table 12 on page 71, N/A
available Table 13 on page 72, and Table 14 on page 73)
24 Q8301441 1 Kit of 20 o-ring seals for water input (on wedge) N/A
25 Q8301442 1 Kit of 10 o-ring seals for probe (on wedge) N/A

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Table 9 Spare parts (continued)

Part order Marketing
Item Qty Description
number number
26 Q7500065 N/A Kit of 12 foam gaskets for water wedge used on FlexoFORM-
small pipe diameters, 114 mm (4.5 in.) to 203 mm SP-SFoam
(8.0 in) OD
Q7500066 N/A Kit of 12 foam gaskets for water wedge used on pipe FlexoFORM-
diameters over 203 mm (8.0 in) OD SP-LFoam
27 Q8301421 1 Water connector N/A
28 N/Aa 1 Fitting, barbed brass, 1/8 NPT × 10-32 N/A
29 Q8301438 1 Tube, water, 6.0 mm × 200 mm N/A
30 Q8301439 1 Union, straight, QS-6 N/A
31 Q8301443 2 Wheel set (2) N/A
32 Q8301420 4 Wheel shaft N/A
33 Q8301462 8 Bearing, 6.0 × 5.0 N/A
34 Q8301463 4 Flanged bushing, ID 6.0 × 8.0 × 4.0 mm N/A
35 Q8301427 4 Flat washer #4, M3 N/A
36 Q8301428 4 Socket button head cap screw (SBHCS), N/A
M3.0 × 0.5 × 6.0
N/A Q7500060 N/A FlexoFORM scanner (without probe, wedges, FlexoFORM-
carrying case, spare part and accessories) for SCN
corrosion inspection of pipe elbows.
Package includes: irrigation tubes as well as encoder
cable with LEMO connector compatible with current
generation of OmniScan and FOCUS PX
instruments. Cable and tube are 5 m long. Requires
FA1 probe and SFA1 water wedges, which are
ordered separately.
N/A Q8000207 N/A FlexoFORM encoder cable, 5 m long with LEMO FlexoFORM-
connector compatible with current generation of SP-Cable
OmniScan and FOCUS PX instruments
N/A Q7500064 N/A Basic spare part kit for FlexoFORM scanner — FlexoFORM-
includes o-rings, screws and basic hardware (see SP-Basic
Figure 7-2 on page 68).
N/A Q8301464 N/A Line marking template tool N/A
N/A Q8301440 N/A Flexible magnetic straightedge, 1.6 mm × 12.7 mm × N/A
3.05 m (1/16 in. × 1/2 in. × 10 ft)
N/A Q8301465 N/A Allen key, 2.5 mm N/A

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Table 9 Spare parts (continued)

Part order Marketing
Item Qty Description
number number
N/A Q8301466 N/A Allen key, 2 mm N/A
N/A Q8301467 N/A Allen key, 1.5 mm N/A

a. Item included in spare parts kit (P/N: Q7500064)

Figure 7-2 Basic spare parts kit (P/N: Q7500064)

Figure 7-3 on page 69 shows an exploded view of the SFA1-AUTO and SFA1-SMALL
wedges. A list of spare parts for these wedges is provided in Table 10 on page 69.

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Figure 7-3 SFA1-AUTO and SFA1-SMALL wedges exploded view

Table 10 SFA1 wedge spare part list

Part order
Item Description Marketing number
number
1 Q8301442 Kit of 10 o-ring seals for probe (on N/A
wedge)
2 Q7500066 Kit of 12 foams for SFA1-AUTO FLEXOFORM-SP-
water wedges. Compatible with LFOAM
pipe diameters of 8.625 in. OD and
up
Q7201701 Kit of ten (10) foams for SFA1- SFA1-SMALL-SP-Foam-
SMALL-OD1.3 water wedge. OD1.3
Q7201702 Kit of ten (10) foams for SFA1- SFA1-SMALL-SP-Foam-
SMALL-OD1.66 water wedge OD1.66
Q7201703 Kit of ten (10) foams for SFA1- SFA1-SMALL-SP-Foam-
SMALL-OD1.9 water wedge OD1.9

