Sonel GUD-1 Ultrasonic Leak Detectors User Manual

USER MANUAL
TUD-1 **GUD-1
v1.03 08.07.2022
ULTRASONIC LEAK
AND ELECTRIC DISCHARGE DETECTOR TUD-1
ULTRASONIC GENERATOR GOD-1
** SONEL S.A. Wokulskiego 11
58-100 Świdnica  Version 1.03 08.07.2022

The TUD-1 detector and GUD-1 generator are modern, high-quality measuring devices, easy and safe to use. Please acquaint yourself with this manual in order to avoid measuring errors and prevent possible problems in the operation of the devices.

Introduction

Thank you for purchasing our ultrasound detector of electrical leaks and discharges. TUD-1 is a portable device for non-destructive testing and diagnostics. It is designed for detecting and locating ultrasound signals indicating damage. GUD-1 generator is dedicated for the detector as the source of the ultrasound signal. Depending on the version, the device may be purchased with standard or optional equipment.
CAUTION! Read the manual before using the detector. Strictly comply with the safety rules and manufacturer’s recommendations.
To ensure proper operation of the device and the desired accuracy of the measurement results, observe the following guidelines:

• any application that differs from those specified in the manual may result in damage to the device and constitute a source of danger for the user,
• the detector may be used only by qualified personnel having knowledge of safety rules,
• it is unacceptable to operate the device when:
•  it is damaged and completely or partially out of order,
• its cords and accessories have damaged insulation,
• it was stored for an excessive period of time in disadvantageous conditions (e.g.excessive humidity)
• repairs may be performed only by an authorized service point.
• it is forbidden to use the device with opened or incorrectly closed battery cover,
• the device must not be supplied from sources other than those indicated in this manual,
• the device is designed for operation in general industrial work and is not suitable for potentially explosive atmospheres.

1.1 Safety symbols
This symbol located near another symbol or terminal indicates that the user should read the further information is contained in the manual.
Protection class II – double insulation.
This symbol indicates, that the device cannot be disposed of with other household waste, but carried to a specific collection point of electronic wastes.
The device meets the necessary European requirements.

 TUD-1 Detector

2.1 Controls and indicators

1. AMPLIFICATION knob – for adjusting the gain of the input signal
2. “SIGNAL LEVEL” – a 5-level indicator of the strength of the received audio signal
3. “ON” LED – an indicator of activated device Switch
4. “BAT” LED – an indication of discharged battery

The headphones are connected to the cable with a 3.5 mm audio connector (mini- jack).
The device is equipped with additional adapters that affect the sensitivity and response of the instrument when receiving the ultrasound.
CAUTION!  During the installation of the tip (acoustic probe) hold the device only by its threaded nut. It is not allowed to generate a substantial torque during the assembly.

2.2 Functional description of the detector
TUD-1 device is designed for locating defects in various systems and objects. Damages in objects are a source of acoustic waves in the range of infrasound, audible sound, ultrasound and hypersound. The human ear can pick up sounds in the range of 16 … 20 000 Hz. Due to the nature of ultrasound, their source may be correctly identified after converting them into the audible frequency spectrum.

The group of defects includes mainly gas leaks, leakages and any incorrect connections of pipelines or welds in tanks and electrical discharges of different physical nature. TUD-1 is an ultrasound detector of electrical leaks and discharges, which detects acoustic waves in the narrow ultrasound range.
The principle of operation is based on the reception of ultrasound waves propagating in the air from their source and converting them into an electrical signal.
The ultrasound signal is converted into an electrical signal by a piezoelectric transducer having a frequency response with a reception acoustic resonance within the frequency range of (40±1) kHz.

• An electronic circuit provides an initial amplification of the signal from the piezoelectric and marking of spectrum components within the desired bandwidth.
• Then, the signal is converted to an alternating voltage with a frequency in the sound range.
• After amplification, the signal is sent to the headphones and a 5-stage LED signal strength indicator. The strength of the received signal may be smoothly adjusted using the knob. The device is constructed according to the design of a direct conversion receiver and performs the functions of an electronic detector to assess the intensity of captured ultrasonic vibration without measuring its level in physical units. Additional features of the device:
• protection against reverse polarity of connected battery;
• short-circuit protection in the power supply circuit.

2.3 Installation of acoustic probes
TUD-1 may operate independently or with installed acoustic probes of a different type, depending on the area of application

• The acoustic probe of type 1 is a funnel-shaped probe used for coarse leak detection of a wide scanning area.

• The acoustic probe of type “2” is straight and is designed to narrow down the scan range. Its shape is suitable for penetrating openings of narrow diameter in order to carry out the measurement within the tested objects.

