VYC 003 Service manual

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Ultrasonic leak detector. Mod. 003.
To detect leaks:
In condensate purgers
In valve seals
Checking for wear on bearings
Solving mechanical problems in general

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Safety warning
Please read this before using your Detector
WARNING!
Misuse of the Ultrasonic leak detector could result in death or serious injury. Please follow all the
safety instructions. Do not try to carry out repairs or adjustments while the equipment is in
operation. Make sure that you turn off and block all the electrical and mechanical sources before
doing any corrective or preventative maintenance work. Always check local guidelines on
maintenance and prevention.
Safety instructions:
Although the Ultrasound leak detector is designed to be used when the equipment is in operation,
the proximity of hot pipes, electrical equipment and rotating parts is potentially dangerous for the
user. Take great care when using the Detector close to energized equipment. Avoid direct contact
with hot parts or piping, any part in movement and electrical connections. Do not try to confirm the
results by touching the inspected equipment with your hands or fingers. Make sure that you use
the appropriate lockout procedures when carrying out repairs.
Take care with loose hanging parts, such as the wrist strap and the headphone cable, when
carrying out inspections near moving mechanical devices, since these elements may become
trapped. Do not touch moving parts with the ultrasonic probe. This will not only damage the part
and the Detector, it could also cause personal injury.
Wear the appropriate protective clothing. Do not get too close to the point of verification. Your
Detector can locate problems from a distance. Take care when working around high temperature
pipes. Wear protective clothing and do not try to touch any of the pipes or equipment while they
are hot. Check with your safety officer before entering the work area and follow all the safety
procedures.

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Index
Page
1. Ultrasonic leak detector. Mod.003 4
2. Table of contents 5
Components 5
Measuring gun 5
oBargraph display 5
oBattery life display 5
oSensitivity selector 5
oConnector for headphones 5
oSwitch 5
Stethoscope module 6
Headphones 6
3. Uses of the Ultrasonic leak detector. Mod.003 6
3.1. Detection of leaks in condensate purgers 6
Confirmation of: Steam/ Condensation/ Flash Steam 7
Inverted floater purger 7
Closed buiy purger with a thermostatic element 8
Thermodynamic purger 8
Thermostatic purger. (Bimetallic or with balanced element) 8
3.2. Detection of leaks in valve seals 9
Detecting bearing faults 9
Confirming a leak 10
3.3. Checking for wear on bearings 10
Detecting bearing faults 11
Low velocity bearings 11
4. Solving general mechanical problems 12
Solving problems 13
5. Ultrasound technology 13
6. General catalogue 14

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1. Ultrasonic leak detector. Mod. 003
It provides a simple way to detect leaks and carry out accurate mechanical inspections using
advanced ultrasound technology.
Before you start taking measurements, we recommend that you first familiarize yourself
with the components of your equipment.

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2. Table of contents
· Components
· Measuring gun
The main component of the Detector is the ultrasound gun. We will examine each part from back
to front.
· Bar graph display
The screen contains a bar graph display with ten LED segments which indicate the intensity of the
ultrasound signal. If only a few LEDs are lit up, this indicates a low level of ultrasound, while more
intense ultrasound signals will lead to a large number of LEDs being lit up.
· Battery life display
This red light only comes on when the batteries need recharging.
NOTE: When the on/off switch is moved to the "on" position, the battery life light will flash before turning off
again. This is normal and does not indicate the condition of the battery.
· Sensitivity selector
There are eight (8) levels of sensitivity that are read in decibels displayed from "0" to "70". As the
dial is turned to the right, toward "0", the sensitivity of the instrument increases. As the selector is
turned to the left, toward "70", the sensitivity will decrease. A low level ultrasound emission
produces low amplitude. To detect low level ultrasounds, the instrument must be in a position of
high sensitivity. 0 is the highest sensitivity setting. For higher amplitude signals, move the
sensitivity to the left towards the "70".
Combination of the bar graph display and sensitivity selector: Each bar lit up in the bar graph is
equal to 3 dB. Example A: Sensitivity selector set at 0 dB and the LED bar graph has 3 bars lit, so
the total reading is 0 dB+9 dB=9 dB. Example B: Sensitivity selector set at 40 dB and the bar
graph has 4 bars lit, so the total reading is 40 dB+12 dB=52 dB.
· Connector for headphones
This is where the headphones are connected. Ensure they are connected firmly, until you hear a
click. If you are going to use a recorder, please insert the connector cable here. (It uses a
Miniphone connector).
· Switch
This is found at the bottom of the Detector. The Detector is always "switched off" until this switch
is pressed. To operate it, simply press the switch, and release the switch to turn off the instrument.