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Table 10 SFA1 wedge spare part list (continued)

Part order
Item Description Marketing number
number
Q7201704 Kit of ten (10) foams for SFA1- SFA1-SMALL-SP-Foam-
SMALL-OD2.375 water wedge OD2.375
Q7201705 Kit of ten (10) foams for SFA1- SFA1-SMALL-SP-Foam-
SMALL-OD2.875 water wedge OD2.875
Q7201706 Kit of ten (10) foams for SFA1- SFA1-SMALL-SP-Foam-
SMALL-OD3.5 water wedge OD3.5
Q7201707 Kit of ten (10) foams for SFA1- SFA1-SMALL-SP-Foam-
SMALL-OD4 water wedge OD4
Q7201708 Kit of ten (10) foams for SFA1- SFA1-SMALL-SP-Foam-
SMALL-OD4.5 water wedge OD4.5

Table 11 FlexoFORM scanner and probe kits

Part order Marketing
Description
number number
Q7500061 FlexoFORM scanner kit (without probe and wedges) for FlexoFORM-
corrosion inspection of pipe elbows. K-SCN
Package includes: encoder cable with LEMO connector
compatible with current generation of OmniScan and FOCUS PX
instruments, irrigation tube, basic spare parts, and accessories
packaged in a carrying case. Cable and tube are 5 m long.
Requires FA1 probe and SFA1 water wedges, which are ordered
separately.
Q7500062 FlexoFORM scanner kit for corrosion inspection of pipe elbows. FlexoFORM
Package includes: Flexible 7.5 MHz, 64 element FA1 phased
array probe, one (1) SFA1 water wedge for 219 mm (8.625 in.)
outside diameter, encoder cable with LEMO connector
compatible with current generation of OmniScan and FOCUS PX
instruments, irrigation tube, basic spare parts, and accessories
packaged in a carrying case. All cables and tube are 5 m long.
Requires SFA1 water wedges, which are ordered separately.

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Table 11 FlexoFORM scanner and probe kits (continued)

Part order Marketing
Description
number number
Q7500063 FlexoFORM scanner kit for corrosion inspection of pipe elbows. FlexoFORM-
Package includes: Flexible 7.5 MHz, 64 element FA1 phased Kit
array probe, six (6) SFA1 water wedges for 114 mm (4.5 in.),
168 mm (6.625 in.), 219 mm (8.625 in.), 273 mm (10.75 in.),
324 mm (12.75 in.), and 406 mm (16 in.) outside diameters,
encoder cable with LEMO connector compatible with current
generation of OmniScan and FOCUS PX instruments, irrigation
tube, basic spare parts, and accessories packaged in a carrying
case. All cables and tube are 5 m long.
Q3301201 Flexible phased array probe, 7.5 MHz linear array, 64 elements, 7.5L64-64X7-
64 × 7 mm total active aperture, 1.00 mm pitch, 7 mm elevation, FA1-P-5-OM
FA1 case type for FlexoFORM scanner, SFA1-SMALL and SFA1-
AUTO wedge series, impedance matching to water, PVC
sheathing, 5 m cable length, OmniScan connector

Table 12 FlexoFORM standard wedges

Part order
Description Marketing number
number
Q7500067 Standard wedge for flexible array probe (FA1) and SFA1-Flexo-OD4.5
compatible with FlexoFORM scanner. The wedge is used
to generate 0° longitudinal waves and features a
curvature matching 114 mm (4.5 in.) OD for inspection of
extrados and intrados of pipe elbows. The wedge also
features a 9 mm high water column allowing inspection
of up to 30 mm thick carbon steel materials.
Q7500068 As above, but for 141 mm (5.563 in.) pipe OD SFA1-Flexo-OD5.563
Q7500069 As above, but for 168 mm (6.625 in.) pipe OD SFA1-Flexo-OD6.625
Q7500070 As above, but for 219 mm (8.625 in.) pipe OD SFA1-Flexo-OD8.625
Q7500071 As above, but for 273 mm (10.75 in.) pipe OD SFA1-Flexo-OD10.75
Q7500072 As above, but for 324 mm (12.75 in.) pipe OD SFA1-Flexo-OD12.75
Q7500073 As above, but for 356 mm (14 in.) pipe OD SFA1-Flexo-OD14
Q7500074 As above, but for 406 mm (16 in.) pipe OD SFA1-Flexo-OD16
Q7500075 As above, but for 457 mm (18 in.) pipe OD SFA1-Flexo-OD18
Q7500076 As above, but for 508 mm (20 in.) pipe OD SFA1-Flexo-OD20
Q7500077 As above, but for 559 mm (22 in.) pipe OD SFA1-Flexo-OD22

