Version 1 1
ULTRAPROBE® 201
Instruction Manual
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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.
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Theory .............................................................................................................................................. 4
Monitoring bearing wear ............................................................................................................. 5
Component assembly magnetic mount sensor ........................................................................... 6
Basic components ........................................................................................................................ 6
Component Assembly Instructions .............................................................................................. 7
UE Systems Grease Caddy Docking Station Mounting Instructions ............................................ 7
UE Systems Grease Caddy Docking Station Mounting Instructions ............................................ 8
Metered Housing ......................................................................................................................... 9
Headphones ............................................................................................................................... 10
Using the Ultraprobe 201 Grease Caddy ................................................................................... 11
Specifications Ultraprobe 201 (Grease Caddy) .............................................................................. 12
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Theory
Ultrasound consists of high frequency sound waves that are above the hearing limits of human
perception. Generically ultrasonic frequencies are considered to start at 20,000 cycles per
second ( 20 kilohertz or 20 kHz). Most ultrasonic instrumentation used for equipment condition
analysis includes frequencies that range from 20 to 100 kHz. Instruments such as the Ultraprobe
201 Grease Caddy use an electronic process called “heterodyning” to allow for accurate
translation of ultrasound produced by operating equipment into the audible range where users
can hear these sounds through headphones and observe the amplitude of the sound on a meter.
The short wave, high frequency nature of ultrasound offers many advantages for instruments
used to inspect operating equipment
1. The amplitude of generated ultrasounds will fall off rapidly as the sound travels from its’
source providing a “localized” signal that can be detected and monitored with relative ease
in most noisy environments.
2. The subtle nature of this signal provides for early warning of potential failure modes.
3. Increases in friction of rolling elements can be detected and used as an indication of low
lubrication levels.
4. Using base line information, amplitude levels can be used as a guide for determining when
and when not to lubricate a bearing.
5. The heterodyned signal helps users hear when grease is entering the bearing and
recognize when to stop lubricating.
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Monitoring bearing wear
In a bearing, normal bearing loads cause 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, a side from
normal wear, the fatigue or service life of a bearing is strongly influenced by the relative film
thickness provided by an appropriate lubricant.
Ultrasonic inspection and monitoring of bearings is by far the most reliable method for detecting
early stages of bearing failure and conditions such as lubrication starvation. 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 the beginning stages of fatigue failure
related to 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 irregular surfaces, which
will cause an increase in the emission of ultrasonic sound waves.
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.
When listening to a bearing, 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. Louder rushing sounds similar to that of a good bearing
only slightly rougher, can indicate lack of lubrication.
A change in amplitude from the original base line reading can be an indication of:
a. lack of lubrication or
b. incipient bearing failure.
When a reading exceeds any previous reading by 8-10 dB with no change in the sound quality (a
“rushing” noise) this is an indication of lubrication starvation, an increase of greater than 12 dB
can be considered to be an indication of the beginning of the failure mode.
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Component assembly magnetic mount sensor
Basic components
Your kit consists of the following parts:
A Grease Caddy Assembly
B Clamp
C Sensor Assembly – Magnetic Sensor and Cable with Acoustic Shield
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Component Assembly Instructions
1. Attach the Ultraprobe 201 Grease Caddy A to the grease gun, using Clamp B.
2. Connect cable from Sensor Assembly to input of Grease Caddy
Before you begin testing, it is advisable to familiarize yourself with the basic components of your
kit.
UE Systems Grease Caddy Docking Station Mounting Instructions
Docking Station:
Note the Raised disc with the logo.
This is to face away from the grease gun.
1. Remove tip of grease gun 2. Line up indent facing grease gun
3. Srew on Docking Station and tighten 4. Screw on grease gun tip and tighten
NOTE: Do not use Docking Station when using rubber or plastic tubes.
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UE Systems Grease Caddy Docking Station Mounting Instructions
Completed setup
Close up view Ready to use
Keep Magnetic on Docking Station when
greasing
NOTE: Do not use Docking Station when using rubber or plastic tubes.
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Metered Housing
The main component of the Ultraprobe 201 is the metered housing. From back to front, let‘s
examine each part.
On and OFF buttons. To turn the instrument ON, push the ON button in. Once pressed
the instrument will stay on and then automatically turn off after 5 minutes (this will extend
the battery charge and active use of the instrument). To turn the instrument OFF before 5
minutes have elapsed, press the OFF button.
Bar graph Display: The display consists of a ten segment LED bar graph that will indicate
ultrasonic signal strength. A low number of LEDs indicate a low level of ultrasound.
Conversely more intense ultrasonic signals will display more LEDs.
Battery Level Light: This red light turns on only when the batteries need to be recharged.