• The acoustic probe of type “3” is a cone-shaped probe, tapering towards the inlet, in order to obtain very precise indication of the emission source of ultrasound waves.
  To install or replace the acoustic probe with the one of appropriate type proceed as follows:

• gently unscrew the cap covering the socket of acoustic probes or unscrew counterclockwise the  probe previously mounted,

• install the desired acoustic probe by screwing it on clockwise,

•  after use, secure the socket of probes by screwing on cap provided as standard with the equipment.

2.4 Installation of headphones
For proper conversion of electrical signals into audible beeps, the user must connect headphones to TUD-1 receiver. Headphones separate the operator from the sounds of the surrounding environment, providing selective hearing of sound waves, which results in the proper interpretation of received signals and the precise location of the source of generated sounds.

• Take the headphones out of the case.
• Connect the headphone cord, which comes out from TUD-1 and is terminated with a 3.5 mm plug (mini-jack), to the headphones.
• Put the headphones on, taking care of their correct position (“L”- left, “R”- right).

CAUTION!

• **** Unknown sound sources may damage your hearing. Searching for the source of ultrasound in a new environment requires caution. The operation of some machines and equipment may be a source of high-power ultrasound, which may cause hearing damage when using TUD-1. Therefore, before each measurement set the amplification control knob at the lowest level (“0” digit), and then increase the level, if necessary.
•  Before connecting the headphones, make sure that the connecting cable is not damaged.
  It is recommended to use a set of headphones attached to TUD-1.

GUD-1 Generator

3.1 Controls and indicators

1. Ultrasound emitter
2. Switch
3. “ON” LED – an indicator of activated device
4. “BAT” LED – an indication of discharged battery
5. Fixing screws – must be removed to gain access to the battery compartment

3.2 Functional description of the generator
The GUD-1 generator is dedicated to cooperating with the TUD-1 detector as an alternative source of ultrasound for emission testing purposes. Generated ultrasound waves have a frequency adjusted to the reception level of the frequency detector.

Principles and methodology of testing

The device is a very sensitive detector of ultrasound radiation and it has the potential to detect leaks in various technical objects. This kind of situation usually changes the parameters of the ultrasound waves emitted by a given object. This is caused by the presence and characteristics of the processes taking place within the objects, such as:

• cavitation and disruption of the gas or liquid stream,

• friction and collision of the particles,

• sparkling,

• corona or arc discharge.
  In order to effectively use the diagnostic capabilities of the device, the user during the tests must keep in mind the following tips:

• understand the processes occurring in the tested object,

• take into account the physical characteristics of the generation, propagation and attenuation of ultrasound signals,

• creatively implement the diagnosis and analysis of the results.
  To present methods of using the device, the following sections describe testing methods applicable to the ultrasound detector.

4.1 General recommendations for the detection of ultrasound sources
The ultrasound wave that is transferred from the source (tested object) to the receiver (detector) is subject to various changes, resulting in its absorption (attenuation), collapse, or reflection, according to the principles of ultrasound propagation.
Characteristics of acoustic vibrations, propagating in air from any source of ultrasound is dependent on a number of factors, e.g.:

• the intensity of vibration,

• components of the acoustic spectrum of the generated waves,

• ambient temperature and humidity,

• the distance between the source and the receiver,

• the presence of screens and reflective surfaces on the propagation route.
  Finding one ultrasound source in a free (unconstrained) air space does not cause problems and may be easily performed by approaching the detector to potential damage points. Then, with the amplification control knob set at the minimum level, you may examine the strength of the acoustic signal.

• Increasing signal strength indicates approaching to the source of ultrasound.

• Decreasing signal strength indicates that you move away from the source.

It is possible to use the device without additional acoustic probes. However, to obtain the maximum sensitivity of the device and its maximum detection range, it is recommended to use an acoustic probe of type 1 at the beginning of the test and to set the amplification at the minimum level. After detecting the ultrasound source and when approaching it, we recommend using an acoustic probe of type “2”, to determine the source more accurately and to identify the damage location. When using interchangeable probes, remember that the acoustic probe of type “1” narrows the acoustic characteristics and increases the sensitivity of the ultrasound detector, whereas the acoustic probe of type “2” only narrows the acoustic characteristics. Within industrial areas, the sound field is often generated as a result of overlapping sounds from different sources. This makes it difficult to single out the desired source and indicates the need to exclude or maximally reduce the intensity of other ultrasound sources during the diagnostic test. For this purpose, switch off all the devices and equipment emitting ultrasounds during their normal work, in the area of operating the ultrasound detector. This group includes:

• ultrasound-emitting process devices,

• welding machines,

• machine tools and grinders,

• power adapters or high-frequency inverters,

• electrical machinery containing commutator and brushes,

• power tools,

• fans, compressors, gas turbines, motors, etc.
  Even more difficult is detecting ultrasound sources in confined spaces – e.g. in rooms and chambers, where the total sound field is generated by mixing the signals coming from different sources and reflected by different surfaces. I such conditions, the detector may indicate inappropriate damage location, e.g. a wall of the room. Such an indication may suggest that the detected signal is only a reflection and the actual ultrasound source must be sought in the opposite direction from the indicated place.
  In such situations, in addition to the recommendations for using the appropriate types of acoustic probes and eliminating other sources of ultrasound,

• carefully analyze the impact of potential interference and

• use shielding and a cover (e.g. foam, cardboard) to separate the detector from interferences generated by objects (area) located near or to reduce their intensity.

4.2 Detection of gas and liquid leaks

The leakage of a gas or liquid under pressure creates acoustic waves in a wide frequency range, including ultrasound.
The sensitivity threshold of the detector is based on this phenomenon (the smallest detectable movement) and depends on a wide variety of factors, including:

• differential pressure,
• the geometry of leakage route,
• physical properties of the gas and liquid, etc.
  and within the range of (0.001…0.01) m³·Pa/s.

From a practical point of view, the distance of detecting the leaks is quite important.. TUD-1 detector enables user to detect them within approx. 10 meters, depending on the measurement conditions.

4.2.1 Operational rules
Before testing an object for leaks:

• read its technical documentation, paying attention to the range of acceptable pressures in the system (piping, valves, instruments), signaling functions and pressure control in the system and its individual sections, and location of connections, and shut-off valves.
• among the equipment identify such components and devices that emit ultrasound vibrations in normal operating conditions, e.g. pressure controllers and devices with similar principles of operation.
• obtain information about the location and the possibility of temporarily switching off the machines and equipment located in the vicinity of the test area (see sec.4.1) that are significant sources of ultrasound.

4.2.2 The test report
The test report shall present a list and sequence of technological operations performed on the tested object with the use of an ultrasound detector.
The report is created basing on the analysis of data obtained for the object and taking into account the following recommendations:

• during the test, all the ultrasound-emitting devices within the control range should be switched off. If this is not possible, use screens,
• complex systems should be tested with a resolution of its individual components (subsystems, separate devices).
•  in order to detect small leaks, the maximum allowable pressure of the system must be achieved (for a section of the system).

4.3 Detection of electrical discharges
The option of detecting electrical discharges of different physical natures (spark, arc, corona) offered by the ultrasound detector is based on detecting shock disturbances of molecules surrounding the discharge area. This phenomenon causes acoustic vibrations in a wide frequency band, including ultrasound.
The composition of the sound spectrum and its intensity depend on complex mathematical relationships of many factors. Their assessment is possible only with experimental methods – including the range of detecting electrical discharges using the ultrasound detector.
TUD-1 detects electrical discharges:

• in low-voltage switchgear in distances up to 10 meters,

•  in high-voltage power lines in distances up to 30 meters.
  Recommendations for detecting and searching electrical discharges in terms of preparatory work, drafting the test report and preventing the impact of various interferences are the same as in sections 4.1 and 4.2.
  For monitoring electrical objects and equipment using the ultrasound detector, the following issues must be taken into account:

• searching for electrical discharges and leaks in objects with electrical devices under voltage must be performed with strict adherence to safety rules,

• the tested objects may be located in an open environment (e.g. unshielded insulators, cables, switches, etc.), and devices installed inside rooms, e.g. in switchgear, where protective covers have usually slots and vents that may be penetrated by ultrasounds.

• it is recommended to use acoustic probes of type “1” and “2”, during the tests

• to obtain the detailed location of leaks and increased the accuracy of diagnosis, in addition to the detection of ultrasound it is recommended to perform additional test activities, e.g. testing with an infrared camera.

4.4 Assessing unpressurized tanks using the ultrasonic generator
This method involves using a TUD-1 detector with a GUD-1 ultrasound generator. It procedures are as follows:

• GUD-1 generator is placed in the enclosed space of the test and generates ultrasound with a frequency suitable for the reception of the detector,

• the generated ultrasonic waves penetrate the locations of micro-leakages.

