CTRL Systems UL101 User manual

CTRL UL101
Ultrasonic Inspection System
Operator’s Manual
© Copyright 2018 CTRL Systems, Inc.
All rights reserved. Copying, duplicating, or otherwise distributing this document, in whole or
part, without written permission of the publisher in any media is violation of federal copyright
law.
The information contained in this document is subject to change without notice. CTRL
Systems shall not be liable for errors contained herein or for consequential damages in
connection with the furnishing, performance, or use of this material.
CTRL, the CTRL logo, CTRL UL101, InCTRL and PowerBeam 300 are the property of
CTRL Systems, Inc.

CONTENTS
Introduction......................................................................................................... 1
Registration Information .................................................................................... 1
Product Overview ............................................................................................... 2
Advantages of Ultrasonic Inspection with the CTRL UL101.............................. 2
Product Features............................................................................................... 2
Ultrasound Overview......................................................................................... 3
Components................................................................................................... 4-6
CTRL UL101 Receiver, Transmitter, and Components..................................... 7
CTRL UL101 Controls....................................................................................... 8
Getting Started.................................................................................................... 9
CTRL UL101 Set-up Procedure ................................................................... 9-10
Typical Applications ........................................................................................ 11
Tips & Techniques............................................................................................ 12
Operating Techniques..................................................................................... 12
Operating & Technical Tips............................................................................. 13
Adverse Operating Conditions ........................................................................ 14
Important Safety Information........................................................................... 15
General Info....................................................................................................... 16
Maintenance and Care.................................................................................... 16
Expected Battery Life...................................................................................... 16
Determining if Batteries Need to be Changed................................................. 16
Replacing Batteries......................................................................................... 17
Warranty and Repairs ..................................................................................... 17
Additional Resources....................................................................................... 18
Product Support .............................................................................................. 18
Product and Technology Training ................................................................... 19
On-site Training .............................................................................................. 20
Condition-based Monitoring Products ........................................................ 21-22
Corona Discharge & Electrical Arcing Products .............................................. 23
Products & Accessories .................................................................................. 24
Special Note:
Please read this manual in its entirety to obtain a good understanding of how to
test with the UL101. It is also highly recommended that the user take advantage
of additional support and training available through CTRL.
For your safety, please take special note of the Safety Information on
page 15, as well as any section marked with the symbol shown at left.

