Cosasco P/N 748685 - August 2021

Echo Data®
User Manual

08-010011 EN – Revision B
Aug2021

11841 Smith Ave.

Office: (562) 949-0123 www.cosasco.com/echopoint
Santa Fe Springs, CA 90670

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Cosasco, 11841 Smith Ave, Santa Fe Springs, CA 90670

Copyright © 2021 Cosasco, Inc.

All rights reserved. No part of this publication may be reproduced, distributed, or transmitted in any
form or by any means, including photocopying, recording, or other electronic or mechanical methods,
without the express written permission of Rohrback Cosasco Systems, Inc., except in the case of brief
quotations embodied in critical reviews and certain other noncommercial uses permitted by copyright
law.

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

Part Number: 748685

Date: Aug 2021

Printed in the United States

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TABLE OF CONTENTS
1 Operating instructions: Echo Data Configuration
Software ...................................................................................................................... 5
1.1 Overview: ............................................................................................................................ 5
1.2 Theory of operation: ........................................................................................................... 5
1.3 Compatibility:...................................................................................................................... 5
1.4 Communication Drivers ...................................................................................................... 6
1.5 Launching the application: .................................................................................................. 6
1.6 Home Screen, Basic Navigation .......................................................................................... 6
1.6.1 Basic Navigation:..................................................................................................... 6
1.7 Settings: .............................................................................................................................. 7
2 Connecting the Echo Point Sensor ..................................................................... 8
2.1 Connecting the Communication Cable ............................................................................... 8
2.1 Service Port Connector ....................................................................................................... 9
3 Read Function ................................................................................................. 10
3.1 Read Sensors ..................................................................................................................... 10
3.1.1 A-Scan View .......................................................................................................... 12
3.1.1 Thickness View ...................................................................................................... 12
3.1.2 Summary View ...................................................................................................... 13
4 Setting Up The Echo Point Sensor .................................................................... 14
4.1 COMM Settings ................................................................................................................. 14
4.1.1 Com Settings Fields and Descriptions ................................................................... 15
4.2 UT Settings ........................................................................................................................ 17
4.2.1 UT Settings Fields and Descriptions ...................................................................... 18
5 Troubleshooting .............................................................................................. 21
5.1 No COM PORT is shown on the Settings Window ............................................................ 21
6 Software Licensing Agreement ........................................................................ 22

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1 OPERATING INSTRUCTIONS: ECHO DATA CONFIGURATION SOFTWARE

The purpose of this chapter is to introduce the Echo Data Configuration PC application. This chapter
covers the following information:

• Overview
• Theory of Operation
• Compatibility
• Communication Drivers
• Launching the application
• Home Screen, Basic Navigation
• Settings

1.1 OVERVIEW:
The Echo Data Configuration application enables administrative users to set up and modify the settings
of Echo Point sensors. Default factory settings can be changed to optimize the measurement of the
ultrasound echoes, set measurement timing periods and other functions and information within the
devices.

1.2 THEORY OF OPERATION:

The Echo Data Configuration application is workflow based in that the main program functions are
accomplished by navigating the user through a series of User Interface (UI) screens. The main workflows
in the software include: reading data, configuration of communication settings and set up of Ultrasound
measurement settings of the Echo Point sensor.

Additionally, program settings and information are located as icons at the left side of the program
window. These icons are available for navigation from any point in the program operation. Pressing the
“Home” icon will always return the user to the main program window.

1.3 COMPATIBILITY:
The application is compatible with and has been tested with the following operating systems:

• Microsoft Windows 10

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1.4 COMMUNICATION DRIVERS

Echo Point software communicates with the Echo Point sensor via a custom USB serial cable. Connection
to a Echo Point device may require software drivers to be installed onto the laptop/tablet. The
laptop/tablet user must have rights to the com ports of the device. Consult with your IT team to ensure
your laptop/tablet is propery configured for USB-Com Port Communication to the Echo Point sensor.

1.5 LAUNCHING THE APPLICATION:

• Click the logo on the start menu
• OR double click the EchoData.exe program file in C:\Program Files (X86)\Echo Data

1.6 HOME SCREEN, BASIC NAVIGATION

The home screen is shown above and can always be accessed by pressing the “Home” button at the
upper left of the program window.