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Table 12 FlexoFORM standard wedges (continued)

Part order
Description Marketing number
number
Q7500078 As above, but for 610 mm (24 in.) pipe OD SFA1-Flexo-OD24
Q7500079 As above, but for 660 mm (26 in.) pipe OD SFA1-Flexo-OD26
Q7500080 As above, but for 711 mm (28 in.) pipe OD SFA1-Flexo-OD28
Q7500081 As above, but for 762 mm (30 in.) pipe OD SFA1-Flexo-OD30
Q7500082 As above, but for 813 mm (32 in.) pipe OD SFA1-Flexo-OD32
Q7500083 As above, but for 864 mm (34 in.) pipe OD SFA1-Flexo-OD34
Q7500084 As above, but for 914 mm (36 in.) pipe OD SFA1-Flexo-OD36
Q7500085 As above, but for 1067 mm (42 in.) pipe OD SFA1-Flexo-OD42
Q7500086 As above, but for 1219 mm (48 in.) pipe OD SFA1-Flexo-OD48
Q7500087 As above, but for flat surfaces SFA1-Flexo-Flat

Table 13 Wedges for automated inspections

Part order
Description Marketing number
number
Q7500088 Standard wedge for flexible array probe (FA1), compatible SFA1-Auto-OD8.625
with MapROVER and SteerROVER scanners. The wedge
is used to generate 0° Longitudinal waves and features a
curvature matching 219 mm (8.625 in.) OD for inspection
of extrados and intrados of pipe elbows. The wedge also
features a 9 mm high water column allowing inspection of
up to 30 mm thick carbon steel materials. Not compatible
with FlexoFORM scanner.
Q7500089 As above, but for 273 mm (10.75 in.) pipe OD SFA1-Auto-OD10.75
Q7500090 As above, but for 324 mm (12.75 in.) pipe OD SFA1-Auto-OD12.75
Q7500091 As above, but for 356 mm (14 in.) pipe OD SFA1-Auto-OD14
Q7500092 As above, but for 406 mm (16 in.) pipe OD SFA1-Auto-OD16
Q7500093 As above, but for 457 mm (18 in.) pipe OD SFA1-Auto-OD18
Q7500094 As above, but for 508 mm (20 in.) pipe OD SFA1-Auto-OD20
Q7500095 As above, but for 559 mm (22 in.) pipe OD SFA1-Auto-OD22
Q7500096 As above, but for 610 mm (24 in.) pipe OD SFA1-Auto-OD24
Q7500097 As above, but for 660 mm (26 in.) pipe OD SFA1-Auto-OD26
Q7500098 As above, but for 711 mm (28 in.) pipe OD SFA1-Auto-OD28

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Table 13 Wedges for automated inspections (continued)

Part order
Description Marketing number
number
Q7500099 As above, but for 762 mm (30 in.) pipe OD SFA1-Auto-OD30
Q7500100 As above, but for 813 mm (32 in.) pipe OD SFA1-Auto-OD32
Q7500101 As above, but for 864 mm (34 in.) pipe OD SFA1-Auto-OD34
Q7500102 As above, but for 914 mm (36 in.) pipe OD SFA1-Auto-OD36
Q7500103 As above, but for 1067 mm (42 in.) pipe OD SFA1-Auto-OD42
Q7500104 As above, but for 1219 mm (48 in.) pipe OD SFA1-Auto-OD48
Q7500105 As above, but for flat surfaces SFA1-Auto-Flat

