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UE UCA586 ULTRASONIC CONDITION ANALYZER
Instruction Manual
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OVERVIEW ............................................................................................................................................... 3
Mechanical Monitoring Concepts ....................................................................................................... 4
Cavitation ............................................................................................................................................ 4
Monitoring: flow/no flow and leakage ................................................................................................ 4
Solid Flow: Powders, Metal Filings, Etc. .............................................................................................. 4
UE UCA586 INSTALLATION & OPERATION .............................................................................................. 5
POWER REQUIREMENTS ..................................................................................................................... 5
SENSITIVITY CONTROL ......................................................................................................................... 5
THRESHOLD CONTROL ......................................................................................................................... 5
VOLTAGE AND CURRENT OUTPUTS ..................................................................................................... 5
ALARM OUTPUT .................................................................................................................................. 5
HETERODYNED AUDIO OUTPUT .......................................................................................................... 5
SYSTEM SETUP ..................................................................................................................................... 5
DECREASES OF ULTRASOUND LEVELS ................................................................................................. 6
UE UCA586 PIN OUT/DESCRIPTION DIAGRAM.................................................................................... 6
PANEL INDICATORS: ............................................................................................................................ 6
PANEL Adjustments: ............................................................................................................................ 6
Specifications ........................................................................................................................................... 8
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OVERVIEW
The UE UCA586 is an Ultrasonic Detection unit that is targeted for continuous monitoring. The unit
offers an overall dynamic range of roughly 100 decibels, and is configured for structure borne
ultrasonic detection.
ULTRASOUND TECHNOLOGY
The Ultrasound Technology utilized by this system is generally referred to as “Airborne Ultrasound”.
Airborne Ultrasound is concerned with the transmission and reception of ultrasound through the
atmosphere without the need of sound conductive (interface) gels. It incorporates methods of receiving
signals generated through one or more media via wave signals. When it is used to detect/monitor
problems within a specific media, the technology may be referred to as Airborne/ Structure borne
Ultrasound (A/B Ultrasound).
A/B Ultrasound is concerned with sound waves that occur above human perception. The normal
“audible” environment in which the human ear is capable of sensing is 20 Hertz to 20 kHz (1,000 Hertz
is 1 kiloHertz or 1 kHz). The average threshold of human perception is 16,500 Hertz or 16.5 kiloHertz.
These audible wavelengths range in size from as small as 3/4 inch (1.9 cm) to as large as 56 feet (17
m). The frequencies sensed by airborne ultrasound instruments such as the UE UCA586 are above
20 kHz to 100 kHz. The wavelengths are magnitudes smaller than the audible, ranging from 1/8 inch
(0.3 cm) to 5.8 inch (1.6 cm).
The short wave nature of the ultrasonic signal provides many advantages over lower frequencies.
1. High frequency amplitudes drop off quickly as they move from the source of emission.
2. The signals tend to radiate in straight paths providing relative ease of detection.
3. Since the signal strength diminishes rapidly, the sound source is easily separated from
background noise.
4. Subtle changes are detected before a major failure occurs.
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Mechanical Monitoring Concepts
There are ultrasonic components in practically all forms of friction. As an example, if one were to rub
the sensor probe with a finger, an ultrasonic signal will be generated. Although there might be some
audible components to this friction, the sensor will only sense the ultrasonic components which, in this
example, will be considered a gross signal that is also amplified. In fact, due to the comparative low
amplitude nature of ultrasound, amplification is a very important feature. Although there are obvious
audible sounds emitted by most operating equipment, is the ultrasonic elements of the acoustic
emissions that are generally the most important. Ultrasound offers a predictable diagnostic capacity.
When changes begin to occur in the ultrasonic range, there is still time to plan appropriate
maintenance. According to NASA research, when a bearing enters the beginning stages of failure,
there is an amplitude increase of from 12 to 50 times over a set baseline. Not only can the early stage
of bearing failure be monitored and detected, other warning signs can also be noted such as: lack of
lubrication, advanced failure and catastrophic failure.