INTRODUCTION
Thank you for purchasing the CTRL UL101 Ultrasonic Inspection
System (UL101). You have made the right investment for the operational,
maintenance, and quality control needs of your organization. When used
on a regular basis, the UL101 is a valuable tool for diagnosing potential
problems, identifying cost saving opportunities, and increasing production
and profit.
The UL101, originally designed for the U.S. Military, is now used in
several industries throughout the world for condition-based monitoring,
quality control, and leak detection. The UL101 Receiver detects and
converts ultrasound signals produced by industrial machinery and
vehicles into easily recognizable audible sounds (within the human range
of hearing) so the user can evaluate the operating condition of bearings
and gears, detect pressure or vacuum leaks, and identify electrical
problems, such as corona discharge – even in extremely noisy plant
environments.
Tightness and integrity testing can also be performed on non-pressurized
tanks, lines, pipes, and other vessels with the UT2000 Universal
Transmitter (included in the CTRL UL101 Full Kit).
With the CTRL UL101, early warning signs and defects can be detected –
thus preventing costly repairs, safety-related injuries, and downtime.
It is the goal of CTRL Systems, Inc. that you receive the highest return on
investment for your purchase of this system and that it makes your daily
maintenance and operations activities easier. This manual is designed as
a complimentary resource to the Technology Training CD that you
received with the UL101. On-site training is a great way to introduce
ultrasound technologies to your team. See page 20 for details.
Important Product/Warranty Registration Information
To register your product and activate the warranty coverage, complete
the registration card that was included with your system and return it to
CTRL, or register online at www.ctrlsys.com/community.
When you register, you will automatically become a member of the CTRL
Online Community and will have access to online support, tips, and
downloads.
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PRODUCT OVERVIEW
What is Ultrasound?
The UL101 Receiver uses the properties of ultrasound for inspection.
Ultrasound is sound with a frequency above the human hearing range.
Humans can hear sound with frequencies between 20 Hz (Hertz) and
20,000 Hz. Ultrasound is all sound above 20,000 Hz and cannot be heard
by humans. Ultrasound is created when there is:
•Vibration
•Impact
•Turbulence
•Friction
•Electrical arcing or corona discharge
The UL101 Receiver has a reception with the center of frequency at 40
kHz, the optimal frequency for listening for different kinds of industrial
defects. The CTRL UL101 converts ultrasound into audible sound so the
user can diagnose the condition of critical equipment. The primary
properties of ultrasound that make it useful for diagnostic tools are the
following:
•Rate of Attenuation – Ultrasound has a high frequency and
accordingly shorter wavelength, therefore ultrasound waves attenuate
more quickly than sound waves and do not travel as far as audible
sound.
•Directionality – The reception of ultrasound waves with the UL101
Receiver is directional, which allows the user to pinpoint the exact
location of the problem.
•Shielding - Ultrasound waves in air can be easily shielded and do not
travel easily around corners.
•Early Detection - Ultrasound can be detected prior to audible sound,
allowing problems to be detected earlier than with other methods.
These properties allow the user to distinguish and isolate the ultrasound
of individual components and leaks for better equipment diagnosis. For
example, if there are two bearings that are next to each other, because
ultrasound attenuates rapidly, it allows the user to listen to each bearing
individually. If the user is looking for a gas leak and other ultrasounds are
competing, a simple piece of cardboard typically allows the user to block
competing sound so that only leaks in the area being tested are heard. It
is also possible to then pinpoint the exact source of the leak because of
directionality.
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PRODUCT OVERVIEW
CTRL UL101 Component Description
UL101 Receiver
•Handheld sensor detects and electronically converts
ultrasound into easily recognizable sounds within the
human range of hearing.
•Supplies output to a headset, as well as to an analog
meter.
•Detects ultrasound from a greater distance with
a higher signal-to-noise ratio than any other
sensor on the market today.
•Easy-to-use controls include output switch, gain
mode switch, and potentiometer.
•Lightweight and durable.
•Operates on one 9-volt battery for
approximately 45 hours of continuous use.
UT2000 Universal Transmitter
•Used to detect seal, gasket, and weld defects in non-pressurized
systems or enclosures.
•Generates an ultrasonic signal that fills a non-pressurized vessel,
line, or cavity with ultrasound, creating ultrasonic pressure that can be
detected with the UL101 Receiver when leaks are present.
•Can be injected into an air system in order to test for leaks, thus
eliminating the need to run an air compressor during an air survey.
•Simple on/off control switch.
•Operates on a single 9-volt battery for approximately 300 hours of
continuous use.
- 4 -

PRODUCT OVERVIEW
Advantages of Ultrasonic Inspection with the CTRLUL101
•Predictive - Provides the earliest warning signs of failure.
•Extrasensory - Detects many problems that cannot be heard audibly.
•Instantaneous - Provides useful, real-time information.
•Accurate - Allows the user to distinguish and isolate the ultrasound
signal of individual components and leaks.
•Versatile - Can be used to test a wide variety of systems and
components from bearings to non-pressurized vessels.
•Non-Destructive - Causes no adverse effect or interference; testing
can be performed while equipment is operating.
CTRL UL101 Features
•Unmatched sensitivity, signal-to-noise ratio, and selectivity.
•Provides the capability for diagnosing component and system faults.
•Designed for a wide range of applications from bearing analysis to
leak detection.
•Non-destructive; can be used while equipment is operating.
•Convenient, hand-held design for ease of use.
•User-friendly controls include potentiometer for on/off power and
sensitivity adjustment; output switch; and gain mode switch.
•Dual-mode analog meter for ultrasonic signal and battery level
indication.
•No calibration or special maintenance required.
•Operates on a single 9V alkaline battery for approximately 45
continuous hours.
•Extruded aluminum case maximizes tool life in harsh environments.
•Includes several attachments for testing in contact and scan mode.
•Selectable length probes increase the reach for testing.
•Compatible with InCTRL, CTRL’s online condition-based monitoring
(CBM) software. Provides signal logging, benchmarking, trending,
reporting, and email alerts.
* InCTRL is sold separately from the CTRL UL101. For more information call CTRL Systems
(1.410.876.5676) or visit the CTRL website (www.ctrlsys.com)
- 2 -

