UE Systems ULTRAPROBE 2000 User manual

Version 1 1
ULTRAPROBE®2000
Instruction Manual

Version 1 2
Safety advisory
Please read before using your instrument.
Warning
Improper use of your ultrasonic detector may result in death or serious injury. Observe all
safety precautions. Do not attempt to make any repairs or adjustments while the equipment
is operating. Be sure to turn off and LOCK OUT all electrical and mechanical sources before
performing any corrective maintenance. Always refer to local guidelines for appropriate
lockout and maintenance procedures.
SAFETY PRECAUTION: Although your ultrasonic instrument is intended to be used while equipment is
operating, the close proximity of hot piping, electrical equipment and rotating parts are all potentially
hazardous to the user. Be sure to use extreme caution when using your instrument around energized
equipment. Avoid direct contact with hot pipes or parts, any moving parts or electrical connections. Do not
attempt to check findings by touching the equipment with your hands or fingers. Be sure to use appropriate
lockout procedures when attempting repairs.
Be careful with loose hanging parts such as the wrist strap or headphone cord when inspecting near
moving mechanical devices since they may get caught. Don't touch moving parts with the contact probe.
This may not only damage the part, but cause personal injury as well.
When inspecting electrical equipment, use caution. High voltage equipment can cause death or severe
injury. Do not touch live electrical equipment with your instrument. Use the rubber focusing probe with the
scanning module. Consult with your safety director before entering the area and follow all safety
procedures. In high voltage areas, keep the instrument close to your body by keeping your elbows bent.
Use recommended protective clothing. Do not get close to equipment. Your detector will locate problems at
a distance.
When working around high temperature piping, use caution. Use protective clothing and do not attempt to
touch any piping or equipment while it is hot. Consult with your safety director before entering the area.
ULTRAPROBE®2000
Instruction Manua

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Ultraprobe 2000 Kit .........................................................................................................................................5
Components.....................................................................................................................................................6
Metered Pistol Housing ...............................................................................................................................6
Analog Meter (A) .........................................................................................................................................6
Battery Level (B)...........................................................................................................................................6
Sensitivity Dial (C) ........................................................................................................................................6
Headset Jack (D)...........................................................................................................................................6
Trigger Switch (E) .........................................................................................................................................7
Frequency Adjust Dial (F).............................................................................................................................7
Meter Selection Dial (G)...............................................................................................................................7
Recharge Jack...............................................................................................................................................7
When to recharge........................................................................................................................................7
Trisonic™ Scanning Module.........................................................................................................................8
Rubber Focusing Probe................................................................................................................................8
Contact (Stethoscope)Module.....................................................................................................................9
Stethoscope Extension Kit ...........................................................................................................................9
Headset......................................................................................................................................................10
WTG - 1 Warble Tone Generator (Standard).............................................................................................10
To use the WARBLE TONE GENERATOR:....................................................................................................10
To charge the Warble Tone Generator......................................................................................................10
WTG-2SP Warble Pipetone Generator ......................................................................................................11
Ultraprobe Applications.................................................................................................................................12
Leak Detection ...........................................................................................................................................12
How to locate leaks....................................................................................................................................13
To Confirm a Leak ......................................................................................................................................13
Overcoming Difficulties..............................................................................................................................13
Shielding Techniques .................................................................................................................................14
Low Level Leaks..........................................................................................................................................15
Electric Arc, Corona, Tracking Detection .......................................................................................................16
Monitoring Bearing Wear ..........................................................................................................................17
Detecting Bearing Failure ..........................................................................................................................18
For Comparative Test.................................................................................................................................18
Procedure for Bearing History (Historical).................................................................................................18
Simple Method ..........................................................................................................................................18
Attenuator Transfer Curve.........................................................................................................................19

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Lack of Lubrication.....................................................................................................................................20
Over-Lubrication ........................................................................................................................................20
SLOW SPEED BEARINGS .............................................................................................................................20
FFT INTERFACE...........................................................................................................................................20
General Mechanical Trouble Shooting ......................................................................................................21
Trouble Shooting........................................................................................................................................21
Monitoring Operating Equipment .............................................................................................................21
Locating Faulty Steam Traps......................................................................................................................22
Frequency Selection (UP2000 only)...........................................................................................................22
General Steam/Condensate/Flash Steam Confirmation ...........................................................................23
Inverted Bucket Traps................................................................................................................................23
A Float and Thermostatic...........................................................................................................................23
Thermodynamic (Disc)...............................................................................................................................23
Thermostatic Traps ....................................................................................................................................23
Locating Faulty Valves................................................................................................................................24
Confirming Valve Leakage in Noisy Pipe Systems......................................................................................25
Miscellaneous Problem Areas .......................................................................................................................25
Underground Leaks....................................................................................................................................25
Leakage Behind Walls ................................................................................................................................26
Blockage in Pipes .......................................................................................................................................26
Procedure...................................................................................................................................................26
Partial Blockage..........................................................................................................................................26
Procedure: .................................................................................................................................................26
Flow Direction............................................................................................................................................26
Ultrasound Technology..................................................................................................................................27
ATTENUATOR TRANSFER CURVE ...............................................................................................................28
Instructions for setting combination on carrying case ..............................................................................31
UP2000 Specifications ...............................................................................................................................32

