UTG-1

OPERATING
MANUAL

Version 1.0
Part No. 021-002-095 Rev. B

IMPORTANT NOTICE

The following information must be read and understood by any user

of an ultrasonic thickness gauge.
Failure to follow these instructions can lead to errors in thickness
measurements or other test results. Decisions based on erroneous
results can, in turn, lead to property damage, personal injury or
death.
General Warnings
Proper use of ultrasonic test equipment requires three essential
elements:

Selection of the correct test equipment

Knowledge of the specific "test application

requirements"

Training on the part of the instrument operator

This operating manual provides instruction in the basic set-up and

operation of the thickness gauge. There are, however, additional
factors which affect the use of the ultrasonic test equipment.
Specific information regarding these additional factors is beyond the
scope of this manual. The operator should refer to text books on the
subject of ultrasonic testing for more detailed information.
Operator Training
Operators must receive adequate training before using ultrasonic
test equipment. Operators must be trained in general ultrasonic
testing procedures and in the set-up and performance required by a
particular test. Operators must understand:

Soundwave propagation theory

Effects of the velocity of the test material

Behavior of the sound wave where two different materials are in

contact

Areas covered by the sound beam

More specific information about operator training, qualification,

certification and test specifications is available from various technical
societies, industry groups, and government agencies.
Testing Limitations
In ultrasonic testing, information is obtained only from within the
limits of the sound beam. Operators must exercise great caution in
making inferences about the test material outside the limits of the
sound beam. For example, when testing large materials, it maybe
impossible or impractical to inspect the entire test piece. When a
less-than-complete inspection is to be performed, the operator must
be shown the specific areas to inspect. Inferences about the
condition of areas not inspected, based on data from the evaluated
areas, should only be attempted by personnel fully trained in
applicable statistical and probability techniques.
In particular,
materials subject to corrosion or erosion, in which conditions can
vary significantly in any given area, should be evaluated only by fully
trained and experienced operators.

Sound beams reflect from the first interior surface encountered.

Because of part geometry and overlapped flaws or overlapped
surface, thickness gauges may measure the distance to an internal
flaw rather than to the backwall of the material. Operators must take
steps to ensure that the entire thickness of the test material is being
examined.

Ultrasonic Thickness Measurement Critical Operating Procedure

The following operating procedures must be observed by all users of
ultrasonic thickness gauges in order to minimize errors in test
results.

1. Calibration of Sound Velocity

The principle of operation of an ultrasonic thickness gauge is that the

instrument measures the time of flight of an ultrasonic pulse through
the test piece and multiplies this time by the velocity of sound in the
material. Thickness measuring error is minimized by ensuring that
the sound velocity to which the instrument is calibrated is the sound
velocity of the material being tested. Actual sound velocity in
materials often vary significantly from the values found in published
tables. In all cases, best results are obtained if the instrument is
calibrated on a velocity reference block made from the same
material as the test piece; this block should be flat and smooth and
as thick as the maximum thickness of the test piece.

Operator should also be aware that sound velocity may not be

constant in the material being tested; heat treating, for example, can
cause significant changes in sound velocity.
This must be
considered when evaluating the accuracy of the thickness provided
by this instrument. Instruments should always be calibrated before
testing, and the calibration should be checked after testing, to
minimize testing errors.

2. Probe Zero Procedure

The probe zero procedure must be performed as described in this

manual. The zero reference block should be clean and in good
condition, without noticeable wear. Failure to properly perform the
probe zero procedure will result in inaccurate thickness readings.

3. Effects of Temperature on Calibration

Variations in temperature change the sound velocity of materials and

transducer delay lines and therefore, zero calibration.
All
calibrations should be performed on-site and with test blocks at the
same temperature as the test piece, in order to minimize errors due
to temperature variations.

4. Transducer Selection

The transducer used in testing must be in good condition without

noticeable wear of the front surface. Badly worn transducers will
have a reduced effective measuring range. The specified range of
the transducer must include the complete range of thickness to be
tested. The temperature of the material to be tested must be within
the transducer's temperature range.