PRODUCT OVERVIEW
CTRL UL101 Key Components continued
Headset
•Industrial grade headset allows the user to
hear converted ultrasound from the
Receiver.
•Reduces or masks ambient audible sounds so user can distinguish
ultrasound from the component under test.
•Available in over-the-head or behind-the-head (for use with hard hats)
models.
Concentrator Set
•Self-threaded, high-grade plastic attachments
increase the scope and precision of the UL101.
•Designed for scan mode to detect airborne ultrasound
created by gas/air leaks, and bearings, gearboxes, and
steam traps when necessary.
•Includes the Large Concentrator, Mini-
Concentrator, and Acoustic Tip.
•The conical shaped Large Concentrator more than doubles the
distance of the reception of ultrasound for detecting leaks and
narrows the focus of reception from approximately 45º from center to
less than 5º from center.
•The conical shaped Mini-Concentrator narrows the area of reception
to 5º from center, blocking competing ultrasound and improving
accuracy for pinpointing specific failures. Also provides added
convenience for inspection in hard-to-access areas.
•The Acoustic Tip (inverted concentrator) increases the accuracy of
pinpointing airborne ultrasound from a short distance. Recommended
for small leaks, including vacuum, in suspected areas. Also used for
shielding in noisy areas.
One-Inch Acoustic Probe
•Narrows the field of signal reception in scan mode.
•Can be used with the UT2000 Universal Transmitter to
inject ultrasound into non-pressurized vessels, cavities,
and pipes.
- 5 -

PRODUCT OVERVIEW
UL101 Receiver and Components
UT2000 Transmitter
- 7 -

PRODUCT OVERVIEW
CTRL UL101 Controls
Controls on the UL101 are easy to use. They allow the user to adjust the
Receiver settings for exceptional sensitivity (ability to pick up faint
ultrasounds), selectivity (ability to separate and reduce audible signals
and noise from ultrasound signals of unit under test - plus the ability to
differentiate between sources of ultrasound) and discrimination (ability
to identify differences in operating conditions).
•Analog Meter: Indicates intensity of received ultrasound
when the Meter Selector Switch is in the Meter/Headset
position. When the Meter Selector Switch is in the Headset
Only position, the meter becomes a battery tester.
•Potentiometer (Power Supply On/Gain Control Knob): Turns
the unit on and off, and adjusts the sensitivity of the
receiver to the range of signals received. Turn up from 0
to turn the unit on (LED will glow when unit is on). Slowly
increase the gain until desired component is just being
heard through the headset (normally between 0 and 1).
The user may need to increase sensitivity to detect faint
ultrasounds.
Note: The potentiometer works much like a squelch
control on a CB. If turned up too high, the unit will be
filled with “white” noise and limit the effectiveness of the
UL101.
•Gain Mode: Full/Half Gain Switch: Located on the right side
of the receiver, the gain mode switch is used to control
signal distortion. The full gain setting (down position)
reduces signal distortion when high intensity ultrasound is
received and is the most common setting. It allows the unit
to focus on the ultrasound from the component under test.
Always use the minimum necessary gain.
•Meter Switch: The Meter response can be changed from
Signal display when in the Up position and Battery state in
the down position. When displaying battery level a full
battery will register three ticks above the 5/10 mark of the
meter.
- 8 -