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Ultraprobe 2000 Kit

Version 1 6
Components
Metered Pistol Housing
The main component of the Ultraprobe is its' pistol housing. From back to front, let's examine each part.
Analog Meter (A)
This ballistic meter has intensity increments of from 0 to 100. The 50 divisions reflect intensity changes
only: the more intense the ultrasonic signal, the higher
the reading.
Battery Level (B)
This red light turns on only when the batteries need recharging.
NOTE: When the trigger on/off switch is pulled to the on position, the red battery light will flicker
on and off quickly and the meter will Jump rapidly to indicate that the instrument is working properly.
Sensitivity Dial (C)
The increments on this dial allow for 500 individual set-points. There are 2 sets of numbers. The outer
window reflects the whole digit and reads from 0 to 10. The inside digits are for fine tuning and these
smaller gradations are shown as lines which represent 2 divisions each. As the numbers go UP in value,
the sensitivity of the instrument also goes up. The maximum sensitivity level is 10, the minimum sensitivity
level is 0.0. On the sensitivity selection switch is a LOCK lever. This allows a user to lock the sensitivity
selection and thereby prevent it from being moved inadvertently. To lock the sensitivity selection, rotate
the lever clockwise; to release the lock, rotate the lever counter-clockwise.
Headset Jack (D)
This is where you plug in the headset. Be sure to plug it in firmly until it clicks. Should a tape recorder be
utilized, this is where the cord for the tape recorder is inserted. (Use a Miniphone plug). This can also be
used as an output for an oscilloscope, engine analyzer or FFT with the use of a UE-MPBNC-2 Miniphone-
BNC connector cable and UE DC2 FFT adapter.
TURN THE MAIN HOUSING OF THE ULTRAPROBE 2000 UP-SIDE DOWN AND YOU WILL SEE:

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Trigger Switch (E)
The Ultraprobe is always "off' until the trigger switch is pressed. To operate, simply press the trigger; to turn
the instrument off, release the trigger.
Frequency Adjust Dial (F)
There are numbers ranging from 100 kHz down to 20 kHz. These represent the range of frequency
selection capable with the Ultraprobe. These frequencies may be "tuned in" when performing mechanical
and valve analysis with the contact (stethoscope) probe (refer to description of contact probe). There is
also a detented position, labeled "fixed band". This selection automatically locks the circuitry of the
Ultraprobe into the peak response of the transducers of either the contact (stethoscope) module or the
TrisonicTM Scanning Module. It is an extremely narrow band response that, when used with the contact
(stethoscope) module, reduces most stray unwanted pipe and mechanical noises. In the scanning mode,
it provides for extreme sensitivity and is the preferred position in leak detection and electrical inspection
activities.
Meter Selection Dial (G)
There are three positions for this dial:
1. Log: this selection allows the meter to respond in a real-time, instant, mode. This selection is used
when fast, instant meter response is needed, as in leak detection.
2. Lin: this selection, linear, can be considered a slow response. It eliminates the high and low swings
of the meter and averages there sponse for a more measurable result. This selection is utilized for
monitoring bearings or for mechanical analysis when too rapid a meter response might be
confusing to the operator. In this scale the meter indicator may be used to provide a dB
(decibel)relationship for applications such as mechanical monitoring and bearing trending.
3. Aux: this is the auxiliary position, which is to be used ONLY when a specially adapted instrument is
to be interfaced with the Ultraprobe.
Recharge Jack
This jack receives the plug from the recharger. The recharger is designed to plug into a standard electrical
receptacle. There are two wires from the recharger: one is for the Ultraprobe pistol housing and the other is
for the Warble Tone Generator (see TONE GENERATOR for more information).
When recharging:
1. Insert main plug to electrical outlet.
2. Insert Ultraprobe plug (black) into Ultraprobe Recharge jack
3. Insert Tone Generator plug (yellow) into Tone Generator Recharge jack. NOTE: The recharger
has two red LED's. Each will illuminate only if it is connected and charging properly.
When to recharge
When the red low level indicator light goes on,recharge the Ultraprobe for 8 hours. If the instrument is not
used for a week or more, recharge it for 4 hours. If the Ultraprobe is not used for a few days, it can be used
without recharging, however, for best results, it is advisable to recharge it as a "booster" for about an hour
before using.
If a quick charge is necessary, it is advisable to get the Ultraprobe UE-QCH2 QUICK CHARGER. Call
the factory for information.