1.6.1 Basic Navigation:

Navigation of the program involves program utilities that are addressed as icons on the left side of the
screen and the main program functions that are shown as buttons on the middle of the home screen.

1.6.1.1 Program Utilities

Utilities and informational functions are shown as icons on the left side of the main program window.
The following functions are accessible:

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• Home: Returns the user to the main program window

• About: Displays program copyright information and the software revision
• Help: Launches this manual
• Settings: Allows the user to adjust various program settings

1.7 SETTINGS:
The settings functions are addressed on the settings page that is addressed by pressing the settings icon
along the left side of the screen. Below is shown a screen shot of the settings screen. The functions are
described as follows:

• Com Port: This setting identifies the com port of the RS-485 adapter. Select the com port that is
associated with the adapter from the pull-down window. Baud rate control for Echo Point
instrumentation is to be set to 115200.
• Units: Allows the user to set the measurement units (mm or in) and precision
• Auto-Read: When enabled, the auto read function can be used to take repeated measurements
on a timed interval.
• Language: Allows the user to set the language in the program. Contact your Cosasco
representative if you require a language that is not currently available.
• Keyboard button: Invokes the touchpad keyboard.
• Reset button: Used to re-set the sensor configuration with a saved or factory supplied
parameter file.
• Save button: Saves changes to the settings.

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2 CONNECTING THE ECHO POINT SENSOR

The purpose of this chapter is to guide the user through the process of connecting the Echo Point sensor
to the PC/Laptop/Tablet. This chapter covers the following information:

• Connecting the Communication Cable

• Service Port Connector

2.1 CONNECTING THE COMMUNICATION CABLE

To connect the Echo Point sensor to the PC, a communication cable must be used. The cable is plugged
into the USB port of the computer/tablet. The pin connector is connected to the Echo Point sensor
service port. The service port connector is located inside the sensor. The battery cover must be removed
to access the service port.

Open the top of the Echo Point sensor. Remove the two hex head screws from the lid using a small hex
head driver. Pull the cap off the top of the sensor to expose the batteries, on-off switch and service port
connector. Note the location of the 5 pin connector.

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2.1 SERVICE PORT CONNECTOR

The service cable uses a polarized 6 pin linear connector. The end position of the connector is blocked so
to ensure the connector is not inserted into the service port incorrectly. Note the orientation of
connector of Echo Point service cable (03-010135). The green wire hole is blocked off.

Insert the Echo Point commissioning cable into the Echo Point unit as shown below.

Connect the other end to the PC. Confirm the comm-port settings as outlined in section 1.7.

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3 READ FUNCTION
The purpose of this chapter is to guide the user through the process of obtaining a ultrasound thickness
reading from the Echo Point sensor to the PC/Laptop/Tablet using the Echo Data application. This
chapter covers the following information:

• Read Sensors
• A-Scan View
• Thickness View
• Summary View

The main purpose of the program is to read a data record from Echo Point sensor, view the thickness
and waveform and save the file to the laptop/tablet.

The Echo Point sensor must be ready to power on with the service cable connected.

Open the Echo Data software application and verify the proper comm port settings are made.

3.1 READ SENSORS

The Read sensors function is used to collect a UT thickness measurement from the Echo Point sensor
when connected to the service port. The sensor must be powered on and the interface cable plugged
into the sensor.

Step 1 : Launch the Echo Data software. Open Settings and check that the proper com port is selected
and the baud rate is set to 115200. Save settings to return to the main page.

Step 2 : Power on the Echo Point sensor by moving the power switch from off to the on position.

Step 3 : Within 30 seconds of powering on the Echo Point sensor, click the Read Sensors button on the
Echo Data software main screen.

Note : the first 30 seconds after power up, the Echo Point sensor will be scanning the service port for a
computer connection. If no computer connection is made, the sensor will stop communications on the
service port and boot up in radio mode.

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The Echo Data software will scan the Comm Port and establish a connection to the Echo Point sensor.

During the connection process, a message is displayed in the top menu bar with the message Scanning
network… the process circle will rotate for a few seconds.