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· Stethoscope module
This is a module with a long metal probe. This probe is used as a "wave guide" and is sensitive to
the ultrasounds generated internally, such as inside a pipe, the housing of a bearing, condensate
purgers, valves, etc. Once stimulated by the ultrasound, it transfers the signal to a piezoelectric
transducer placed directly in the casing of the module.
To use the stethoscope module:
1. Align the pin located in the rear of the module with the connector found in the tip of the gun and
plug in firmly.
2. Touch the area to test or inspect.
3. Start with a maximum sensitivity in the sensitivity selector and reduce the sensitivity until you
have a satisfactory sound and the level of the meter is reached.
The probe is removable and can be replaced with two or three pieces of probe to achieve different
lengths for the stethoscope.
· Headphones
They are highly resistant headphones designed to block out loud sounds in industrial
environments. They allow the sounds received through the detector to be clearly distinguished.
Connect the headphone cable to the connection located in the measuring gun and place the
headphones over your ears.
IMPORTANT: They are compatible with the security helmet.
3. Uses of the Ultrasonic leak detector. Mod.003
3.1. Detection of leaks in condensate purgers
An ultrasonic test of the condensate purgers is a test that all users of purgers should frequently
perform as a preventative measure. It is a problem of energy efficiency and environmental
awareness, and of course also one of financial savings.
The user will become familiar with the different types of purgers and will know how to recognise
them with great ease.
We should remember that there are three types of purgers:
Thermodynamic
Mechanical (closed buoy and inverted floater)
Thermostatic (bimetallic and balanced element)

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Before starting to detect a leak:
1. Determine what type of purger is in the line. Familiarise yourself with the way the purger works.
It is intermittent or continuous drainage? We should easily recognise the operating sound of each
type.
2. Try to check whether the purger is in operation. Place your hand close to it, but do not touch the
purger, or even better, use a non-contact infra-red thermometer to check if it is hot or cold.
3. Use the stethoscope module.
4. Try to use the probe of the module to touch the discharge side of the purger. Press the switch
and listen.
5. Listen to the intermittent or continuous flow operation of the trap.
Intermittent flow: Inverted floater, thermodynamic and thermostatic.
Continuous flow: Closed buoy with a thermostatic element.
While testing intermittent purgers, listen long enough to measure the true cycle. In some cases
this can exceed 30 seconds. Bear in mind that the greater the load reaching the purger, the more
time it will remain open.
When carrying out an ultrasonic test of a purger, a continuous running sound usually indicates the
passing of steam. There are subtleties with each type of purger that should be taken into account.
Use the sensitivity levels of the Sensitivity Selector to help with your examination. If we are going
to inspect a low pressure line, adjust it for greater sensitivity, toward the "0". If it is a medium
pressure system (over 6-8 bar), reduce the sensitivity level toward "80".
Check upstream and reduce the sensitivity so that the indicator is at around 50% or less. Next,
touch the body of the trap downstream and compare the readings.
Only practice will help here, and we will need lots of it to reach an appropriate level of inspection.
· Confirmation of: Steam/Condensation/Flash Steam
In the cases where it is difficult to determine the sound of steam, flash steam or condensate:
1. Touch the immediate downstream side of the purger and reduce sensitivity to obtain a reading
on the meter midline (approximately 50%).
2. Move between 15-30 cm (6-12 inches) downstream and listen. Flash steam will show a large
drop in the intensity, while exiting steam will show a slight drop in intensity.
· Inverted floater purger
Operates with an inverted floater that moves as a result of the difference in density between the
condensate and the steam. When there is condensate the floater lowers, it frees the seat valve
and allows the condensate to exit. When steam enters, the floater rises and blocks the pathway,
guaranteeing a line free of condensates. This action is repeated cyclically, automatically removing
the accumulated air and condensates.