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Trisonic™Scanning Module
Trisonic Scanning Module
This module is utilized to receive air-borne ultrasound such as the ultrasounds emitted by pressure leaks
and electrical discharges. There are three prongs at the rear of the module. For placement, align the
prongs with the three corresponding jacks in the front end of the metered pistol housing and plug in.The
TrisonicTM Scanning Module has a phased array of three piezoelectric transducers to pick up the air-borne
ultrasound. This phased array focuses the ultrasound on one "hot spot" for directionality and effectively
intensifies the signal so that minute ultrasonic emissions may be detected.
To use the Trisonic Scanning Module:
1. Plug in to front end.
2. Select the LOG position on the meter selection dial.
3. For general use position the frequency selection dial to the "fixed-band" mode.
4. Start with the sensitivity selection dial at maximum (10).
5. Start to scan the test area. a. The method of air borne detection is to go from the "gross to the
fine". If there is too much ultrasound in the area, reduce the sensitivity, place the rubber focusing
probe (described below) over the scanning module and proceed to follow the test sound to its'
loudest point constantly reducing the sensitivity and following the meter.
Rubber Focusing Probe
The Rubber Focusing Probe is a cone-shaped rubber shield. It is used to block out stray ultrasound and to
assist in narrowing the field of reception of the Trisonic-Scanning Module. To use, simply slip it over the
front of the scanning module or the contact module.
NOTE:To prevent damage to the module plugs, always remove the module BEFORE attaching and
removing the Rubber focusing Probe.

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Contact (Stethoscope)Module
Stethoscope Module
This is the module with the metal rod. This rod is utilized as a "waveguide" in that it is sensitive to
ultrasound that is generated internally such as within a pipe, bearing housing, steam trap or wall. Once
stimulated by ultrasound, it transfers the signal to a piezoelectric transducer located directly in the module
housing. This module is shielded to provide protection from stray RF waves that have a tendency to effect
electronic receiving. This module can be effectively utilized in practically any environment ranging from
airports to broadcasting towers. It is equipped with low noise amplification to allow for a clear, intelligible
signal to be received and interpreted.
To use :
1. Align the pins located at the rear of the module with the three jacks in the front end of the Metered
Pistol Housing (MPH) and plug in.
2. For detecting leaks in valves, steam traps, etc., position the meter selection dial to LOG. If
performing mechanical analysis, bearing monitoring, etc., select the LIN mode on the meter
selection dial.
3. For general use, position the frequency selection dial to "Fixed-Band". For problem solving, i.e.
finding a problem sound (refer to section on Mechanical Analysis).
4. Touch test area.
5. As with the scanning module, go from the "gross" to the "fine". Start a maximum sensitivity on the
Sensitivity Selection dial and proceed to reduce the sensitivity until a satisfactory sound and meter
level is achieved.
Stethoscope Module At times it may be necessary to utilize the stethoscope probe with the sensitivity level
at or near maximum. Occasionally when in this situation stray ultrasound may interfere with clear reception
and be confusing. If this occurs, place the RUBBER FOCUSING PROBE over the Stethoscope probe to
insulate against the stray ultrasound.
Stethoscope Extension Kit
This consists of three metal rods that will enable a user to reach up to 78 cm (31 additional inches) with
the Stethoscope Probe. To use:
1. Remove the Stethoscope Module from the Metered Pistol Housing.
2. Unscrew the metal rod in the Stethoscope Module.
3. Look at the thread of the rod you just unscrewed and locate a rod in the kit that has the same size
thread - this is the "base piece".
4. Screw the Base Piece into the Stethoscope Module.
5. If all 78 cm are to be utilized, locate the middle piece. (This is the rod with a female fitting at one
end)and screw this piece into the base piece.
6. Screw third "end piece" into middle piece. If a shorter length is desired, omit step 5 and screw "end
piece" into "base piece".

