CONTENTS

CONTENTS
Preface ................................................................................................................................. II

Operation Cautions and Safety Guide............................................................................. III

Chapter 1 Product Introduction ..................................................................................... 1-1

1.1 Parameters of Crawler .................................................................................1-1

1.2 Composition of Crawler ............................................................................... 1-1

1.3 Introduction of Parts ..................................................................................... 1-4

Chapter 2 Assembly Instruction for Crawler ................................................................ 2-1

2.1 Node Assembly ............................................................................................ 2-1

2.2 Probe holder.................................................................................................2-3

2.3 Wheel and encoder wheel assembled to truss............................................ 2-7

2.4 Assembly of Pipeline PI-13 and Irrigation Device IH-05 ............................. 2-9

2.5 Truss assembled to node........................................................................... 2-11

Chapter 3 Preparation for Testing .................................................................................. 3-1

Chapter 4 Troubleshooting .............................................................................................4-1

Chapter 5 Maintenance ...................................................................................................5-1

5.1 Probes and wedges ..........................................................................................5-1

5.2 Crawler.............................................................................................................. 5-1

5.3 Irrigation Device ................................................................................................5-2

Appendix A Configuration List of Nodes and Pipes ................................................... A-1

DCY4.021.277/282/283/CPS02SS/V1.0/A-E

I
 Preface

Preface

The CPS-02 series crawler is suitable for long-distance pipeline with diameter of

100~1000mm. The crawler includes two PA probe holders and one pair of TOFD probe

holders. Phased array or TOFD testing plan is available according to requirements. The

main features are as follows:

a) Node structure, easy to assemble and disassemble, can quickly adapt to pipeline

testing.

b) Spring rail structure, the probe holder can move up and down with the tested

surface, so that the wedge is well coupled with the tested workpiece.

c) The scanning is stable and the defect detection rate is high.

d) Sturdy and lightweight, easy to carry and operate.

To learn how to operate the product quickly, please read this manual carefully before

using the product. If you have any questions, please contact us through the contact

information below.

Contact information:

Shantou Institute of Ultrasonic Instruments Co., Ltd. (SIUI)

Add: 77 Jinsha Road, Shantou, Guangdong 515041, China

Tel: 86-754-88250150 Fax: 86-754-88251499

Web site: http: //www.siui.com/

E-mail: siui@siui.com

II
 Operation Cautions and Safety Guide

Operation Cautions and Safety Guide

Before use, please read this Manual carefully and follow the instructions for assembly.

Please keep this manual properly. SIUI shall not be responsible for any loss due to not

following the instructions in the Manual.

 Please keep this manual in a safe and easy-to-find location for quick access.

 Some mechanical details in this manual may differ from the actual ones, but the

principle of operation is the same.

 When using this product to test a workpiece not horizontally placed or assembled,

if the testing is suspended, the product shall be withdrawn in time to prevent the

product from falling accidentally.

 Be sure to use instruments and equipment conforming to SIUI technical

specifications to avoid any incompatibility.

 Do not try to disassemble or repair the crawler by yourself, so as to avoid

personal injury or equipment damage.

 Do not use the CPS-02 series crawler for any area not related to its intended

purpose.

 Be sure to disconnect the crawler from the task equipment when cleaning.

III
 Product Introduction

Chapter 1 Product Introduction

1.1 Parameters of Crawler

Table 0-1 CPS-02 Series crawler parameters

No. Parameter Value

1 Dimensions 30×10×375cm (for Max. pipe diameter)

Applicable
2 Pipes with diameter 100~1000mm
parts
Encoder
3 0.12mm (8.6steps/mm)
precision
4 IP rating IP68
Applicable
5 0~40℃ (32~104℉)
temperature
★ The values do not include the wedge, irrigation device and other
accessories.