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The inverted floater purger operates intermittently. If steam is leaking through the valve, we will
detect the loss of this intermittent nature and the escape sound will be strong and continuous.
· Closed buoy purger with a thermostatic element
Operates with a float valve that opens up for the accumulation of condensates and transports it. It
also incorporates a thermostatic element that allows for the automatic elimination of air.
A closed buoy purger normally has a fault in the "closed" position. The valve is damaged or the
thermostatic element leaks.
If there is a leak through the valve, the sound will be constant and easy to hear.
If there is no leak through the valve and we detect the passing of steam, the leak must come from
the thermostatic element.
You are wasting energy.
· Thermodynamic purger
The operation of a thermodynamic purger is based on the "Bernoulli" principle: "In a fluid in
movement, the sum of the static and dynamic pressures remains constant at all points. So if one
increases, the other decreases and vice versa".
The input pressure acts on the shut-off disc, which allows for the immediate discharge of
condensate and air at the temperature of steam.
The steam then enters the purger. The high speed produced by the expansion of the steam
creates a low pressure area at the rear of the shut-off disc.
The flow is diverted to the back of the shut-off disc and creates a high pressure zone through
recompression. The shut-off disc starts to lower.
When the high pressure is acting on the entire surface of the shut-off disc, it exercises a force
greater than the input pressure. The purger closes. The subsequent presence of condensate in
the entrance repeats the cycle.
A thermodynamic purger in good condition has a cycle (retention-discharge-retention) of 4-10
times a minute. In general, when there is a fault this is in the open position, allowing for a
continuous stream of steam.
· Thermostatic purger
All thermostatic purgers work on the basis of the difference in temperature between the
condensate and the steam.
· Bimetallic purger:
A bimetallic purger works on the basis of the principle of the combination in a column of metallic
discs of two faces in a single bimetal, where each face has a different expansion coefficient.
The bimetals are stacked in pairs, with the faces with the same coefficient (faces without notches)
facing each other.

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In the presence of cold water, the bimetals remain flat. On detecting a higher and higher
temperatures, they become deformed in a convex shape, moving the seat against the valve.
Maximum convexity, and with it, a totally watertight seal, is obtained just at the mid-point of
moving from condensate to steam.
· Thermostatic purger with balanced element:
The thermostatic action of the balanced element allows the condensate and cold air to freely leave
when starting up.
When the temperature of the condensate reaches that of saturation, the element closes and
blocks the steam.
When the condensate cools, the elements opens and evacuates it. When steam is at the point of
appearing, the cycle is repeated and the element closes, and so on.
If the purgers have a fault, you will hear a constant leak noise.
3.2. Detection of leaks in valve seals
When a low pressure fluid escapes through a small space, it moves from a laminar flow to a
turbulent flow. The turbulence generates a wide spectrum of sound known as "White Noise".
As the ultrasound will be stronger at the location of the leak, the detection of the signal is relatively
easy.
In the case of a valve where the valve is leaking, the fluid that escapes will move from an area of
high pressure to one of low pressure, creating turbulence in the low pressure or "downstream"
side. The ultrasonic component of this "White Noise" is much stronger than the audible
component. If the valve has an internal leak, the ultrasonic emissions generated in the location of
the orifice will be heard and registered by the meter.
The sounds of a valve with a leak can vary depending on the density of the fluid. In some cases, a
subtle crackling sound will be heard, other times there will be a loud sound of leakage. Sound
quality depends on the viscosity of the fluid and internal pressure differentials of the pipe.
As an example, water flowing at low or medium pressure can be easily recognised as water.
However, high pressure water running through a partially open valve may sound very much like
steam. To discriminate between them: reduce the sensitivity, touch the line of steam and listen to
the quality of the sound, then touch a line of water. Compare and once familiar with the sound
differences, continue your inspection.
A correctly positioned valve will not generate any sound. In some high pressure situations, the
ultrasound generated within the system will be so intense that the surface waves will move from
other valves or parts of the system and make it difficult to diagnose the leaks in the valve. In this
case we make a comparison of sonic differences by reducing the sensitivity and touching the
upstream part of the valve, in the valve seat and just downstream of the valve.
· How to locate leaks
1. Use the stethoscope module and the headphones.
2. Start with the sensitivity selector at 0 (Maximum).