After the connection is made, the Echo Data software will instruct the sensor to make a thickness
measurement. The Echo Point Sensor will make ultrasound measurements and the software will display
the A-Scan window.

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From the A-Scan window, you can use the menu buttons at the bottom of the page to view the thickness
values, view summary, and done to exit and return to the main menu.

3.1.1 A-Scan View

3.1.1 Thickness View

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3.1.2 Summary View

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4 SETTING UP THE ECHO POINT SENSOR

The purpose of this chapter is to guide the user through the process of setting up the Echo Point sensor.
Communications and ultrasound settings. This chapter covers the following information:

• COM Settings
• UT Settings
• A-Scan View

The Echo Point sensor comes from the factory with default communication and ultrasound set up
information pre-loaded. It maybe necessary to input network information and adjust ultrasound
parameters to optimize ultrasound thickness measurement performance.

4.1 COMM SETTINGS

The Echo Point sensor uses communication settings to instruct the sensor when to make a thickness
measurement and also the network ID and Join Key.

Step 1 : Launch the Echo Data software. Open Settings and check that the proper com port is selected
and the baud rate is set to 115200. Save settings to return to the main page.

Step 2 : Power on the Echo Point sensor by moving the power switch from off to the on position.

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Step 3 : Within 30 seconds, click the COM Settings button on the Echo Data software main screen.

Note : the first 30 seconds after power up, the Echo Point sensor will be scanning the service port for a
computer connection. If no computer connection is made, the sensor will stop communications on the
service port and boot up in radio mode.

Once connected, the COMM settings window will be displayed.

4.1.1 Com Settings Fields and Descriptions

Serial Number: This is a display only field. It displays the serial number of the Echo Point sensor.

Probe Model: Select the sensor ultrasound probe model from the pull down list. This is typically pre-set
at the factory and should not be changed.

Model: This is a display only field. It displays the model type of the Echo Point sensor.

Shot Time Interval: The three fields (Day:Hour:Minute) is set to instruct the Echo Point sensor how
frequently to turn on and make an ultrasound thickness measurement. The minimum value for the shot
time interval is 5 minutes. A warning message will be displayed if the value entered is lower than 5
minutes.

Network ID: This field contains the network ID value as assigned by (0-65,535)

Common Join Key: These 4 fields contain the Join Keys for the network. Each field is Alphanumberic (0-9,
A-F)

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Program Button: When the network ID and Join Key information is entered in the fields, clicking the
program button will transfer the data into the Echo Point sensor.

Join Status: Information as read from the sensor regarding the network connection and status
information. Note that when the sensor is connected to the PC using the commissioning cable, it will
show a connection to the network but is not sending ultrasound/temperature data to the network.

Click the Save button when done updating the required fields.

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4.2 UT SETTINGS
This mode of the Echo Data software is used to set up the ultrasound measurement settings of the Echo
Point sensor.

The UT Settings window is used to set-up the Echo Point device after it has been installed and
normalized to the test object.

Step 1 : Launch the Echo Data software application and check that the proper com port is selected and
the baud rate is set to 115200.

Step 2 : Power on the Echo Point sensor by moving the power switch from off to the on position.

Step 3 : Within 30 seconds, click the COM Settings button on the Echo Data software main screen.

Note : the first 30 seconds after power up, the Echo Point sensor will be scanning the service port for a
computer connection. If no computer connection is made, the sensor will stop communications on the
service port and boot up in radio mode.

Once connected, the UT Settings window will be displayed.

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4.2.1 UT Settings Fields and Descriptions

A-Scan: The live A-Scan is displayed at the top of the window. Adjustments can be made to the A-Scan
by clicking on the A-Scan and while holding down the left mouse key, drag down to expand the A-Scan
image. Click and drag left or right to move the A-Scan to the left or right within the A-Scan viewing
window area.

Within the A-Scan window, the gate(s) are displayed for measuring the thickness. The A-Scan echo
crossing the threshold of the gate is where the measurement is made. When the system is making a
measurement on an A-Scan within the gate, a carrot is displayed at the bottom of the A-Scan indicating
the point on the A-Scan being used to make the thickness measurement.

Dual element sensor types will display a single gate. UHT single element sensors will display two gates.
Controls lower in the Sensor Params page control the position of the gates.