PRODUCT OVERVIEW
CTRL UL101 Key Components continued
Solid Probe Set
•Selectable length solid metal probes with self-
threaded plastic base.
•Designed for contact mode to provide increased
sensitivity, better clarity, and a better reduction of
competing noise.
•Eliminate airborne ultrasound, detecting only
the vibration of the component being tested.
(A gas leak can produce ultrasound a hundred times more intense in
air than a bearing or gearbox, so it is advantageous to focus on
specific components).
•Recommended for inspection of mechanical components such as a
gearbox, valve, bearing, or valve seat. Can also be used to inspect
internal fluidic systems such as internal hydraulics for cavitation,
leakage, and blockage.
•Includes 3”, 5”, 8” and 13” probes. Each length is designed for reach
in different situations, while maintaining performance
(It is best to use the shortest probe possible because ultrasound
attenuates very quickly, unlike audible vibration).
Acoustic Probe Set
•Designed for inspection in difficult conditions
such as hard-to-reach areas or for working
around electrical components.
•The acoustic probes improve the ability to locate the source of the
ultrasound signal by narrowing the area of the field of reception.
•Includes: two 12” hollow aluminum probes threaded at each end; one
single-threaded 12” hollow aluminum probe; one single-threaded 12”
hollow polycarbonate (non-metallic) probe for electrical applications;
and an adaptor.
•Each of the probes can be connected together to provide an
additional reach of three feet.
To reduce the chance of sustaining a shock or damaging equipment,
always use non-metallic Polycarbonate Acoustic Extension Probe when
working near electrical equipment.
- 6 -

GETTING STARTED
CTRL UL101 Set-up Procedure
There are several items in your tool kit. Each item, if used properly, can
be an important accessory for diagnosing your equipment.
UL101 Receiver
1. Remove the UL101 Receiver from the Carrying Case. Serial numbers
are located at the bottom. If you have an intrinsically safe UL101, the
serial number will begin RA3, which means your device was
manufactured according to intrinsically safe standards and can be
used in hazardous environments.
2. Remove the End Cap by turning the End Cap Screw counter
clockwise 1.5 – 2 rotations.
3. Insert a 9-v alkaline battery. Check the decal inside the housing for
correct installation. Do not push the battery or you may bend the
contacts.
Always change Receiver and Transmitter batteries in a non-hazardous
area. When inspecting in a potentially explosive environment, the
Intrinsically Safe model of the CTRL UL101 should be used.
4. Replace the End Cap. Refer to Page 17 for instructions.
5. Push the headset jack firmly into the Receiver. There are two types of
headsets including Over-The-Head (OTH) and Behind-The-Head
(BTH), for use with hardhats. If you have a behind-the-head headset,
make sure the plastic portion goes to the back of your head and the
strap goes over top.
6. Turn on the Receiver using the Potentiometer (Power Supply On-Off
Switch/Gain Control Knob). The LED should glow green.
7. Put on the headset. Turn the Output Switch to the Headset and Meter
position and start with the Gain Mode Switch set to full gain. Rub your
fingers in front of the microphone to create friction. Slowly increase
the Potentiometer from 0 to reach the minimum setting (usually
between 0 and 1) required to hear the converted ultrasound through
the headset and see the meter move. If the signal is too strong,
switch the Gain Mode Switch to half gain.
8. Attach the appropriate probe to the Receiver for the current
application.
- 9 -

GETTING STARTED
Typical Applications
Mechanical Systems
•Roller, Ball, Pillow Block and
Other Bearings
•Trunion & Wheel Bearings
•Gears & Gearboxes
•Butterfly and Other Valves
•Pumps
•Motors & Engines
•Transmissions & PTO’s
•Belts/Chains/Pulleys
Electrical Systems
•Electric Motor
•Bearings/Bushings/Brushes
•Ignition Systems & Alternators
•Switches, Coils, Spark Plugs &
Wiring
•High Voltage Insulators
•Corona Discharges
•Transformers/Relay & Power
Boxes
Hydraulic & Pneumatic Systems
•Cylinder Head Gaskets
•Check & Control Valves
•Actuator & Stop Valves
•Pumps & Valves
•Fittings & Hoses
•Bearings
•Internal Valve Leaks
Pressure & Vacuum Systems
•Compressed Air & Gas Leaks
•Cooling System Leaks
•Exhaust & Intake Manifold
Leaks
•Steam Traps
•Condensers
•Refrigeration & Heating
Systems
•Vacuum Leaks
•Pumps & Valves
•Fittings & Hoses
•Piping & Lines
Non-Pressurized Vessels
•Storage Tanks
•Pipes
•Door & Window Gaskets
•Bulkhead & Hatch Seals
•Windshields & Weather
Stripping
•Clean Rooms
•Railroad Cars & Truck Bodies
- 11 -