Sensitivity Selection Dial: There are eight (8) sensitivity levels which read out in related
decibels of „0“ to „70“. As the dial is turned to the right, to „0“, the sensitivity of the
instrument increases. As the dial is turned to the left, to „70“, the sensitivity decreases. A
low-level ultrasound emission produces low amplitude. To detect low-level ultrasounds,
the instrument should be in a high sensitivity position. 0 is the highest sensitivity position.
For higher amplitude signals, move the sensitivity to the left towards „70“.
The dial dB indications, along with the LED indications in the bar graph may be used to
establish dB levels. To do this, just add 3 dB for each LED bar graph indication to the dB
level set in the sensitivity dial. EX: 0 dB on the sensitivity dial, plus 3 LED bar graph
levels = 9dB (0+9). 40 dB on the sensitivity dial plus 4 bar graphs = 52 dB (40+12)
“Phone” Jack: This is where you plug in the headphones. Be sure to plug it in firmly until
it clicks. Should a recording device be utilized, this is where the cable is inserted. (Use a
miniphone plug).
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Headphones
The standard headphone plugs into the “phone” jack. NOTE: Always use the headphones when
operating the Ultraprobe 201 Grease Caddy. There may be times where stray signals influence
the LED indicator. Using the headset will assure that the sounds being received are coming from
the subject test bearing.
a. Should inspections be performed in areas where either hard hat or hearing protection is
required, there are optional headphones available for both hard hat use and for use in
high noise areas. These heavy duty headphones are designed to block out intense
sounds often found in industrial environments so that the user may easily hear the
sounds received by the ULTRAPROBE 201.
b. For those situations in which it is not possible or difficult to wear the standard
headphones described above, UE Systems has two other options available: 1. the DHC
1991 Earpiece which loops around the ear, and 2. the SA-2000 Speaker Amplifier which
is a loud speaker that is compatible with the Ultraprobe headphone output jack.
Front:
A Guide Light
When the unit is on, the guide light automatically is on to help users see in dark locations.
B Wave Guide Connection
C Recharge Jack
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Using the Ultraprobe 201 Grease Caddy
You may use your Ultraprobe 201 Grease Caddy to know when to lubricate by setting a baseline
level. You may choose to lubricate whenever a bearing exceeds a pre-set baseline by 8 dB-12
dB accompanied by a uniform white noise or rushing sound. If a bearing is below this level, it
does not need lubrication, therefore do not lubricate bearings with low level readings when
compared to a baseline.
A. When lubricating:
I. Listening while adding lubrication
a. Be sure the grease coupler is securely connected to the zerk fitting and that the
magnetic sensor is in full contact with the bearing housing.
b. Wear your headphones and be sure the head phones are plugged into the
headphone jack.
c. Turn the Ultraprobe 201 ON.
d. If the sound is too loud, reduce the sensitivity: turn the Sensitivity Dial LEFT until
the LED’s are at approximately 50% of scale.
e. Apply the lubrication and listen.
II. When to STOP lubricating:
While applying the lubrication the sound level will begin to drop. You may stop:
a. when the sound level drops off and suddenly rises or
b. when the sound level approaches a pre determined baseline level which (usually
a drop of 2-3 LED bars on the meter).
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Specifications Ultraprobe 201 (Grease Caddy)
Housing
Attaches directly to the grease gun, gives visual and audible
indication for proper lubrication
Construction
Aluminum housing
Dimensions
13.3 x 6.7 x 4.5 cm (LWH)
Operating Temperature
0 °C to 60 °C
Relative
10-95% non-condensing at up to 30 °C
Circuity Humidity
SMD/Solid State heterodyne receiver
Transducer
Magnetically mounted piezoelectric transducer
Frequency Response
Peak response: centered around 38 kHz
Indicator
10 Segment LED Bar Graph (red)
Bright white LED for illumination of test area
Sensitivity Selection
8 position precision attenuation
Power
Rechargeable nickel metal hydride
Power off
Time delay after five (5) minutes
Low Battery indicator
LED
Headset
Deluxe noise isolating headset for hard hat use
Over 23 dB of noise attenuation
Meets or exceeds ANSI Specifications and OSHA standards
Attachment
Universal: fits most commercially used cartridge grease guns
Weight
0.45 kg
Warranty
1-year parts/labor standard,
5 years with completed warranty registration card.
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Need further support?
Want information regarding products or training?
Contact :
UE Systems Europe, Windmolen 20, 7609 NN Almelo (NL)
e: info@uesystems.eu w: www.uesystems.eu
t: +31 (0)546 725 125 f: +31 (0)546 725 126
www.uesystems.eu
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