• the detector located outside detects the leaks.
  TUD-1 detector may detect the causes of leaks in different objects: manholes, cabins, compartments, motor vehicles, air and sea ships, containers and unpressurized tanks, seals, windows, doors, etc.
  The active method of ultrasound testing using the GUD-1 generator + TUD-1 detector in the frequency range of (40±1) kHz enables user to detect micro- leakages within a range of (0.005…0.01) m³·Pa/s. Before testing the object for leaks:

• refer to the technical documentation of the object, paying attention to structural elements, sealing materials, legislation, procedures governing the control of tightness,

• obtain information about the location and the possibility of temporarily switching off the machines and equipment located in the vicinity of the test area, if they are significant
  sources of ultrasound. Then, prepare a test report that should include the type and sequence of tests performed on the tested object. The report is created based on the analysis of data obtained for the object and taking into account the following recommendations:

• during the test, all the ultrasound-emitting devices within the control range should be switched off. If this is not possible, use screens,

• a complex system should be diagnosed by dividing it first into individual sections (manhole, container, inner partition, etc.).

• setting and fixing the generator in the test zone may take place using magnetic holders or mounting brackets.

• if necessary, fixing and moving the generator around the perimeter of tested seal may be performed with the cooperation with a second operator, who coordinates his/her operations with the main operator via a suitable communication channel.

Power supply

5.1 TUD-1 Detector
The device is powered by a 6LR61 9V battery.
Activation of the “BAT” LED indicates that the device can be operated only for another 1 hour. If you need a longer operation time, replace the battery.

To replace the battery:

• turn off the device and unplug the headphones
•  loosen the screw fix the battery cover,
• remove the cover,
• replace discharged batteries with new ones, observing the polarity,
• put on the cover and tighten the fixing screw.

CAUTION!
Do not use batteries other than those specified in this manual.
5.2 GUD-1 Generator
The device is powered by a 6LR61 9V battery.
Activation of the “BAT” LED indicates that the device can be operated only for another 1 hour. If you need a longer operation time, replace the battery.

To replace the battery:

• turn off the device and unplug the headphones
•  unscrew 4 screws that fix the cover,
• remove the cover,
• replace discharged batteries with new ones, observing the polarity,
•  put on the cover and tighten the fixing screws.

CAUTION!
Do not use batteries other than those specified in this manual.

Maintenance and care

The meter has been designed for many years of reliable use, provided that the following
recommendations are observed for its maintenance and care:

1. THE DEVICE MUST BE DRY. Wipe the dampened DEVICE.
2. THE DEVICE MUST BE USED AND STORED IN NORMAL TEMPERATURES. Extreme temperatures may shorten the life of electronic components and distort or melt plastic parts.
3. THE DEVICE MUST BE HANDLED CAREFULLY AND GENTLY. Dropping the device may damage its electronic elements or the housing.
4. THE DEVICE MUST BE KEPT CLEAN. From time to time wipe the housing with a damp cloth. DO NOT use chemicals, solvents or detergents.
5. USE ONLY NEW BATTERIES OF RECOMMENDED SIZE AND TYPE. Remove the discharged battery pack from the meter to avoid leakage and damage.
6. IF THE DEVICE IS TO BE STORED LONGER THAN 60 DAYS, disconnect the battery and keep it separately.
   The electronic system of the device does not require maintenance.

Storage

During the storage of the device, the following recommendations must be observed:

• disconnect the test leads from the meter,
• make sure that the meter and accessories are dry,
• when the device is to be stored for a longer time, remove the battery pack
  The storeroom should be free from contamination, acidic or alkaline vapors that cause corrosion.

Dismantling and disposal

Worn-out electric and electronic equipment should be gathered selectively, i.e. it must not be placed with waste of another kind.
Worn-out electronic equipment should be sent to a collection point in accordance with the law of waste electrical and electronic equipment.
Before the equipment is sent to a collection point, do not dismantle any elements.
Observe local regulations concerning disposal of packages, waste batteries and rechargeable batteries.