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3. Start to scan, directing the module downstream of the valve and listen through the headphones.
4. If you detect a lot of ultrasound in the area, reduce the sensitivity adjustment and continue
scanning.
5. Try to listen for an "escape" sound while watching the meter.
6. Follow the sound to the point where it is the strongest. The meter will show a higher reading
the closer you are to the leak.
7. In order to focus on the leak, keep reducing the sensitivity and work on the suspect area until
finally in a position to confirm whether one exists.
8. For comparative readings, generally in high pressure systems:
1. Touch the upstream area and reduce the sensitivity to minimize any sound (in general,
set the meter at the midline "50%" reading).
2. Touch the valve seat area and/or the downstream side.
3. Compare the sonic differences. If the valve has a leak, the sound level in the seat or
downstream side will be equal to or greater to that of the upstream side.
· To confirm a leak
In high pressure systems, there can be parasite signals or false signals produced by nearby valve
or pipes. In order to determine whether the signal analysed comes from a valve being inspected,
proceed as follows:
1. Move closer to the suspect source.
2. Touch the upstream side of the suspect source.
3. Reduce the sensitivity until the meter shows a midline "50%" reading.
4. Touch it in short intervals, for example every 15-30 cm (6-12 inches) and watch for changes in
the meter.
5. If the level of sound reduces as it is moved towards the valve to be tested, this indicates that
the valve has no leaks.
6. If the level of sound increases as it is moved towards the valve to be tested, this indicates that
the valve has a leak.
3.3. Checking foe wear on bearings
The ultrasound inspection and monitoring of the bearings is the most reliable method of detecting
incipient faults in the bearings.
The ultrasonic warning appears in response to an increase in the temperature or the increase in
low frequency vibration levels.

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The ultrasound inspection of the bearings is extremely useful as a preventative measure:
a. Start of a fault due to fatigue.
b. Fault in the surface of the bearing - Brinelling.
c. Lack of lubrication.
In ball bearings, when the metal in the track, the roller or the ball of the bearing starts to wear out,
there is a slight deformation which will increase in line with its use. This deformation in the metal
generates an increase in the emission of ultrasonic sound waves.
The changes in the amplitude of 12 to 50 times compared to the reading for a new one is an
indication of an incipient fault in the bearing. When a reading exceeds any previous reading by 12
dB, it can be assumed that the bearing has a fault.
This information was discovered through experiments carried out by NASA on ball bearings. In the
tests carried out while monitoring the bearings in the frequencies from 24 to 50 kHz, they found
that the changes in the amplitude indicate the start of a fault and that precedes other indicators,
such as thermal indicators or changes in vibrations.
An ultrasonic system based on the detection and analysis of modulations of the resonance
frequencies of the bearing can provide the capacity for fine detection while the conventional
methods are incapable of detecting very minor faults. An example is when a ball passes over a pit
or a fault in the surface of the bearing, producing an impact. A structural resonance of one of the
components of the bearing vibrates or "rings" due to this repetitive impact. The sound produced is
observed as an increase in the amplitude of the monitored ultrasonic frequencies of the bearing.
The "brinelling" of the surfaces of the bearing will produce a similar increase in amplitude due to
the flattening process as the balls leave the guide. These flat spots also produce a repetitive
ringing that is detected as an increase in the amplitude of the monitored frequencies.
Ultrasonic frequencies detected by the Detector are reproduced as audible sounds.
This "heterodyne" signal can assist a user in determining bearing problems. When listening, it is
recommended that the user first become familiar with the sounds of a bearing in perfect condition.
A new bearing is heard as a hissing or running noise.
Crackles or rough sounds indicate a problem. In certain cases, a damaged ball can be heard as a
clicking sound, whereas at a high intensity, a rough uniform sound may indicate damage to the
track or uniform damage in the ball.
Loud running sounds, like the running sound of a bearing in good condition, only a little rougher,
may indicate a 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 support surfaces, rather than rotating. If this
condition is detected, we recommend carrying out much more frequent preventative inspections.