Table 14 Wedges for small-diameter pipes

Part order
Description Marketing number
number
Q7500106 Standard wedge for flexible array probe (FA1) for manual SFA1-Small-OD1.3
inspection of small pipes or elbow extrados. (Not suitable
for inspection of elbow intrados.) The wedge is used to
generate 0° Longitudinal waves and features a curvature
matching 33.4 mm (1.315 in.) outside diameter (OD) for
inspection of elbow extrados. The wedge also features an
11 mm high water column allowing inspection of up to
35 mm thick carbon steel materials. Compatible with the
Mini-Wheel encoder. Not compatible with FlexoFORM
scanner.
Q7500107 As above, but for 42 mm (1.66 in.) pipe OD SFA1-Small-OD1.66
Q7500108 As above, but for 48 mm (1.9 in.) pipe OD SFA1-Small-OD1.9
Q7500109 As above, but for 60 mm (2.375 in.) pipe OD SFA1-Small-OD2.375
Q7500110 As above, but for 73 mm (2.875 in.) pipe OD SFA1-Small-OD2.875
Q7500111 As above, but for 89 mm (3.5 in.) pipe OD SFA1-Small-OD3.5
Q7500112 As above, but for 101.6 mm (4 in.) pipe OD SFA1-Small-OD4

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Appendix A: Setting Up to Inspect a Straight Pipe —

Unidirectional or Bidirectional Scan

Depending on your inspection needs, setup, and preferences, Olympus recommends

the unidirectional or bidirectional scanning methods for straight pipe or cylinder
surfaces.

Unidirectional scan
The principal advantage of performing a unidirectional scan is that the same
starting reference is retained for each scan, because the encoder in the scan
direction is always reset to the origin value every time the indexing button is
pressed (see Figure A-1 on page 75).

Scan axis

Index axis

Figure A-1 Unidirectional scan pattern

Setting Up to Inspect a Straight Pipe — Unidirectional or Bidirectional Scan 75

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

To set up for a unidirectional scan

 Set the parameters as outlined in “To set the parameters for a symmetrical scan”
on page 25. The setup and functionality are the same.

Bidirectional scan
The advantage of a bidirectional scan is that it is faster when inspecting long parts
(see Figure A-2 on page 76).

Scan axis

Index axis

Figure A-2 Bidirectional scan pattern

To set up for a bidirectional scan

1. Set the scan encoder and input parameters according to steps 1, 2, and 4 in “To set
the parameters for a symmetrical scan” on page 25.
2. Set the indexing button’s encoder number (2) and type (Clicker):
a) Select Scan > Encoder > Encoder = 2.
b) Select Scan > Encoder > Type = Clicker.
A bidirectional scan differs from a symmetrical scan as follows:

• The scan start value can be set to 0 instead of a negative value (Scan > Area > Scan
Start).
• The scan position value is not reset to zero when the indexing button is pressed.

76 Appendix A
 10-003591-01EN [Q7780031], Rev. 4, January 2020

Appendix B: Calculating True Defect Length

To calculate the true defect length (Lo) along the index axis, use equation (2) on
page 77. The variables are illustrated in Figure B-1 on page 77.

Lo = True defect length

l = Measured defect length
Ro = Outside radius
h = Water column height (9 mm for SFA1-FLEXO
and SFA1-AUTO wedge series, and 11 mm for
SFA1-SMALL wedge series)
d = Measured depth of defect
t = Thickness of material (reference only)

Figure B-1 Variables for calculating true defect length along the index axis

( R o – d )l
L 0 = ---------------------- (2)
( Ro + h )

Calculating True Defect Length 77

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

78 Appendix B
 10-003591-01EN [Q7780031], Rev. 4, January 2020

List of Figures

Figure i-1 Labels location for scanner ................................................................................. 1