Cavitation
As air enters a valve or pump, the dynamics of the pressure within can create cavitation: the forming
and explosion of bubbles. Although cavitation may be present, it does not necessarily create a
problem. It becomes a maintenance problem only when the process increases to produce conditions
that will cause internal damage. By setting a baseline, the increase in cavitation activity can be
monitored to a point where an alarm can be set and preventive measures can be taken.
Monitoring: flow/no flow and leakage
Valves control fluid flow. Whether the valve’s function is to provide a simple flow/ no flow operation
(on/off) or to regulate the amount of flow, a malfunction can be critical.
Changes in amplitude related to these conditions can be monitored and alarm levels may be set to
note or control these changes. When leak occurs, the fluid will move from high pressure (upstream),
through the valve seat, to the low pressure (downstream) side. As it reaches the low pressure side , it
expands briefly, producing a turbulent flow. This turbulence has strong ultrasound components. The
amplitude of the turbulence is related to a few basics:
1. Fluid Viscosity
Under identical environments, pressures, leak size, etc.; a lighter fluid, such as air will produce
more turbulence than a heavier fluid, such as oil.
2. Orifice Size
The more restriction on a fluid, the less amplitude generated. A smaller diameter hole will not
produce as much sound as a larger hole under similar flow conditions.
3. Pressure Differential
Given identical leak sizes, when there is a greater pressure difference between the upstream
and downstream sides, the leak with the greater difference will produce a louder signal.
4. Orifice Shape
Under the same environmental conditions, a smooth orifice will not produce as much
turbulence as a jagged edge orifice.
Solid Flow: Powders, Metal Filings, Etc.
As solid moves through a carrier, such as piping, the particles will produce friction which may be
monitored. Any flow disruption will display a drop in amplitude over a preset baseline and will be
detected. This may be set up to produce an alarm.
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UE UCA586 INSTALLATION & OPERATION
POWER REQUIREMENTS
The UE UCA586 requires a 24 Volt, DC power source @ 200 milliamperes total. The power
connections are to be made to the I/O cable. Refer to the Pin Out/Description Diagram for the
connections.
SENSITIVITY CONTROL
In order to accommodate the entire 100 decibel dynamic range, some adjustment in the field is
required. This is set by the 20 turn potentiometer located inside the unit. It is accessed through the
front panel behind the hex head screw next to the DB9 connector. The sensitivity is preset at the
factory to maximum or fully clockwise. If this is too sensitive, turn the potentiometer counterclockwise
to decrease the sensitivity.
THRESHOLD CONTROL
The threshold adjustment is available if an alarm output is required. This is the adjustment used to get
a simple output signal change when the ultrasonic input has either exceeded or gone below a set
point. There is a Alarm Threshold Sense output at pin 8 on the DB9 connector or on the Blue colored
I/O Cable wire. This can be detected as a voltage from 0-10 VDC which is where the threshold or set
point is currently adjusted to. To raise the level, turn the potentiometer clockwise and to lower
the level turn the potentiometer counterclockwise.
VOLTAGE AND CURRENT OUTPUTS
The sensor provides voltage, and current outputs. The voltage and current outputs are continuous
analog signals that are proportional to the ultrasonic activity sensed.
The voltage output has a range of 0 to 10 volts DC full scale. A 2.5 volt change in output voltage
corresponds to a 10dB change in ultrasonic input signal. Therefore, the entire 10 volt range represents
a 40 dB change in ultrasonic input level.
The current output has a range of 4 mA to 20 mA DC. Therefore, the full 4 mA to 20 mA range
represents an ultrasonic level change of 40dB. The output can be connected to a 250 OHM resistor
from current output to current output return and fed to a 5V A to D converter if digital monitoring is
required. Refer to the diagram for connections. Note: Current output is 4-20 mA output (pin 2) and
current output return is pin 3 .
ALARM OUTPUT
The sensor provides an alarm output which is an open collector transistor. The open collector can
switch 24 volts DC @10 mA maximum. The alarm is preset at the Factory to transition at 50% of full
scale. There are no “dead bands”. The alarm output stops conducting when the input or ultrasonic
signal level exceeds the threshold level or set point.