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Headset
This heavy duty headset is designed to block out intense sounds often found in industrial environments so
that the user may easily hear the sounds received by the ULTRAPROBE. To use, simply plug the headset
cord into the headset Jack on the metered pistol housing, and place the headphones over your ears. If a
hard hat is to be worn, it is recommended to use
UE Systems' model UE-DHC-2HH Hard Hat Headphones which are specifically designed for hard hat use.
For those situations in which it is not possible or difficult to wear the standard headphones described
above, UE Systems has two options available:
1. The DHC 1991 Earpiece which loops around the ear,
2. The SA-2000 Speaker Amplifier which is a loud speaker that is compatible with the Ultraprobe
headphone output jack.
WTG - 1 Warble Tone Generator (Standard)
The WTG-1 Tone Generator is an ultrasonic transmitter designed to flood an area with ultrasound. It is
used for a special type of leak test. When placed inside an empty container or on one side of a test item,
it will flood that area with an intense ultrasound that will not penetrate any solid but will flow through any
existing fault or void. By scanning with the Trisonic Scanning Module, empty containers such as pipes,
tanks, where the "warble" ultrasound penetrates. As an example, if the item to be tested is the seal
around a window, place the Warble Tone Generator on one side of the window, close it and proceed to
scan on the opposite side. To test the condition of the Warble Tone Generator battery, set to the LOW
INTENSITY position and listen to the sound through the Ultraprobe in the FIXED BAND mode. A smooth
continuous warbling sound should be heard. If a "beeping" is heard instead, then a full recharge of the
Warble Tone Generator is indicated.
To use the WARBLE TONE GENERATOR:
1. Turn Tone Generator on by selecting either "LOW" for a low amplitude signal (usually
recommended for small containers) or "HIGH" for high amplitude. In high, the Warble Tone
Generator will cover up to 113m³(4,000 cubic feet) of unobstructed space. When the Tone
Generator is on, a red light (located below the recharge Jack in the front) flickers.
2. Place the Warble Tone Generator within the test item/container and seal or close it. Then scan the
suspect areas with the Trisonic Scanning Module in the Ultraprobe and listen for where the
"warble" ultrasound penetrates. As an example, if the item to be tested is the seal around a
window, place the Warble Tone Generator on one side of the window, close it and proceed to scan
on the opposite side.
To charge the Warble Tone Generator
Follow directions in 1.1-1 RECHARGE JACK
wtg1 warble tone generator (optional)UE-WTG-2SP Warble Pipe Tone Generator

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WTG-2SP Warble Pipetone Generator
This is an option that is used for test conditions where it is not possible to physically place the standard
WTG-1 Warble Tone Generator, such as in pipes or in certain heat exchangers or tanks.
1. Features:
a. Threaded Pipe Fitting: The ultrasonic transducer is at this end. When testing, make sure that the
transducer is positioned so that it can adequately "flood" the test area. This can be accomplished
by screwing the male nipple connection into a threaded hole. The nipple size is 1" NPT.
b. Warble Rate Indicator Lamp (top). This LED will flash to indicate that the unit is on.
c. Variable Intensity Control (top). This dial has whole numbers and decimal numbers. The whole
number appears in the window. Maximum output is "10" and minimum output is "0". The dial can
be rotated counter clockwise to reduce intensity of output and clockwise to increase intensity
output. There is a lock lever located to the right on the variable intensity control dial. Should a
specific output intensity be required, the level may be preset and locked into position so that it will
not be inadvertently moved during a test. To lock, press the lock lever down. to unlock, push the
lock lever up.
d. On/Off Switch (middle). To turn the unit on, push the switch to the left.
e. Recharge Jack (bottom). This receptacle is compatible with the Ultraprobe Tone Generator Battery
recharger. To use, follow the instructions for the recharge jack, section 1-H (page 2).
f. LED Indicator Lamp (bottom). This red lamp will glow only if the battery needs to be charged.
Should the light glow, charge the battery immediately.
g. Adapters: The adapter kit consists of an acoustical foam rubber shield/sleeve - inside the sleeve is a
coupler, 1" female pipe thread to female pipe thread. There are two adapters: one is 3/4" female and
the other is 1/2" female that can be screwed on to the coupler. When attached, the adapters can
then be screwed on to an appropriate male threaded connection.

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Ultraprobe Applications
Leak Detection
This section will cover airborne leak detection of pressure and vacuum systems. (For information
concerned with internal leaks such as in Valves and Steam Traps, refer to the appropriate sections).
What produces ultrasound in a leak? When a gas passes through a restricted orifice under pressure, it is
going from a pressurized laminar flow to low pressure turbulent flow (Fig. 1). The turbulence generates a
broad spectrum of sound called "white noise". There are ultrasonic components in this white noise. Since
the ultrasound will be loudest by the leak site, the detection of these signals is
usually quite simple.
Figure 1: Pressure Leak
Figure 2: Vacuum Leak
A leak can be in a pressurized system or in a vacuum system. In both instances, the ultrasound will be
produced in the manner described above.
The only difference between the two is that a vacuum leak will usually generate less ultrasonic amplitude
than a pressure leak of the same flow rate. The reason for this is that the turbulence produced by a vacuum
leak is occurring within the vacuum chamber while the turbulence of a pressure leak is generated in the
atmosphere (Fig.2).
What type of gas leak will be detected ultrasonically? Generally any gas, including air, will produce a
turbulence when it escapes through a restricted orifice. Unlike gas specific sensors, the Ultraprobe is sound
specific. A gas specific sensor is limited to the particular gas it was designed to sense (e.g., helium). The
Ultraprobe can sense any type of gas leak since it detects the ultrasound produced by the turbulence of a
leak. because of its versatility, the Ultraprobe may be utilized in a wide variety of leak detection. Pneumatic
systems may be checked, pressurized cables, such as those utilized by telephone companies, may be
tested. Air brake systems on railroad cars, trucks, and buses may be checked. Tanks, pipes, housings,
casings and tubes are easily tested for leakage by pressurizing them. Vacuum systems, turbine exhausts,
vacuum chambers, material handling systems, condensers, oxygen systems can all easily be tested for
leakage by listening for the turbulence of the leak.
nual