Figure i-2 FlexoFORM scanner .......................................................................................... 17
Figure 1-1 Case contents ...................................................................................................... 19
Figure 1-2 Scanner components ......................................................................................... 20
Figure 1-3 Mini-Wheel encoder standard hardware kit ................................................. 21
Figure 2-1 Selecting Plate in the Specimen Type field .................................................... 24
Figure 2-2 Symmetrical scan pattern for a pipe elbow inspection of 360° ................... 25
Figure 2-3 Installing the probe and wedge ....................................................................... 27
Figure 2-4 Scanner connections example .......................................................................... 28
Figure 3-1 Attachment point for lanyard .......................................................................... 30
Figure 3-2 Extrados — maximum outer elbow curve length ......................................... 31
Figure 3-3 Example Scan Start and Scan End setting in the OmniScan ........................ 32
Figure 3-4 Example index Resolution setting in the OmniScan .................................... 32
Figure 3-5 Marking the zero position (left) and scan (right) lines on an elbow ........... 34
Figure 3-6 Drawing the scan lines on an elbow ............................................................... 35
Figure 4-1 An example S-scan display free of bubbles ................................................... 38
Figure 4-2 Alignment marks ............................................................................................... 39
Figure 4-3 Scan pattern for a pipe elbow .......................................................................... 40
Figure 4-4 Probe element marks on the wedge ................................................................ 41
Figure 4-5 Variables for calculating probe beam width on the surface ........................ 43
Figure 5-1 Changing a wheel .............................................................................................. 48
Figure 5-2 Changing the encoder ....................................................................................... 50
Figure 5-3 Changing the foam gasket ................................................................................ 51
Figure 5-4 Changing the probe’s o-ring seal on the wedge ............................................ 52
Figure 5-5 Changing the o-ring seal for the water connection ....................................... 52
Figure 5-6 Changing the tube (shown disassembled) ..................................................... 53
Figure 5-7 Disassembly steps for changing the cable sleeve .......................................... 55
Figure 6-1 LEMO connector pinout diagram (5 pin to 16 pin) ...................................... 61
Figure 6-2 Scanner dimensions ........................................................................................... 62
Figure 6-3 SFA1-SMALL wedge clearances ...................................................................... 63

List of Figures 79
10-003591-01EN [Q7780031], Rev. 4, January 2020

Figure 6-4 SFA1-SMALL wedge width .............................................................................. 64

Figure 7-1 Scanner exploded view ..................................................................................... 65
Figure 7-2 Basic spare parts kit (P/N: Q7500064) ............................................................. 68
Figure 7-3 SFA1-AUTO and SFA1-SMALL wedges exploded view ............................. 69
Figure A-1 Unidirectional scan pattern .............................................................................. 75
Figure A-2 Bidirectional scan pattern ................................................................................. 76
Figure B-1 Variables for calculating true defect length along the index axis ............... 77

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

List of Tables

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

Table 2 Ancillary equipment ............................................................................................... 6
Table 3 Effective beam width on surface (mm) .............................................................. 42
Table 4 Multiplication factors for defect length correction along index axis ............. 44
Table 5 Troubleshooting guide ......................................................................................... 56
Table 6 General specifications ........................................................................................... 57
Table 7 Range of pipe diameters covered by each wedge ............................................ 59
Table 8 SFA1-SMALL wedge series dimensions and clearances ................................. 64
Table 9 Spare parts .............................................................................................................. 66
Table 10 SFA1 wedge spare part list ................................................................................... 69
Table 11 FlexoFORM scanner and probe kits ................................................................... 70
Table 12 FlexoFORM standard wedges ............................................................................. 71
Table 13 Wedges for automated inspections ..................................................................... 72
Table 14 Wedges for small-diameter pipes ....................................................................... 73