5. Use of Couplants

Operators must be familiar with the use of ultrasonic couplants.

Testing skills must be developed so that couplant is used and
applied in a consistent manner to minimize variations in couplant
layer thickness and errors in test results. Calibration and actual
testing should be performed under similar coupling conditions, using
a minimum of couplant and applying consistent pressure on the
transducer.

6. Doubling

Ultrasonic thickness gauges will, under certain conditions, display

readings which are twice (or in some cases, three times) the actual
material thickness being measured. This effect, commonly known as
"doubling," can occur below the minimum specified range of the
transducer. If the transducer being used is worn, doubling is
possible at thicknesses greater that the minimum specified range.

When using a new transducer, any reading which is less than twice
the minimum specified range of the transducer may be a "doubled"
reading, and the thicknesses of the material being tested should be
verified by the use of other methods. If the transducer shows any
sign of wear, doubling may occur at thicknesses greater than twice
the minimum specific range. This thickness should be determined
by calibrating the instrument/transducer combination on reference
blocks that represent the complete range of possible thicknesses
that may be encountered in testing. This is particularly important
when the test piece is being ultrasonically measured for the first time
or in any case where the history of thickness of the specimen in
unknown.

Table of Contents

IMPORTANT NOTICE. -------------------------------------- 1

TABLE OF CONTENTS ------------------------------------- 6
THEORY OF OPERATION. -------------------------------- 7
INITIAL SETUP. ----------------------------------------------- 9
OPERATION.------------------------------------------------- 11
HELPFUL HINTS ON OPERATION. ------------------- 18
MAINTENANCE AND TROUBLESHOOTING.------ 19
SPECIFICATIONS. ----------------------------------------- 20
APPENDIX A. ------------------------------------------------ 24

1. Theory of Operation
A.

ULTRASONIC WAVE

The UTG-1 measures the thickness of a material by

transmitting an ultrasonic wave into the material using an
ultrasonic transducer and calculating the time for the wave to
pass through the material and reflect back to the transducer.
The time is multiplied by the previously determined velocity in
the material and the thickness is then displayed on the readout
in inches or millimeters.

B.

PROBE ZERO FUNCTION

Each transducer (probe) and the electronics varies in the

amount of time to transmit the signal to be measured. This
time must be subtracted from the total transmission time. This
time correction is accomplished automatically by performing a
"PROBE ZERO operation. The means to perform this simple
task is resident on the UTG-1 and will be explained in detail
later.

C.

SINGLE POINT VELOCITY

CALIBRATION

Upon successful completion of PROBE ZERO, a calibration

of the velocity of the material to be measured must be done. A
representative piece of the material to be measured should be
used for the CAL operation. Through the CAL operation the
UTG-1 measures the ultrasonic transit time, calculates the
velocity of the material and places the velocity calculation in
the UTG-1's memory for future measurements. If the velocity
of the material is already known then it may be entered using
the keypad. Important: Since this velocity constant is used to
determine thickness for all measurements (until it is changed
through another CAL function), the accuracy of the thickness
measurement depends upon the consistency of the ultrasonic
properties in the material being measured.
For best results, both the transducer face and the material to
be measured should be wiped clean. A drop of couplant

should then be applied to either the probe face or contact point

on the material being measured. Foreign matter between the
probe and the material can distort or prevent readings.
Select a calibration piece that has the same shape and is
equal to or slightly thicker than the work piece being
measured. Perform a PROBE ZERO and re-calibrate the
UTG-1 when the temperature of the work piece changes 5C
or more from the calibration piece.

2. Initial Setup
A.

INTRODUCTION

For those settings which are seldom changed during operation

of the UTG-1, the INITIAL SETUP procedure is designed to
allow the operator access to those settings without
unnecessary complication of normal operation.
These settings include:
Backlight on/off
Selection of Metric or English units of measure
Calibration Lock
The INITIAL SETUP procedure is accessed by holding the
CAL key down and pressing the ON/OFF key.
When this is done the UTG-1 will display the version code of
the operating software contained in the unit until the CAL key
is released. This information will be useful should the unit
require service or updated software is desired.
Upon release of the CAL key the SETUP procedure continues
as follows:

B.