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How to locate leaks
1. Use the TRISONIC SCANNING MODULE.
2. Select the LOG setting on the meter selection dial.
3. Use "fixed-band" position on the Frequency selection dial. If too much background noise is present,
try some of the shielding methods listed below.
4. Start off with the sensitivity selection at 10 (Maximum).
5. Begin to scan by pointing the module towards the test area. The procedure is to go from the "gross"
to the "fine" more and more subtle adjustments will be made as the leak is approached.
6. If there is too much ultrasound in the area, reduce the sensitivity setting and continue to scan.
7. If it is difficult to isolate the leak due to competing ultrasound, place the RUBBER FOCUSING
PROBE over the scanning module and proceed to scan the test area.
8. Listen for a "rushing" sound while observing the meter.
9. Follow the sound to the loudest point. The meter will show a higher reading as the leak is
approached.
10.In order to focus in on the leak, keep reducing the sensitivity setting and move the instrument closer
to the suspected leak site until you are able to confirm a leak.
To Confirm a Leak
Position the Trisonic Scanning Module, or the rubber focusing probe (if it is on the scanning module) close
to the suspect leak site and move it, slightly, back and forth, in all directions. If the leak is at this location,
the sound will increase and decrease in intensity as you sweep over it. In some instances, it is useful to
position the rubber focusing probe directly over the suspect leak site and push down to "seal" it from
surrounding sounds. If it is the leak, the rushing sound will continue. If it is not the leak site, the sound will
drop off.
Overcoming Difficulties
Competing Ultrasounds If competing ultrasounds make it difficult to isolate a leak, there are two
approaches to be taken: Manipulate the environment. This procedure is fairly straightforward. Men
possible, turn off the equipment that is producing the competing ultrasound or isolate the area by
Closing a door or window.
Manipulate the instrument and use shielding techniques. If environmental manipulation is not
possible, try to get as close to the test site as possible, and manipulate the instrument so that it is
pointing away from the competing ultrasound. Isolate the leak area by reducing the sensitivity of
the unit and by pushing the tip of the rubber focusing probe up to the test area, checking a small
section at a time. In some extreme instances, when the leak check is difficult in the fixed band
mode of the frequency selection dial, try to "tune in" to the leak sound by "tuning out" the problem
sound. In this instance adjust the frequency selection dial until the background sound is minimized
and then proceed to listen for the leak.

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Shielding Techniques
Since ultrasound is a high frequency, short wave signal, it can usually be blocked or "shielded". NOTE:
Men using any method, be sure to follow your plant's or company's safety guidelines. Some common
techniques are:
1. Body: place your body between the test area and the competing sounds to act as a barrier
2. Clip Board: Position the clip board close to the leak area and angle it so that it acts as a barrier
between the test area and the competing sounds
3. Gloved Hand: (USE CAUTION) using a gloved hand, wrap the hand around the rubber
focusing probe tip so that the index finger and the thumb are close to the very end and place
the rest of the hand on the test site so that there is a complete barrier of the hand between the
test area and the background noise. Move the hand and instrument together over the various
test zones.
4. Wipe rag: This is the same method as the "gloved hand" method, only, in addition to the glove,
use a wipe rag to wrap around the rubber focusing probe tip. Hold the rag in the gloved hand
so that it acts as a "curtain", i.e., there is enough material to cover the test site without blocking
the open end of the rubber focusing probe. This is usually the most effective method since it
uses three barriers: the rubber focusing probe, the gloved hand and the rag.
5. Barrier: When covering a large area, it is sometimes helpful to use some reflective material,
such as a welders curtain or a drop cloth, to act as a barrier. Place the material so that it acts
as a "wall" between the test area and the competing sounds. Sometimes the barrier is draped
from ceiling to floor, at other times, it is hung over railings.
6. FREQUENCY TUNING If there are situations where a signal may be difficult to isolate, it may
be helpful to utilize the Frequency tuning Dial. Point the Ultraprobe toward the test area and
gradually adjust the frequency tune dial until the weak signal appears to be clearer and then
follow the basic detection methods previously outlined.