HETERODYNED AUDIO OUTPUT
The sensor provides an audio output for use with a speaker or a pair of headphones. The signal can
also be fed into a spectrum analyzer for waveform analysis. The output level is preset at the Factory
@ 90 dBA for the full scale output.
SYSTEM SETUP
Once the system is connected and functioning properly, the sensor should be exposed to the user’s
steady state source of ultrasound (bearing, leak, etc.) this ultrasonic source should represent a
normally functioning valve, bearing, etc. During exposure, the user should monitor the current or
voltage output. The sensitivity should be adjusted so that this steady state ultrasonic level is converted
to an output that is located somewhere in the lower portion of the applicable range (4.3 to 5.0 mA on
the current output or .5 to 1.0 volt on the voltage output).
The unit will now sense the increases in ultrasonic activity above the ambient condition.
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DECREASES OF ULTRASOUND LEVELS
If the application requires the sensing of ultrasonic decreases, the sensitivity of the unit should be
adjusted (with ambient ultrasound sensed) so that the current output and or the voltage output is in
high portion of the applicable range.
UE UCA586 PIN OUT/DESCRIPTION DIAGRAM
PIN#
I/O CABLE
COLOR
DESCRIPTION
1
Orange
0-10 VDC Output
2
Red
4-20 mA Output
3
Green
4-20 mA Return
4
White
Heterodyned (Audio) Output
5
Black
Ground
6
Yellow
Open Collector Alarm Output (rated at 24VDC @10 mA maximun)
7
Black
Ground
8
Blue
Alarm Threshold (Set Point) Sense
9
Brown
Power Supply Voltage Input. 20 to 30 VDC, nominal 24VDC @200 mA maximum.
PANEL INDICATORS:
LED FUNCTION
Blue UCA586 Powered Up & Ok to Monitor
Red LED ON = Alarm Condition
PANEL Adjustments:
Sensitivity Adjust
Threshold Adjust
The Sensitivity and Threshold adjustments are internal and are located behind the black Button Head
Screws on the front panel. Turn clockwise to increase and counterclockwise to decrease.
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HEIGHT = 1.90"
(4) HOLES .1875" DIA
3.3125"
3.6875" TYP.
3.625" TYP.
2.50"
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Specifications
Frequency Range:
25-50 kHz
Outputs:
4-20 mA DC Linear Output Transfer Function: dB/mA DC
Scale: 1 mA DC = 2.5 dB input Level Dynamic Measurement Range: 40 dB
(set anywhere along the 100 dB input range) 0-10 DC V Linear Output
Transfer Function: dB/VDC Scale: 1 VDC = 4 dB input level
Dynamic Measurement Range: 40 dB(set anywhere along the 100 dB input
range)
Alarm:
Open collector rated @ 24 VDC, 10 mA Threshold Level: Adjustable over
the output range. Alarm output stops conducting when input level exceeds
the threshold level (set point)
Heterodyned (Audio)
Output:
90 dBA at full scale output into 16 ohms 3 dB bandwidth approx. 6 kHz
Threshold Setting:
Low impedance output which senses the threshold setpoint (set point)
Dynamic Input Range:
Approx. 100 dB
I/O Cable:
RF shielded. Length: 6 ft. (1.82 m)
I/O Connector:
DB9 Transducer Input
Connector:
BNC
Panel Adjustments:
Sensitivity and threshold
Power Indicator:
Blue LED
Alarm Indicator:
(local) Red LED
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ALPINE
COMPONENTS
Postal Address
Alpine Components Ltd
Innovation Centre, Highfield Drive
Churchfields
St. Leonards-on-
Sea
TN38 9UH
United Kingdom
Telephone
01424 858118
Website Address
www.alpine-
components.co.uk
"Alpine Components" is the abbreviated trading name for "Alpine Components Limited"
The company has been trading since 1991 and was incorporated on 13/11/2006 in the United Kingdom
Company Registration Number: 05996485
VAT Number: GB583598190
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