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· Detecting bearing faults
Carry out comparative tests. The comparative method consists of inspecting two or more similar
bearings and "comparing" the potential differences.
1. Use the stethoscope module.
2. Select a "testing point" on the housing of the bearing. Touch this point with the stethoscope
module. Ensure that the module is in contact with the housing of the bearing. If this is difficult,
touch the point where the grease is fed or touch the point closest to the bearing.
3. Approach the bearings at the same angle, touching the same area on the bearing housing.
4. Reduce the sensitivity.
5. Listen to the sound of the bearing through the headphones to hear the "quality" of the signal for
the correct interpretation.
6. Select the same type of bearings under similar load conditions and the same speed of rotation.
7. Compare differences in meter readings and the sound quality.
It is important to consider two elements of potential failure. One is the lack of lubrication, while the
other is over-lubrication.
Normal bearing loads cause an elastic deformation of the elements in the contact area giving a
smooth distribution of the elliptical stress. However, the support surfaces are not perfectly smooth.
Therefore, the distribution of the real stress in the contact area will be affected by random surface
roughness. In the presence of a lubricant film on a support surface, there is a moderating effect on
the stress distribution and the acoustic energy produced will be low. Lubrication can be reduced to
a point where the stress distribution is no longer present, the normal rough spots will be in contact
with the track surface and will increase the acoustic energy.
These microscopic uniformities begin to generate wear and it is possible that they will develop
small cracks. Therefore, apart from normal wear, the useful or fatigue life of a bearing is strongly
influenced by the relative thickness of the film provided by an appropriate lubricant.
· Low velocity bearings
Monitoring low speed bearings is easy with the Detector. The sensitivity range enables us to hear
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" or larger) and greased with high viscosity
lubricant.
Most often no sound is heard when the grease absorbs most of the acoustic energy.
If a sound (usually a crackling sound) is heard, this is some indication that deformation is
occurring.

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4. Solving general mechanical problems
When mechanical components are subject to wear, breakage, misalignment, etc., they are also
producing changes in their usual ultrasound behaviour. This change can save us time and effort in
diagnosing problems if properly monitored. Therefore, an ultrasonic history of key elements can
avoid unscheduled downtime. And most importantly, if the equipment should begin to fail, the
Detector can be extremely useful in preventing potential problems.
· Solving problems
1. Use the stethoscope module.
2. Touch the area to be inspected and listen through the headphones, observing the bar graph
display.
3. Adjust the sensitivity until the mechanical operation of the equipment can be clearly heard.
4. Examine the equipment, touching the suspect areas.
5. To focus on the sounds that are of interest for the diagnosis of problems, those to measure,
gradually reduce the sensitivity to help to locate them.
6. Follow the sound to its strongest point and that is where the problem is.
5. Ultrasound technology
Ultrasound technology refers to sound waves above the range that can be heard by humans. The
average threshold for being heard by humans is 16,500 hertz. However, some people are capable
of hearing sounds up to 21,000 hertz, so ultrasound technology relates to frequencies of 20,000
hertz or more. The equivalent of 2,000 hertz is 20 kHz or kilohertz. One kilohertz is equal to 1000
hertz.
Low frequency.
High frequency.
Figure A.

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As ultrasound is high frequency, it has a short wavelength. Its properties are different to low
frequency or audible sounds. A low frequency sound requires less acoustic energy to travel the
same distance as a high frequency sound. (Fig. A)
The ultrasound technology used by the Detector is what is generally referred to as air-coupled
ultrasound. This type of ultrasound refers to the transmission and reception of ultrasound through
the atmosphere without the need for a coupling agent (interface).
There are ultrasonic components in almost all forms of friction. For example, if you rub your thumb
and forefinger together, a signal will be generated in the ultrasonic range. Although you may be
able to very faintly hear audible noise of the friction, with the equipment the sound is very loud.
The reason for the loudness is that the Detector converts the ultrasonic signal into an audible
range and then amplifies it. Due to the comparatively low-frequency nature of ultrasound,
amplification is a very important feature. Although audible sounds are emitted by most equipment
in operation, it is the ultrasonic elements of the acoustic emissions that are generally the most
important.
For preventative maintenance, an individual will often listen to a bearing through a basic audio
system to detect whether it has become worn. As this individual can only listen to the audio
elements of the signal, the results of this type of diagnosis are general. The subtleties of the
change within the ultrasonic range are not perceived and therefore omitted. When a bearing is
clearly having problems in the audio range, this bearing need to be replaced immediately.
Ultrasound offers a capacity for preventive diagnosis. When changes start to be detected by
ultrasound, there is still time to plan some proper maintenance.
In the area of leak detection, ultrasound offers a fast and accurate way to locate any type of leak.
6. General catalogue