BACKLIGHT ON/OFF

When the CAL key is first released the UTG-1 will display the
words ON or OFF to indicate the status of the backlight. The
backlight setting can be selected by pressing the UP or DOWN
arrow key.
NOTE: It is recommended that the backlight be OFF when
measurements are made in well-illuminated areas, as this will
greatly increase battery life.

C.

METRIC/ENGLISH UNITS
9

Press the CAL key a second time.

The UTG-1 will display the units in which it is set to measure
thickness (IN or MM).
Press the UP or DOWN arrow keys to select the desired unit
of measurement.

D.

CALIBRATION LOCK

Press the CAL key a third time.

The UTG-1 will display the status of the calibration lock
function (CAL or LOC).
When CAL is displayed the velocity calibration function can be
performed as described in Operation.
When LOC is displayed the calibration function is disabled.
The velocity used in measurement cannot be changed without
entering this INITIAL SETUP procedure again to change
settings to CAL.
It is recommended that the lock feature be used when
supervising personnel wish to prevent unauthorized change of
the calibrated velocity.
Pressing the CAL key a final time completes the SETUP
procedure and returns the UTG-1 to the measurement mode.

10

3. Operation
A.

ON / OFF FUNCTION

Press this key to turn the UTG-1 on. The

unit will display a reading of zero. In order to compensate for
any change in the ultrasonic transducer, a PROBE ZERO
function should be performed at this point. The UTG-1 is
now ready for measurement or calibration.

B.

PROBE ZERO FUNCTION

The PROBE ZERO function compensates the UTG-1 for the

fixed delay of the ultrasonic transducer. This function should
be performed at the start of each day (to compensate for
transducer wear) or whenever the transducer is changed.
Apply a drop of couplant to the end of the transducer. Press
the ON/OFF button on the keyboard to turn on the UTG-1.
Place the transducer in steady contact with the probe disk
located on the top of the UTG-1. DO NOT use another 0.250
test piece since the velocity of the probe disk is carefully
controlled and errors will result.
The UTG-1 recognizes that the probe is in contact with the
probe disk, and automatically performs the PROBE ZERO
function. Upon completion of the function Prb0 will appear on
the display indicating that the appropriate transducer delay
factor has been entered in memory.
NOTE: During the PROBE ZERO function, the UTG-1 velocity
is temporarily reset to the velocity of the probe disk (0.2330
in./sec.). Upon completion of the PROBE ZERO function the
velocity will return to the last calibrated value. This allows the
operator to continue measurements on the previously
calibrated material.

11

C.

MATERIAL CALIBRATION
TO KNOWN THICKNESS

The following procedure is used to calibrate the UTG-1 sound

velocity to a known sample of material. Some materials may
exhibit sound velocity variations which can cause errors in
measurement. Be sure to check a representative group of
samples to determine if such variation is present.
First follow the above PROBE ZERO procedure (B.) to
calibrate the delay of the ultrasonic transducer being used.
Apply a drop of couplant to the representative piece of material
of known thickness. This piece is called the sample.
Place the probe in steady contact with the surface of the
sample. The UTG-1 will display a thickness reading using the
last calibrated velocity.

CAL
Press the CAL key to lock in the reading.
The transducer may now be removed from the sample. The
display on the UTG-1 will momentarily display CAL. Small
arrows will appear in the upper left portion of the display
above the thickness readings. This indicates that the UTG-1 is
in the calibration mode and enables the UP/DOWN arrow
keys.

Adjust the thickness shown on the UTG-1

display by using the UP and DOWN arrows. Note that when
these keys are held continuously, the speed at which the
thickness changes will increase, making it easy to make large
adjustments for materials such as plastic and aluminum.