TIPS & TECHNIQUES
Operating Techniques
There are two techniques used to inspect, test and diagnose with
ultrasonic technology:
Scan Mode
Used in scan mode with one of the Acoustic Probes, Concentrators, or
the One-Inch Acoustic Probe attachment, the UL101 enables the user to
detect and pinpoint problems such as air, steam, gas, and vacuum leaks;
leaks in exhaust systems, exchangers, and A/C systems; and electrical
arcing or discharge. In addition, when used in conjunction with the
UT2000, defects in seals and gaskets of non-pressurized vessels or
cavities can be detected and pinpointed.
The user aims the Receiver, moving it side to side, up and down to locate
the strongest (most intense) ultrasound signal, following the ultrasound to
its source. In order to pinpoint the location of the leak, it is helpful for the
user to reduce the sensitivity of the Receiver by adjusting the
Potentiometer down as he/she gets closer to the source of ultrasound.
Contact Mode
Used with a Solid Probe attachment, the UL101 allows the user to
distinguish the ultrasound generated by individual components. This
mode is used to determine the operating condition of an internal
component such as bearings, gears, valves, solenoid valves, cylinders,
actuators, etc. By distinguishing the ultrasound of individual components,
the user is able to determine changes in the operating condition of those
components very early in the failure process.
The user places the tip of the solid probe on a housing nearest the
component, such as a bearing or gear, under test. The user will start with
the Gain Mode in full gain and will slowly increase the Potentiometer from
0 until converted ultrasound of the component under test becomes
audible. (This setting is normally somewhere between 0 and 1.) If the
signal is too strong, adjust the Gain Mode to half gain.
- 12 -

GETTING STARTED
CTRL UL101 Set-up Procedure continued
UT2000 Universal Transmitter
1. Remove End Cap. Turn End Cap Screw counter clockwise 1.5 – 2
rotations.
2. Insert 9-volt battery. Check decal inside housing for correct
installation.
Always change Receiver and Transmitter batteries in a non-hazardous
area. When inspecting in a potentially explosive environment, the
Intrinsically Safe model of the CTRL UL101 should be used.
3. Replace End Cap. Refer to Page 17 for instructions.
4. Push the On/Off Switch toward the LED to turn the Transmitter “ON”.
The LED should glow green.
- 10 -

TIPS & TECHNIQUES
Operating & Technical Tips
Use the UL101 on a daily basis for a wide variety of inspection, testing
and diagnostic applications. It will cut your troubleshooting time and often
detect defect conditions when they are just starting, before damage
occurs.
When beginning to use the CTRL UL101, listen to components often in
order to naturally develop a sense of how normal operation sounds.
When the user recognizes normal, abnormal will stand out.
Keep operating conditions and UL101 Receiver settings the same each
time you test a piece of equipment. Any noticeable change can be
attributed solely to the change in the equipment’s condition.
Always start with the Gain Mode set to full gain, and only switch to half
gain when necessary.
Don’t turn the Potentiometer too high for testing. Start with the Knob at 0
and slowly increase the setting to reach the minimum setting required to
hear the converted ultrasound through the headset and see the meter
move.
Reduce sensitivity of Receiver to minimum if there is a need to aim the
Receiver directly at the Transmitter from short distances. This avoids
discomforting sound.
To prolong battery life, both the Receiver and Transmitter should be shut
off when not in use. Batteries should be removed if not used for extended
periods.
When auditing a compressed air, gas or steam system or an electrical
system, start near the power source and scan along the system. Keep
the receiver within several inches of system lines and components for
best results.
When using the Transmitter, make sure that the opening into which it is
placed is closed to prevent the escape of ultrasonic waves that could be
misleading.
The One-Inch Acoustic Probe or the Acoustic Extension Probes can be
attached to the Transmitter to inject ultrasound into a non-pressurized
vessel or cavity. To reduce the intensity of ultrasound being received, the
user can attach a 3/8” diameter plastic hose (flexible or rigid) to the one-
inch acoustic probe. The flexible hose may also be used in crowded
areas (such as under the hood of a car) to gain access to a component.
Call CTRL Product Support for assistance when problems arise.
- 13 -