1.2 Composition of Crawler

The CPS-02 Series crawlers include: CPS-02, CPS-02A and CPS-02B, with composition

as follows:

Table 0-2 Composition of CPS-02 crawler

No. Part Part No. Qty Remark

1 Truss F1-12 1

2 Probe holder HFL-20 1

3 Probe holder HFR-20 1

4 Gantry node CL-14 1 Including encoder EN-17

5 Node CPS-02-EN 1

6 Pipeline PI-02 1

1-1
 Production Introduction

Fig. 0-1 Composition of CPS-02 crawler

Table 0-3 Composition of CPS-02A crawler

No. Part Part No. Qty Remark

1 Truss F1-12 1

2 Truss F2-09 1

3 Probe holder HFL-20 1

4 Probe holder HFR-20 1

5 Probe holder HFL-21 1

6 Probe holder HFR-21 1

7 Gantry node CL-14 1 Including encoder EN-17

8 Wheel WFM-08 4

9 Encoder wheel EN-13B 1

10 Node CPS-02A-EN 1

11 Pipeline PI-13 1

12 Pipeline PI-02 1

1-2
 Production Introduction

Fig. 0-2 Composition of CPS-02A crawler

Table 0-4 Composition of CPS-02B crawler

No. Part Part No. Qty Remark

1 Truss F2-09 1

2 Probe holder HFL-20 1

3 Probe holder HFR-20 1

4 Probe holder HFL-21 1

5 Probe holder HFR-21 1

6 Wheel WFM-08 4

7 Encoder wheel EN-13B 1

8 Node CPS-02B-EN 1

9 Pipeline PI-13 1

1-3
 Production Introduction

Fig. 0-3 Composition of CPS-02B crawler

1.3 Introduction of Parts

The CPS-02 series crawler consists of the combination of parts in Table 1-5, addressing

various testing requirements of different pipe diameters.

Table 0-5 Composition of CPS-02 Series Part

No. Part Part No. Drawing

1 Truss F2-09

2 Truss F1-12

Probe
3 HFL-20
holder

1-4
 Production Introduction

No. Part Part No. Drawing

Probe
4 HFR-20
holder

Probe
5 HFL-21
holder

Probe
6 HFR-21
holder

7 Wheel WFM-08

Encoder
8 EN-13B
wheel

Gantry
9 CL-14
node

10 Node CPS-02/02A/02B-EN

1-5
 Production Introduction

No. Part Part No. Drawing

11 Pipeline PI-13

12 Pipeline PI-02

1-6
 Assembly Instruction for Crawler

Chapter 2 Assembly Instruction for Crawler

2.1 Node Assembly

a) According to Appendix A Configuration List of Nodes and Pipes, use the
appropriate configuration list subject to pipe diameter and testing requirements,
and select the proper type and number of nodes. See Composition of CPS-02
Nodes for the node types.

Table 2-1 Composition of CPS-02 Nodes

No. Part Drawing Remark

Medium
1 Dark grey node
node

2 Hook node Red node

3 Short node

4 Hook

5 Long node

2-1
 Assembly Instruction for Crawler

No. Part Drawing Remark

6 Truss node

Gantry Including an
7
node encoder

Gantry Excluding an
8
node encoder

b) Pull the plunger out to the limit and rotate it by 90° to open the plunger at the
opening of the node, insert the other end of the node into the opening, and
rotate the plunger 90° to retract it. Move the node slightly so that the plunger
may snap into the opening at the end. All the nodes can be connected end to
end in the same manner to complete the node assembly.

Rotate 90° while

pulling outward to
the limit

After inserting the

node, rotate 90°,
and the plunger
can be retracted.

Fig. 2-1 Node assembly

2-2
 Assembly Instruction for Crawler

c) Place the node on the pipe so that the guides on the node catch the rail. Hook
the hook node, adjust the knob and then lock the handle backwards, and adjust
it several times so that push the whole node with a slight resistance.

The hook shall catch the

Adjust the knob and
then pull backward to hook node first
Handle
lock the handle

Knob

Fig. 2-2 Hook assembly

d) Push 2~3 turns quickly in one direction for node correction.