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Low Level Leaks
In ultrasonic inspection of leakage, the amplitude of the sound often depends upon the amount of
turbulence generated at the leak site. The greater the turbulence, the louder the signal, the less the
turbulence, the lower the intensity of the signal. When a leak rate is so low that it produces little, if any
turbulence that is "detectable", it is considered "below threshold". If a leak appears to be of this nature:
1. Build up the pressure (if possible) to create greater turbulence.
2. Utilize LIQUID LEAK AMPLIFIER. This patented method incorporates a UE Systems product called
LIQUID LEAK AMPLIFIER, or LLA for short. LLA is a uniquely formulated liquid substance that has
special chemical properties. Used as an ultra sonic "bubble test, a small amount of LLA is poured
over a suspected leak site. It produces a thin film through which the escaping gas will pass. When
it comes in contact with a low flow of gas, it quickly forms a large number of small "soda-like"
bubbles that burst as soon as they form. This bursting effect produces an ultrasonic shock wave
that is heard as a crackling sound in the headphones. In many instances the bubbles will not be
seen, but they will be heard. This method is capable of obtaining successful leak checks in systems
with leaks as low as 1 xl0-6ml/ sec.
NOTE: The low surface tension of the LLA is the reason small bubbles form. This can be negatively
changed by contamination of the leak site with another leak fluid, which can block LLA or cause
large bubbles to form. If contaminated, clean the leak site with water, solvent or alcohol (checks with
plant regulations before selecting a decontaminating cleaning agent).
3. Use the UE-CFM-2 Close Focus Module. Specifically designed for low level leaks, the unique scanning
chamber is designed to receive low level signals with reduced signal distortion and provides easier
recognition of a low level leak. For more information, call the factory.

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Electric Arc, Corona, Tracking Detection
There are three basic electrical problems that are detected with the Ultraprobe 2000:
Arcing: An arc occurs when electricity flows through space. Lightning is a good example.
Corona: When voltage on an electrical conductor, such as an antenna or high voltage transmission line
exceeds the threshold value, the air around it begins to ionize to form a blue or purple glow.
Tracking: Often referred to as "baby arcing", follows the path of damaged insulation.
Although theoretically the Ultraprobe 2000 can be used in low, medium and high voltage systems, most of the
applications tend to be in medium and high voltage systems. When electricity escapes in high voltage lines or
when it "jumps" across a gap in an electrical connection, it disturbs the air molecules around it and generates
ultrasound. Most often this sound will be perceived as a crackling or "frying" sound, in other situations it will be
heard as a buzzing sound. Typical applications include: insulators, cable, switchgear, buss bars, relays,
contactors, junction boxes. In substations, components such as insulators, transformers and bushings may be
tested. Ultrasonic testing is often used at voltages exceeding 2,000 volts, especially in enclosed switchgear.
Since ultrasound emissions can be detected by scanning around door seams and air vents, it is possible to
detect serious faults such as arcing, tracking and corona without taking the switchgear off line to perform an
infrared scan. However, it is recommended that both tests be used with enclosed switchgear.
NOTE: When testing electrical equipment, follow all your plant or company safety procedures. When in doubt,
ask your supervisor. Never touch live electrical apparatus with the Ultraprobe.
The method for detecting electric arc and corona leakage is similar to the procedure outlined in leak detection.
Instead of listening for a rushing sound, a user will listen for a crackling or buzzing sound. In some instances,
as in trying to locate the source of radio/TV interference or in substations, the general area of disturbance may
be located with a gross detector such as a transistor radio or a wide-band interference locator. Once the
general area has been located, the scanning module of the Ultraprobe is utilized with a general scan of the
area. The sensitivity is reduced if the signal is too strong to follow. When this occurs, reduce the sensitivity to
get a mid-line reading on the meter and continue following the sound until the loudest point is located.
Determining whether a problem exists or not is relatively simple. By comparing sound quality and sound levels
among similar equipment, the problem sound will tend to be quite different. On lower voltage systems, a quick
scan of bus bars often will pick up a loose connection. Checking junction boxes can reveal arcing. As with leak
detection, the closer one gets to the emission site, the louder the signal.
If power lines are to be inspected and the signal does not appear to be intense enough to be detectable from
the ground, use UE Systems, UWC-2000 Ultrasonic Waveform Concentrator (a parabolic reflector) which will
double the detection distance of the Ultraprobe and provide pinpoint detection. The UWC-2000 is
recommended for those situations in which it may be considered safer to inspect electrical apparatus at a
distance. The UWC2000 is extremely directional and will locate the exact site of an electrical discharge.
CHECK TRANSFORMERS, SWITCHGEARAND
OTHER ELECTRICAL APPARATUS