Ultrasonic leak detector
Model 003
To detect leaks:
– In condensate purgers.
– In valve seals.
Checking for wear on bearings.
Solving mechanical problems in general.
Ultrasound is directional and localisable. In a noisy environment we can remove or block the distorting ultrasounds.
During preventive maintenance, we should place the stethoscope properly and we will detect, audibly and visually, the
leaks that are affecting us. We can take corrective action, safeguarding the environment, saving energy, time and con-
sequently money.
It meets and exceeds the requirements of ASTM E1002-2005 for Leak Detection.
Features
―Very easy to use. To correctly interpret the signals, you must have basic training and some mechanical experience,
especially in the use and handling of condensate purgers and valves in general.
The equipment is supplied in a Cordura-type nylon case and comprises:
Ultrasonic pistol:
―This is an ultrasonic processor in the form of an ABS plastic pistol. It comprises a solid state hybrid heterodyne circuit
receiver, with a peak response frequency of 36-44 kHz.
―With an LED type bar graph display (Red). Screen with 10 segments, where each corresponds to 3 dB, allowing us to
calculate the detected decibels. One segment indicates a low level of ultrasound, and ten, a high level.
―LED battery charge level display (Red).
―Sensitivity selector. Graduated from 0 to 70 in tens of dB. It allows us to adjust the equipment to 8 positions, from
higher (0) to lower (70) sensitivity.
―Headphone connector.
―Switch.
―Power: Alkaline battery 9V.
Stethoscope module:
―It acts as a wave guide. It can be plugged in. It incorporates an ultrasonic piezoelectric transducer.
Stethoscope probe:
―The probe is removable and can be replaced with two or three pieces of probe lengthener to achieve different lengths
of stethoscope.
Headphones:
―They are highly resistant headphones designed to block out loud sounds in industrial environments. They allow the
sounds received through the detector to be clearly distinguished.
―They are compatible with the safety helmet.
―Dual monophonic cable provided. Impedance 16 ohms. Over 23 dB of noise attenuation. They meet ANSI and OSHA
requirements.
Complementary technical instructions. (ITC).
IMPORTANT
On demand:
―Speakers.
― Leak amplier liquid.
―Scanning module.
―Rubber concentrator
―Generator of specialised tones.
Model 003

Informative brochure, without obligation and subject to our General Sales Conditions.
[phone] [phone] [email protected] 119 89311
Avenc del Daví, 22 Pol. Ind. Can Petit 08227 TERRASSA (Barcelona) SPAIN
www.vycindustrial.com
Nº PIECE PIECE MATERIAL
1 Ultrasonic pistol ABS plastic
2 Stethoscope module Stainless steel
3Stethoscope probe Stainless steel
4Stethoscope probe
extension Aluminium
5 Headphones ABS plastic
6 Case Cordura-type nylon
OPERATING
CONDITIONS
OPERATING
TEMPERATURE
0º C to 50º C
(32º F to 120º F)
STORAGE
TEMPERATURE
-18º C to 54º C
(0º F to 130º F)
RELATIVE
HUMIDITY
10-95% non-condensing up
to 30ºC (86º F)
612
3
4.1
4.2
4.3
5
l
B
H
A
L
L1+L2
L1+L3+L2
h
l
a
MODEL 003
B 48
H 200
A 122
L 292
L1+L2 681
L1+L3+L2 960
a 125
h 350
l 455
WEIGHT IN kg. 1,71
CODE
2108-003. 0000
Founded in 1914