【Note】:

1) Pull the hook tightly till it is slightly resisted. Too loose will affect the

moving precision, while too tight will lead to excessive resistance during

push movement and even disjoint when travelling over bulged sections

such as spiral weld.

2) Make sure that the nodes are assembled in place before use, that is, the

plungers on both sides are rebounded into place.

2.2 Probe holder

【Note】: There are two types of truss for CPS-02: F1-12 or F2-09 can be

selected according to requirements. The probe holder can be assembled to the

truss in the same way. In this section, F2-09 truss is used as an example. F1-12

can be assembled in the same way.

2-3
 Assembly Instruction for Crawler

a) Align the stud on the probe holder handle with the nut on the truss, and attach

the probe holder to the truss. Tighten the handle clockwise to secure the probe

holder to the truss.

Fig. 2-3 Probe holder assembled to the truss

b) To adjust the position of the probe holder, loosen the handle for about half a turn,

move the probe holder to the desired position and retighten the handle.

Fig. 2-4 Position adjustment of probe holder

2-4
 Assembly Instruction for Crawler

c) To adjust the height of the probe holder relative to the truss, loosen the two

adjusting screws on the side of the probe holder fixing base, adjust to the

appropriate height as needed, and then retighten it.

【Note】: The screws shall be kept safe to avoid loss.

Adjustment

screw

Fig. 2-5 Height adjustment of probe holder

d) Apply the couplant on the mating surface of the probe and the wedge, and then

assemble it onto the wedge using a hex screwdriver.

【Note】: Before assembling the probe and the wedge, make sure that the
mating surfaces of probe crystal and the wedge are clean and free of dust,
rust and other foreign objects to avoid scratching the probe or wedge
during the assembly process. If foreign matter is present at the mating
surface of the probe crystal or wedge, rinse it with water and wipe it off
with soft cloth. Do not wipe the probe or wedge directly with soft cloth in
the presence of foreign matter, which may lead to damage due to direct
friction between the foreign matter and the probe/ wedge.

Wedge

Wedge Probe

Probe

Fig. 2-6 Probe assembly

2-5
 Assembly Instruction for Crawler

e) To achieve water coupling, the probe shall be connected to the pipeline and the

irrigation device. The connection of the hose and the wedge is as shown in the

figure.

【Note】: After assembly, check whether the two water outlets of the wedge can

discharge water. If there is blockage or uneven water discharge, it is likely that the

outlet holes are blocked by the coupling agent. Please clear the coupling agent.

Water outlet
Water injection joint

Fig. 2-7 Checking wedge blockage

f) Loosen the probe screw on the probe holder first. Then align the wedge

positioning hole with the probe screw. Tighten the probe screw to fix the wedge

on the probe holder to complete the probe assembly.

【Note】: The probe screws shall be kept safe to avoid loss.

Loosen the

probe screw

2-6
 Assembly Instruction for Crawler

Fig. 2-8 Probe holder assembly

2.3 Wheels and encoder wheel assembled to truss

【Note】: Wheels and the encoder wheel are required for assembly only when

using F2-09 truss. The wheels and the encoder wheel are not required when using

F1-12 truss.

a) Align the stud on the wheel handle with the nut on the truss, and attach the wheel

base to the truss. Tighten the handle clockwise to secure the wheel to the truss.

Fig. 2-9 Wheels assembled to the truss

2-7
 Assembly Instruction for Crawler

b) Insert the four wheels into the truss, adjust them to the appropriate position and

tighten the handles. To adjust the wheel position, loosen the handles for about

half a turn, and move the wheels to the appropriate position and then re-tighten

the handles.

Fig. 2-10 Wheel assembly

c) Assemble the encoder wheel onto the truss with a hex wrench in the same way,

adjust to the appropriate position and tighten the screws. To adjust the wheel

position, use the hex wrench to loosen the screw for about half a turn and move

the wheel to the proper position and then retighten it.