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Monitoring Bearing Wear
Ultrasonic inspection and monitoring of bearings is by far the most reliable method for detecting incipient
bearing failure. The ultrasonic warning appears prior to a rise in temperature or an increase in low frequency
vibration levels. Ultrasonic inspection of bearings is useful in recognizing:
a. The beginning of fatigue failure.
b. Brinelling of bearing surfaces.
c. Flooding of or lack of lubricant.
In ball bearings, as the metal in the raceway, roller or ball bearing begins to fatigue, a subtle deformation
begins to occur. This deforming of the metal will produce an increase in the emission of ultrasonic sound
waves. Changes in amplitude of from 12 to 50 times the original reading is indication of incipient bearing
failure. When a reading exceeds any previous reading by 12 dB, it can be assumed that the bearing has
entered the beginning of the failure mode.
This information was originally discovered through experimentation performed by NASA on ball bearings. In
tests performed while monitoring bearings at frequencies ranging from 24 through 50 kHz, they found that the
changes in amplitude indicate incipient (the onset of) bearing failure before any other indicators including heat
and vibration changes. An ultrasonic system based on detection and analysis of modulations of bearing
resonance frequencies can provide subtle detection capability; whereas conventional methods are incapable
of detecting very slight faults. As a ball passes over a pit or fault in the race surface, it produces an impact. A
structural resonance of one of the bearing components vibrates or "rings" by this repetitive impact. The sound
produced is observed as an increase in amplitude in the monitored ultrasonic frequencies of the bearing.
Brinelling of bearing surfaces will produce a similar increase in amplitude due to the flattening process as the
balls get out of round.
These flat spots also produce a repetitive ringing that is detected as an increase in amplitude of monitored
frequencies.
The ultrasonic frequencies detected by the Ultraprobe are reproduced as audible sounds. This "heterodyned"
signal can greatly assist a user in determining bearing problems. When listening, it is recommended that a
user become familiar with the sounds of a good bearing. A good bearing is heard as a rushing or hissing
noise. Crackling or rough sounds indicate a bearing in the failure stage. In certain cases a damaged ball can
be heard as a clicking sound whereas a high intensity, uniform rough sound may indicate a damaged race or
uniform ball damage. Loud rushing sounds similar to the rushing sound of a good bearing only slightly
rougher, can indicate lack of lubrication.
Short duration increases in the sound level with "rough" or "scratchy" components indicate a rolling element
hitting a "flat" spot and sliding on the bearing surfaces rather than rotating. If this condition is detected, more
frequent examinations should be scheduled.

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Detecting Bearing Failure
There are two basic procedures of testing for bearing problems:
COMPARATIVE AND HISTORICAL. The comparative method involves testing two or more similar bearings
and "comparing" potential differences. Historical testing requires monitoring a specific bearing over a period of
time to establish its history. By analyzing bearing history, wear patterns at particular ultrasonic frequencies
become obvious which allows for early detection and correction of bearing problems.
For Comparative Test
1. Use contact (stethoscope) module.
2. Select a "test spot" on the bearing housing and mark it for future reference by marking it with a center
punch or with dye or by epoxy bonding a washer to the spot. Touch that spot with the contact module.
In ultrasonic sensing, the more mediums or materials ultrasound has to travel through, the less accurate
the reading will be. Therefore, be sure the contact probe is actually touching the bearing housing. If this
is difficult, touch a grease fitting or touch as close to the bearing as possible.
3. Approach the bearings at the same angle, touching the same area on the bearing housing.
4. Reduce sensitivity) until the meter reads 20 (if unsure of this procedure, refer to SENSITIVITY
SELECTION DIAL (See page 6
5. Listen to bearing sound through headphones to hear the "quality" of the signal for proper interpretation.
(Refer to page 17 for discussion of audio interpretation.)
6. Select same type bearings under similar load
conditions and same rotational speed.
7. Compare differences of meter reading and sound quality.
Procedure for Bearing History (Historical)
There are two methods to historically "trend" a bearing. The first is a very common, field proven method
called the "SIMPLE" method. The other provides greater flexibility in terms of decibel selection and trending
analysis. It is referred to as the "ATTENUATOR TRANSFER CURVE method. Before starting with either of
the two HISTORICAL methods for monitoring bearings, the COMPARATIVE method must be used to
determine a baseline.
Simple Method
1. Use basic procedure as outlined above in steps 1-7.
2. Note frequency, meter reading, and sensitivity selection on your Reference Chart 1 (page 25).
3. Compare this reading with previous (or future readings). On all future readings, adjust level to the
original level recorded in the Reference Chart.
a. If the meter reading has moved from the original 20 mark up to or past 100, there has been a 12
dB increase (increments of 20 on the meter in the linear mode is about 3 decibels. e.g.: 20-40=3
dB, 40-60=3db, etc.). NOTE: Increase of 12 dB or greater indicates the bearing has entered the
incipient failure mode.
b. Lack of lubrication is usually indicated by an 8 dB increase over baseline. It is usually heard as a
loud rushing sound. If lack of lubrication is suspected, after lubricating, re-test. If readings do not
go back to original levels and remain high, consider bearing is on the way to the failure mode and
recheck frequently.