 Operating data

9.1 TUD-1 detector
a) centre frequency of the frequency band of detected ultrasound radiation ………………………………………………… (40±1) kHz
b) dynamic range for receiving and converting the ultrasound radiation into the sound signal ……………………………… ≥60 dB
c) power consumption ……………………………………………………………………………………………………………………………….. ≤0.35 W
d) power supply ………………………………………………………………………………………………………………………….. 6LR61 9 V battery
e) time of continuous operations (without battery replacement) …………………………………………………………………………… ≥20 h
f) weight with battery installed ……………………………………………………………………………………………………………………. ≤0.22 kg
g) dimensions ……………………………………………………………………………………………………………………………… 190 x 60 x 70 mm
h) relative humidity not exceeding ………………………………………………………………………………………………………. 80% at +20ºС
i) operating temperature range ………………………………………………………………………………………………………….. -20ºС…+45ºС
j) maximum operating altitude ……………………………………………………………………………………………………………………… 2000 m
k) storage temperature …………………………………………………………………………………………………………………………… -20..+60ºC
l) max. relative humidity of storage ………………………………………………………………………………….. 80% at a temp. up to 31ºC
……………………………………………………………………………………….. linearly decreasing to 50% with temp. increasing to 40ºC
9.2 GUD-1 generator
a) frequency of the generated ultrasound ………………………………………………………………………………………………… (40±1) kHz
b) sound power ………………………………………………………………………………………………………………………………………..0.0016 W
c) power consumption ……………………………………………………………………………………………………………………………….. ≤0.02 W
d) power supply ………………………………………………………………………………………………………………………….. 6LR61 9 V battery
e) weight with battery installed ……………………………………………………………………………………………………………………. ≤0.28 kg
f) dimensions ……………………………………………………………………………………………………………………………. 100 x 100 x 80 mm
g) relative humidity ……………………………………………………………………………………………………….. not exceeding 80% at +20ºС
h) operating temperature range ………………………………………………………………………………………………………….. -20ºС…+45ºС

Accessories

The current list of accessories can be found on the manufacturer’s website.
10.1 TUD-1 detector
The standard set of equipment supplied by the manufacturer includes:

• TUD-1 ultrasonic detector
• Type 1 acoustic probe – WASONAKU1
• Type 2 acoustic probe – WASONAKU2
• Type 3 acoustic probe – WASONAKU3
• Headphones – WAPOZSLU1
• MicroUSB cable – WAPRZUSBMICRO
• 6LR61 9 V battery (MN1604)
• Probe socket plug
• М6 carrying case – WAFUTM6
• User manual
• Guarantee card
• Declaration of verification

10.2 GUD-1 generator
The standard set of equipment supplied by the manufacturer includes:

• GUD-1 ultrasonic generator
•  6LR61 9 V battery (MN1604)
•  Declaration of verification

 Service

The provider of guarantee and post-guarantee services is:
SONEL S.A.
Wokulskiego 11
58-100 Świdnica
Poland
tel. +48 74 858 38 60
fax +48 74 858 38 09
e-mail: export@sonel.pl
internet: www.sonel.pl

Note!  Service repairs must be performed only by the manufacturer.
Manufactured in Russia.

 Laboratory services

SONEL Testing and Calibration Laboratory has been accredited by the Polish Center for Accreditation (PCA) – certificate no. AP 173.
Laboratory offers calibration for the following instruments that are used for measuring electrical and non-electrical parameters.

• METERS FOR MEASUREMENTS OF ELECTRICAL PARAMETERS
  o voltage meters,
  o current meters (including clamp meters),
  o resistance meters,
  o insulation resistance meters,
  o earth resistance and resistivity meters,
  o RCD meters,
  o short-circuit loop impedance meters,
  o power quality analyzers,
  o portable appliance testers (PAT),
  o power meters,
  o multimeters,
  o multifunction meters covering the functions of the above-mentioned instruments

• ELECTRICAL STANDARDS
  o calibrators,
  o resistance standards,

• METERS FOR MEASUREMENTS OF NON-ELECTRICAL PARAMETERS
  o pyrometers,
  o  thermal imagers,
  o lux meters.

The Calibration Certificate is a document that presents a relation between the calibration standard of known accuracy and meter indications with associated measurement uncertainties. The calibration standards are normally traceable to the national standard held by the National Metrological Institute. According to ILAC-G24 „Guidelines for determination of calibration intervals of measuring instruments”, SONEL S.A. recommends periodical metrological inspection of the instruments it manufactures no less frequently than once every 12 months. For new instruments provided with the Calibration Certificate or Validation Certificate at the factory, recalibration should be performed within 12 months from the date of purchase, however, no later than 24 months from the date of purchase.
ATTENTION!
The person performing the measurements should be absolutely sure about the efficiency of the device being used. Measurements made with an inefficient meter can contribute to an incorrect assessment of the effectiveness of health protection and even human life.

SONEL S.A. Wokulskiego 11 58-100 Swidnica
Poland
PL +48 74 858 38 00 (Biuro Obstugi Klienta)
e-mail: bok@sonel.pl
GB +48 74 858 38 60 +48 74 858 38 00
fax: +48 74 858 38 09
e-mail: export@sonel.pl
www.sonel.pl

References

• Offer to sell domain: somel.pl
• Standard (metrology) - Wikipedia

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