Screw

Fig. 2-11 Encoder wheel assembled to truss

2-8
 Assembly Instruction for Crawler

2.4 Assembly of Pipeline PI-13 and Irrigation Device IH-05

a) Select the appropriate location on the truss (a nut is available on the truss to hold
the water separator) and use the enclosed hex wrench to secure the water
separator to the truss. To adjust the position, loosen the screw on the water
separator, move the water separator to the appropriate position, and then
re-tighten it.

Water
separator

Fig. 2-12 Water separator assembly

b) Connect the water distribution pipe and the main water pipe with the connector of
the water separator. Note: There are two courses in the connection. The first
one is for locking, and the second one is for sealing. During the connection,
ensure that both courses are completed!

Water

distribution

pipe
Main water

pipe

Fig. 2-13 Connection of water distribution pipes

2-9
 Assembly Instruction for Crawler

c) To pull out the hose, firstly hold the section as indicated and then remove the
hose.

Hold here to pull out

the hose

Fig. 2-14 Pull out the water pipe

d) Assemble the water injection joint to the probe wedge.

Water injection joint

Fig. 2-15 Water injection joint assembled to the wedge

e) Connect the two outlet hoses of the water distribution pipe with the two water
injection joints on the irrigation wedge, so as to complete the assembly of the
pipeline and the probe.

Water injection joint

Fig. 2-16 Connection of the hoses and the water injection joints

2-10
 Assembly Instruction for Crawler

f) Connect the main pipe of the water separator with the quick connector the
irrigation device to complete the assembly.

Connecting the main pipe

of the water separator

Irrigation device
Quick Connector IH-05

Fig. 2-17 Connecting water pipe and irrigation device

Note:
 There are two courses in the connection of the water pipe and the quick
connector. The first one is for locking, and the second one is for sealing.
During the connection, ensure that both courses are completed.

 When pulling out, hold and press the black plastic button of the quick
connector in place before pulling out the hose.

2.5 Truss assembled to node

【Note】: When using F2-09 truss, assemble according to steps a)~ b); when

using F1-12 truss, assemble according to step c).

a) Adjust the flank distance of the wedge according to the testing requirements.
When adjusting, loosen the triangle handle as indicated and move the probe
holder.

2-11
 Assembly Instruction for Crawler

Fig. 2-17 Adjust the flank distance of the wedge

b) After assembling the node, loosen the handle on the truss node, adjust the
wheel and encoder wheel positions to avoid interference with the truss node,
then snap the truss into the truss node and press down firmly to ensure the
wedge and the encoder wheel can be attached to the tested workpiece, and
then tighten the handle.

Truss handle

Fig. 2-18 Truss F2-09 assembled to Truss node

2-12
 Assembly Instruction for Crawler

Note:

 The handle of the truss node can be adjusted by pulling up, turning to the
appropriate angle and releasing it.
Pull up, turn to
the proper
angle and
release it

Fig. 2-19 Handle position adjustment

 Please pay attention to avoid interference between the encoder wheel and the
nodes during assembly process.
 Continue to press the truss in the assembly process to make it in good contact
with the pipeline.
c) Loosen the handle of the gantry chain node, put the truss into the gantry node,
adjust the position and height of the probe holder, press the wedge firmly to
ensure that the wedge and the workpiece fit together, and tighten the handle to
fix the truss.

2-13
 Assembly Instruction for Crawler

Truss

Fig. 2-20 Truss F1-12 Assembly

2-14
 Preparation for Testing

Chapter 3 Preparation for Testing

a) Assemble the node to the pipeline [for details, see 2.1 Node Assembly].

b) Assemble the wedge onto the probe holder [for details, see f) of 2.2 probe

holder].

c) Assemble the truss onto the node [for details , see 2.5 Truss assembled to

node].

d) Assemble the probe holder onto the truss. Adjust the position of the probe holder

according to the testing requirements [for details, see a) and b) of 2.2 Probe

holder].

e) Connect the pipeline with the irrigation device.

f) Connect the probe cable and the encoder cable with the instrument for

performing testing.