The scale of the A-Scan window can be changed by clicking and dragging the mouse pointer within the
A-Scan window. Click and drag left or right to move left or right in the A-Scan. Click and Drag up and
down to change the range of the A-Scan.

Measured Thickness: The measured thickness value is displayed under the A-Scan window.

Model displays the sensor type being used for the thickness measurement.

Type* displays the sensor configuration being used for the thickness measurement.

Description* is a field where additional description information can be added. The fields cannot contain
any of the following characters: \ / : * ? " < > |

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Latitude*: Enter the location latitude into this field

Longitude*: Enter the location longitude into this field

Material Velocity: This is a factory setting set to the approximate value of carbon steel. If the Echo Point
is being mounted to a material other than carbon steel, the velocity value can be changed to the known
acoustic velocity of the non-carbon steel material.

Nominal Wall Thickness*: This is typically the as new wall thickness value or the value when first
beginning to monitor a TML.

Minimum Wall Thickness*: This is the wall thickness value which will output an alarm condition for the
TML.

Warning Wall Thickness*: This is the wall thickness value which will output an caution condition for the
TML.

Cal Zero Offset: This value is factory set for each sensor. It is used to adjust the acoustic thickness offset
for the delays within the dual element sensor.

Setup1 Tab

Pulse Width: This is the width of the pulse used to drive the sensor. This is set based on the frequency of
the sensor. The factory setting is 85 nanoseconds. Do not change this unless instructed by Cosasco.

Gain: This adjusts the amplitude of the A-Scan echoes within the A-Scan image (top of page). The
maximum is 39.9dB. This is typically set at the factory and then adjusted after the sensor has been
mounted to the test object and normalized.

Automatic Gain Control*: Checking the box disables the Gain value above and puts the system into
automatic gain control mode. This is only used is special situations where the sensor signal gain is
subject to large variations due to surface coupling issues. Only use this when instructed by qualified
factory trained personnel. (Not active in Echo Point Sensor)

Sensor Number*: Shows the sensor number being adjusted. For a Echo Point this will always be set at 1.

Averages*: Number of acoustic shots made and averaged used to display the A-Scan and make a
thickness reading. The factory setting is 16. It is suggested to keep this at 16 to achieve the most stable
reading. Only change when instructed by qualified factory trained personnel.

Ascan Start: This is factory set default based on the sensor type. Only change when instructed by
qualified factory trained personnel.

Measurement Mode: This is factory set default based on the sensor type. 0 for dual element, 1 for single
element. Only change when instructed by qualified factory trained personnel.

Gates

Start: Controls the position of the starting point for gate 1 or gate 2 as shown in the live A-Scan window
at the top of the screen.

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Width: Controls the position of the end point for gate 1 or gate 2 as shown in the live A-Scan window at
the top of the screen.

Threshold: Controls the location, positive or negative in relation to the base line of the A-Scan for gate 1
or gate 2 as shown in the live A-Scan window at the top of the screen.

* denotes local data stored on device only. Not transmitted to network.

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5 TROUBLESHOOTING

5.1 NO COM PORT IS SHOWN ON THE SETTINGS WINDOW

This software uses COM PORT communication to connect and communicate with the Echo Point
instrument. The Commissioning Cable (P/N ZXXXXX) is required for this function. COM PORT drivers for
the commissioning cable are also required to be installed and registered on the local PC. Drivers are
supplied as a separate installation execuitable with the Echo Point software.

The PC user profile must have access to the COM & LPT ports of the machine. Consult with your IT
department to ensure the user has these authorities on the local machine. Confirmation of the COM
PORT access and driver installation can be confirmed in the Windows Device Manager.

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6 SOFTWARE LICENSING AGREEMENT

NOTICE TO USER: PLEASE READ THESE TERMS AND CONDITIONS CAREFULLY. BY USING ALL OR ANY PORTION OF THE
SOFTWARE YOU ACCEPT ALL THE TERMS AND CONDITIONS OF THIS AGREEMENT, INCLUDING, IN PARTICULAR THE
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YOU. IF YOU DO NOT AGREE, DO NOT USE THIS SOFTWARE.

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