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Attenuator Transfer Curve
(SAMPLE DO NOT USE WITH YOUR INSTRUMENT)
In order to use this method, refer to the ATTENUATOR TRANSFER CURVE which is supplied for each
instrument There are two curves. Use the curve marked STETHOSCOPE MODULE.
On the curve, the vertical axis numbers indicate various SENSITIVITY levels, while the horizontal axis
displays DECIBELS. By following where the curve lines intersect on the chart it is possible to obtain decibel
changes from one reading to the next.
1. Use the basic procedure as described in the Comparative test (steps 1-7.)
2. Note, meter reading, and sensitivity selection on your Reference Chart. NOTE: in this method, the
meter reading is going to be your most consistent reading. For this reason, select a meter reading
that provides the majority of users comfort and ease when listening to the sound quality through the
headphones)
3. On subsequent readings, adjust the sensitivity dial until the meter reads exactly as noted in the
baseline reading.
4. Note the new sensitivity reading on the chart.
5. Refer to the Attenuator Transfer Curve and locate the decibel level for the current reading.
6. Note the decibel level for the baseline reading.
7. Subtract the original decibel reading from the current reading and you will have the decibel change
from the baseline reading to the present reading.
8. If this level exceeds 8 dB, it may indicate a lack of lubrication, if the reading exceeds 12 dB, it may
indicate the onset of the failure mode.
When using the ATTENUATOR TRANSFER CURVE method, there are three warning levels that have
been established. They vary somewhat from the SIMPLE method, but provide more information.
The three levels are:
a. 8 dB : Pre-Failure, Lack of Lubrication
b. 16 dB :Failure Stage
c. 35-50 dB: Catastrophic Failure
a. Pre-Failure: This is the earliest stage of failure. The bearing may have developed hairline cracks or
microscopic spalls that are not visible to the human eye. This also signals a need to lubricate.
b. Failure Stage: At this stage, visible flaws develop along with a marked rise in acoustic energy and the
temperature of the bearing begins to rise. It is at this stage that the bearing should be replaced or more
frequent monitoring should occur.
c. Catastrophic Stage: here, rapid failure is imminent. The sound level is so intense as to be audible and the
temperature of the bearing has risen enough to overheat the bearing. This is a highly dangerous stage
since the bearing clearances increase and can cause additional friction/rubbing within a machine causing
potential damage to other components.

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It is important to consider two elements of potential failure. One is lack of lubrication while the other is over
lubrication.
Normal bearing loads causes an elastic deformation of the elements in the contact area which give a
smooth elliptical stress distribution. But bearing surfaces are not perfectly smooth. For this reason, the
actual stress distribution in the contact area will be affected by a random surface roughness. In the
presence of a lubricant film on a bearing surface, there is a dampening effect on the stress distribution
and the acoustic energy produced will be low. Should lubrication be reduced to a point where the stress
distribution is no longer present, the normal rough spots will make contact with the race surfaces and
increase the acoustic energy. These normal microscopic disuniformities will begin to produce wear and
the possibilities of small fissures may develop which contributes to the "Pre-Failure" condition. Therefore,
aside from normal wear, the fatigue or service life of a bearing is strongly influenced by the relative film
thickness provided by an appropriate lubricant.
Lack of Lubrication
To avoid lack of lubrication, note the following:
1. As the lubricant film reduces, the sound level will increase. A rise of about 8 dB over baseline
accompanied by a uniform rushing sound will indicate lack of lubrication.
2. When lubricating, add just enough to return the reading to base line.
3. Use caution. Some lubricants will need time to run to uniformly cover the bearing surfaces. Lubricate
a little at a time. DO NOT OVER-LUBRICATE
Over-Lubrication
One of the most common causes of bearing failure is over-lubrication. The excess stress of lubricant
often breaks bearing seals or causes a build-up of heat which can create stress and deformity.
To avoid over-lubrication:
1. Don't lubricate if the base line reading and base line sound quality is maintained.
2. When lubricating, use just enough lubricant to bring the ultrasonic reading to baseline.
3. As mentioned in 3 above, use caution. Some lubricants will need time to uniformly cover the
bearing surfaces.
SLOW SPEED BEARINGS
Monitoring slow speed bearings is possible with the Ultraprobe 2000. Due to the sensitivity range, it is
quite possible to listen to the acoustic quality of bearings. In extremely slow bearings (less than 25 RPM),
it is often necessary to disregard the meter and listen to the sound of the bearing. In these extreme
situations, the bearings are usually large (1"-2" and up) and greased with high viscosity lubricant. Most
often no sound will be heard as the grease will absorb most of the acoustic energy. If a sound is heard,
usually a crackling sound, there is some indication of deformity occurring.
On most other slow speed bearings, it is possible to set a base line and monitor as described. It is suggested
that the Attenuator Transfer Curve method be used since the sensitivity will usually have to be higher than normal.
FFT INTERFACE
The Ultraprobe may be interfaced with FFT's via the UE-MP-BNC-2 Miniphone to BNC connector or the UE DC2 FFT
Adapter. The Miniphone plug is inserted into the headphone jack of the Ultraprobe and the BNC connector is attached
to the analog-in connector of the FFT. Using the heterodyned - converted low frequency signal, the FFT will be able to
receive the ultrasonic information detected from the Ultraprobe. In this instance it can be used to monitor and trend
low speed bearings. It can also extend the use of the FFT to record all types of mechanical information such as
leaking valves, cavitation, gear wear, etc.