3-1
 Troubleshooting

Chapter 4 Troubleshooting

Table 4-1 Troubleshooting List

No. Failure Possible Cause Solution

Wedge shake during The probe screw does not Tighten the screw of the probe
1
use clamp the wedge tightly. arm [see f) of 2.2 probe holder].

Stop the water outlet hole that

outflows normally at the bottom
No water flow from the
2 The water outlet is blocked of the wedge, so that the
wedge outlet
blockage on the other side is
pushed out by the water flow.
The probe holder does Probe holder height Adjust the probe holder height
3 not touch the tested adjustment is not as needed [see step c) of 2.2
workpiece. appropriate. probe holder].

4-1
 Maintenance

Chapter 5 Maintenance

5.1 Probes and wedges

a) Try to avoid removing the wedge from the probe to ensure no damage to the
probe crystal during transportation and storage. If the wedge must be removed,
properly package the probe (especially the crystal side). It is highly
recommended to ensure that the probe is assembled with the wedge in
any situation for safe and reliable protection.
b) After using for a period of time, check whether the coupling agent between the
probe crystal and the wedge is sufficient and replenish it in time to avoid
affecting the detection effect.
c) When removing the TOFD probe cable, hold the knurled part of the plug to avoid
damage to the cable or socket.

Knurled
part

Fig. 5-1 Connection of TOFD probe cable

d) When installing the probe adapter, it is recommended to tighten the M3 screw.
e) Be sure to use the wedge model that fits the pipe to ensure a good and stable
coupling.

5.2 Crawler
a) The TOFD probe cable, and the plug and socket of the encoder shall not be
removed at the site as much as possible to ensure that they will not cause bad
contact or damage due to sand, mud or other dirt.
b) Remove the encoder plug and instrument plug by holding the knurled part of the
plug to avoid damage to the cable or socket.
c) After use, rinse the dirt on the crawler with clean water, then wipe it gently with
soft cloth.
d) When cleaning the wheel, turn the wheel while removing the fine dirt inside.
When cleaning the chain nodes, the plunger can be pulled back and forth to

5-1
 Maintenance

remove the fine dirt inside.

e) At the instrument, use a cable tie to secure the cable to avoid damage to the
cable plug when pulled.
f) The encoder precision shall be corrected after a period of use to ensure the
testing accuracy.

5.3 Irrigation Device

a) When filling water, please be careful to avoid the water volume exceeding the
rated capacity (Max. 5L). Otherwise, pressurization may lead to excessive
pressure, water leakage, or even accelerating to pump damage.
b) When transporting the irrigation device, please turn the handle counterclockwise
to snap it into the slot before using the handle to lift the irrigation device.
Otherwise, the pump may be damaged due to excessive force.

Turn
counterclockwise
into the slot

Fig. 5-2 Transport of irrigation device

c) The irrigation device should be placed upright after being filled with water to
avoid lateral, inclined or inverted placement, otherwise the sealing layer may be
damaged to cause water leakage and water flow back from the pump.
d) When not using the irrigation device for a long time, please remove the internal
pressure. The specific step is to pull the exhaust valve out till the sound of “si-si”
is gone.

5-2
 Maintenance

Exhaust valve

Fig. 5-3 Exhaust of irrigation device

e) After using on the same day, please rinse the inside of the irrigation device to
remove the debris inside to avoid blockage of the irrigation device.
f) The irrigation device can only be filled with tap water. Do not use other solvents.

5-3
 Configuration List of Nodes and Pipes

Appendix A Configuration List of Nodes and Pipes

When the CPS-02 Series crawler is equipped with single beam nodes (CL-14 and CL-15),

see Table A-1 for Configuration List of Nodes and Pipes, which covers the range of pipe

diameter 100~1000mm. For the use of the dual beam nodes (CL-16) or mixed use (that is,

the single beam node CL-14 and CL-15 are mix used with the dual beam node CL-16),

see Table A-2 for the range of pipe diameter 300~1000mm.