– +
IMPORTANT SAFETY INFORMATION
Safety Tips
Users of the UL101 must be properly trained on and follow all safety
requirements and standards when working in the area of equipment
under test.
DANGER
To avoid possible death or serious injury from
electric shock:
Never touch the UL101 or its attachments to electrical
equipment or its components unless they are properly
grounded.
Always use the non-metallic Polycarbonate Acoustic
Probe, which has high electrical resistance, when
searching for airborne ultrasound near high voltage
equipment.
WARNING
To avoid possible entanglement hazard:
Never touch moving components with the UL101 or its
attachments.
WARNING
Always change Receiver and Transmitter batteries in a
non-hazardous area.
When inspecting in a potentially explosive environment, the
Intrinsically Safe model of the CTRL UL101 should be
used.
WARNING
Power Supply: 9 volt Alkaline Battery such as DURACELL
- Procell #PC 1604-9V, Eveready, Energizer, or equivalent.
Ensure battery is inserted properly for normal operation.
- 15 -

GENERAL INFORMATION
Maintenance and Care
•The UL101 tool requires no special maintenance or calibration.
•The UL101 should be cared for as any high quality electronic tool.
Wipe clean as necessary and check for proper operation as
described in the Set-Up Procedure.
•It is recommended that the UL101 Receiver Jacket (sold separately)
be used to help protect the Receiver from everyday wear and tear,
and any accidental misuse.
•Do not immerse the Receiver or Universal Transmitter in liquid.
•Use only alkaline batteries. Batteries should be removed if not used
for extended periods.
•Use only a Headset with impedance of 600 Ohms +/- 15%. It is
strongly recommended that the UL101 be used only with the Headset
provided by CTRL Systems.
•For repair services call CTRL Systems, Inc. at 877-287-5797.
Expected Battery Life
The CTRL UL101 Receiver and UT2000 Transmitter are both powered by
a 9-volt alkaline battery. A single battery can power the UL101 for
approximately 45 hours of continuous use. With typical use of the UL101,
the life of the battery is approximately 5 months. A single fresh battery
can power the UT2000 for up to 300 hours of continuous use.
Determining if Batteries Need to be Changed
The meter output on the UL101 Receiver becomes a battery power
indicator by turning the output switch to the down position where only the
headphones are pictured. The battery will need to be replaced if the
needle drops below the “5-10” mark on the meter.
The battery for the Transmitter should be replaced once the LED does not
light up.
- 16 -

TIPS & TECHNIQUES
Adverse Operating Conditions
When using the UL101 ultrasound diagnostic tool, the user may have to
perform testing in adverse operating conditions. The following are
techniques that minimize the effect of these conditions.
Too much competing ambient noise:
Too much competing ambient noise may result in difficulty hearing the
individual component under test.
Solutions:
1. If feasible, change the testing environment by moving or shutting
down the competing system.
2. Use InCTRL Mobile in conjunction with the UL101 to capture the
signal from the component. Play the sound back later in a quiet
environment.
Too much competing ultrasound:
Too much competing ultrasound may result in difficulty hearing and
discriminating the signal from the individual component under test.
Solutions:
1. Turn the Gain Mode Switch to half gain.
2. Turn the Potentiometer to a lower setting.
3. Shield the component under test from other sources of ultrasound
with a piece of cardboard, clipboard, etc. If possible, inspect the
component under test with your back to the competing system.
4. If feasible, change the testing environment by moving or shutting
down the competing system.
Reflection:
When following ultrasound leads to an unlikely source, such as a wall, the
ultrasound may have traveled to the wall and reflected off of it.
Solutions:
Turn your body around 180°and then scan again for the most intense
ultrasound. Follow the most intense ultrasound to its source. If the source
of ultrasound is very strong, multiple reflections may occur.
* InCTRL is sold separately from the CTRL UL101. For more information call CTRL Systems
(1.410.876.5676) or visit the CTRL website (www.ctrlsys.com)
- 14 -