List of Tables 81
10-003591-01EN [Q7780031], Rev. 4, January 2020

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

Index

A CE 2
air bubbles 37 FCC (USA) 13
ancillary equipment 6 ICES-001 (Canada) 14
Australia, RCM compliance 2 RCM (Australia) 2
connection, scanner 28
B connector pinout 60
bidirectional scan 76 correction factors 41
bubbles, air 37
D
C DANGER signal word 8
cable sleeve 53 defect length calculation 77
calculation, defect length 77 dimensions, scanner 61
case contents, scanner 19 direct current symbol 3
CAUTION signal word 8 disposal, equipment 10
cautions
E
finger crushing 27, 46
flexible probe installation 26 elbow inspection parameters 24
instrument compatibility 6 encoder change 50
magnetic repulsive force 48 equipment disposal 10
magnetic wheel change 47 European Community (CE) 10
modification prohibited 7 exploded view, scanner 65
objects on magnetic wheels 47 F
probe connector cleaning 46
FCC (USA) compliance 13
wedge in scanner 30
CE (European Community) 10 G
CE marking 2 gasket change 51
China RoHS 3, 11
cleaning I
general 45 ICES-001 (Canada) compliance 14
inspection surface 30 important information 5
magnetic wheels 49 IMPORTANT signal word 9
compatibility, instrument 6 index parameter setup 31
compliance inspection

Index 83
10-003591-01EN [Q7780031], Rev. 4, January 2020

correction factors 41 overlap of scan 33

purging air bubbles 37 overview, scanner 19
scan procedure 38
P
instruction manual 5
instrument pacemaker warning 47
compatibility 6 packing and return shipping 14
loading a setup 23 parts, spare 65
manuals 17 pinout, connector 60
interference, visual 7 precautions
drop 29
K general safety 9
KC (South Korea Community) 12 preparation
KN 61000-6-2 12 cleaning inspection surface 30
KN 61000-6-4 12 scan lines 33
Korea Communications Commission (KCC) 12 probe
Korean standard 2 caution, handling 26
installation 26
L
probe connector cleaning caution 46
labels 1 probe seal change 51
length correction, defect 41 problem resolution 55
lines, scan 33
R
M
rating label location 1
magnetic wheels RCM mark 2
safety 46 repair, industrial inspection system 6
warning 47 return shipping 14
maintenance RoHS symbol 3, 11
cable sleeve 53
changing wheels 46 S
encoder change 50 safety
gasket change 51 accidental drop 29
magnetic wheel cleaning 49 instrument compatibility 6
preventive 45 magnetic wheels 46
probe seal change 51 misuse of instrument 5
product cleaning 45 precautions 9, 29
water connection seal change 52 signal words 8
water tube 52 symbols 7
manual, instruction 5 scan
manuals, instrument and software 17 bidirectional 76
modification, industrial inspection system 6 lines 33
parameter setup 31
N
procedure 38
NOTE signal word 9 unidirectional 75
notes, information signal words 9 serial number format 3
O setup
installing probe and wedge 26
Olympus technical support 15

84 Index
 10-003591-01EN [Q7780031], Rev. 4, January 2020

loading an instrument setup 23 TIP signal word 9

parameters, pipe elbow 24 troubleshooting 55
scan and index parameters 31
U
scanner connections 28
signal words unidirectional scan 75
information notes 9 use, intended 5
IMPORTANT 9 V
NOTE 9
visual interference 7
TIP 9
safety 8 W
CAUTION 8 WARNING signal word 8
DANGER 8 warning symbols
WARNING 8 finger crushing 7
sleeve, cable 53 general 7
South Korea Community (KC) 12 magnetic field 8
spare parts 65 marking 3
specifications warnings
dimensions, scanner 61 accidental drop 29
environment 58 general 9
general 57 magnetic field 47
support information, technical 15 misuse of instrument 5
surface pacemaker 47
cleaning 30 warranty information 14
scan lines 33 waste electrical and electronic equipment 11
symbols 1 water connection seal change 52
CE 2 water tube 52
direct current 3 wedge
Korean standard 2 installation 26
RCM (Australia) 2 mounting precaution 30
RoHS 3, 11 WEEE directive 11
safety 7 symbol 3
warning 3 wheels
WEEE 3 magnetic 46
T safety 46
width correction, probe beam 41
technical support 15

Index 85
10-003591-01EN [Q7780031], Rev. 4, January 2020

86 Index