Table A-1 Configuration List of Nodes and Pipes

Note:

1. Applicable to the case where only single beam nodes (CL-14 and

CL-15) are assembled.

2. CL-14, CL-15 and medium nodes can be replaced.

Range of pipe diameter Number of nodes (pc)

Short Medium Long

Min. (mm) Max.(mm)
node node node

100 109 0 0 0

110 127 1 0 0

128 144 0 1 0

145 162 1 1 0

163 179 0 2 0

180 198 1 2 0

199 214 0 3 0

215 233 1 3 0

234 249 0 4 0

250 269 1 4 0

270 285 0 5 0

A-1
 Range of pipe diameter Number of nodes (pc)

Short Medium Long

Min. (mm) Max.(mm)
node node node

286 306 1 5 0

307 322 0 6 0

323 342 1 6 0

343 357 0 7 0

358 377 1 7 0

378 393 0 8 0

394 413 1 8 0

414 429 0 9 0

430 448 1 9 0

449 464 0 10 0

465 483 1 10 0

484 500 0 11 0

501 519 1 11 0

520 535 0 12 0

536 555 1 12 0

556 570 0 13 0

571 590 1 13 0

591 606 0 14 0

607 625 1 14 0

A-2
 Range of pipe diameter Number of nodes (pc)

Short Medium Long

Min. (mm) Max.(mm)
node node node

626 642 0 15 0

643 661 1 15 0

662 677 0 16 0

678 697 1 16 0

698 710 1 5 4

711 725 0 6 4

726 744 1 6 4

745 760 0 7 4

761 779 1 7 4

780 795 0 8 4

796 814 1 8 4

815 830 0 9 4

831 849 1 9 4

850 864 0 10 4

865 883 1 10 4

884 899 0 11 4

900 919 1 11 4

920 934 0 12 4

935 954 1 12 4

A-3
 Range of pipe diameter Number of nodes (pc)

Short Medium Long

Min. (mm) Max.(mm)
node node node

955 969 0 13 4

970 989 1 13 4

990 1000 0 14 4

A-4
 Table A-2 Configuration List of Nodes and Pipes

Note:

1. Applicable to the case where dual beam nodes are assembled, or

single and dual beam nodes are mix used.

2. Single beam nodes include CL-14 and CL-15, and dual beam nodes

include CL-16.

3. CL-14, CL-15 and medium nodes can be replaced.

4. CL-16 is only suitable for pipe diameters above 300.

Range of pipe diameter Number of nodes (pc)

Short Medium Long

Min. (mm) Max.(mm)
node node node

300 314 0 5 0

315 332 1 5 0

333 349 0 6 0

350 367 1 6 0

368 383 0 7 0

384 402 1 7 0

403 418 0 8 0

419 437 1 8 0

438 453 0 9 0

454 472 1 9 0

473 488 0 10 0

489 507 1 10 0

508 523 0 11 0

A-5
 Range of pipe diameter Number of nodes (pc)

Short Medium Long

Min. (mm) Max.(mm)
node node node

524 543 1 11 0

544 558 0 12 0

559 578 1 12 0

579 594 0 13 0

695 614 1 13 0

615 629 0 14 0

630 649 1 14 0

650 665 0 15 0

666 698 1 15 0

699 714 0 5 4

715 733 1 5 4

A-6
 Range of pipe diameter Number of nodes (pc)

Short Medium Long

Min. (mm) Max.(mm)
node node node

734 748 0 6 4

749 767 1 6 4

768 783 0 7 4

784 802 1 7 4

803 818 0 8 4

819 837 1 8 4

838 852 0 9 4

853 872 1 9 4

873 887 0 10 4

888 907 1 10 4

908 922 0 11 4

923 942 1 11 4

943 957 0 12 4

958 977 1 12 4

978 993 0 13 4

993 1000 1 13 4

A-7