12


When the correct thickness appears on the
display, press the CAL key again to display the sound velocity
of the calibrated material as calculated by the UTG-1. The
display of sound velocity will be indicated by the appearance of
appropriate velocity units (IN/S or M/s) above the displayed
velocity value. Press the CAL key one final time to accept this
sound velocity and return to the measurement mode.
Check the calibration by replacing the probe on the sample
piece. The UTG-1 should display the corrected thickness of
the sample.
NOTE: When the UTG-1 is in the CALIBRATION mode the
unit will not make further measurement until the calibration
procedure is completed.

13

D.

CALIBRATION TO
KNOWN VELOCITY

The following procedure is used to calibrate the UTG-1 to a

given material velocity. Follow the above PROBE ZERO
procedure (B.) to calibrate the delay of the ultrasonic
transducer being used.

CAL
Press the CAL key. The arrow symbols
will appear in the upper left portion of the display indicating
the UP/DOWN arrow keys are active.
Press the CAL key a second time. The display on the UTG-1
will display the current velocity and the appropriate units of
measure.

IN/S

.2 3 0 0
Or if metric units are selected:

M/s

.5 9 1 8

14


Use the UP and DOWN arrow keys to scroll
the velocity to the known velocity of the material. Note that
when these keys are held continuously, the speed that the
velocity changes will increase, making it easy to make large
adjustments for materials such as plastic and aluminum.

When the desired velocity appears on the

display, press the CAL key again to enter that velocity for use
in thickness measurements and return to the measurement
mode.

E.

THICKNESS MEASUREMENT

Remove dirt, loose material, and couplant residue from the

surface of material at points where measurements are desired.
Verify that the PROBE ZERO and CAL functions have been
performed.
Place a drop of couplant on the material surface at the
measurement point.
Place the transducer in steady contact with the surface of the
material at the measurement point.
When a detectable echo is received from the back surface of
the material, the echo indicator in the upper right of the display
will indicate the detection of an echo by changing in
appearance to represent contact between the transducer and
the sample surface.

NO ECHO

ECHO DETECTED

15

The UTG-1 will display the thickness of the material and the
appropriate units of measure (inches or millimeters).
NOTE: If the detected echo is of marginal magnitude a
question mark ? will appear to the left of the echo indicator.
This will alert the operator that the measurement may be
subject to error, and steps should be taken to improve the
transducer coupling or position.

If no echo is detected for a period of 4

minutes, the UTG-1 will automatically shut-off. The probe and
velocity calibration factors are retained in memory. Operation
may be resumed immediately by pressing the ON/OFF key.

F.

MEASUREMENT UNITS

The UTG-1 can display thickness in either English or Metric

units.
The unit system may be selected during the INITIAL SETUP of
the UTG-1 as described previously.

16

G.

LOW BATTERY

The UTG-1 automatically monitors the charge state of the

battery to ensure that sufficient voltage is available to operate
the unit properly.
When the UTG-1 detects minimum allowable battery level, the
numbers on the display will blink on and off. This alerts the
operator that the batteries should be replaced before further
operation.
When the battery level falls below the minimum allowable
level, the UTG-1 will turn off and not allow further operations
until batteries are replaced.

H.

REPLACING BATTERIES

The UTG-1 comes standard with 4 AA alkaline batteries.

To change the batteries, loosen the screw on the bottom end
cap and remove the spent batteries.
Care must be used to replace the batteries in the correct
polarity as indicated on the battery holder.
NOTE: After changing batteries be sure to perform the
PROBE ZERO procedure and recalibrate the UTG-1 for the
material to be measured.

17

4. Helpful Hints on Operation

A.

BACKLIGHT

The UTG-1 features a backlit LCD display. The display

illuminates when an echo is detected. Using the backlight will
significantly reduce battery life. Therefore, you may wish to
deactivate the backlight when using the UTG-1 in a well-lit
environment.

B.

CLEAN THE SURFACE

Clean the probe and the material to be measured and apply

only enough couplant to obtain a steady, valid reading.
Usually one drop is enough.

C.

MATERIAL CONSISTENCY

Best results will be obtained if the work piece and the

calibration piece are the same temperature, shape, material,
and size.

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5. Maintenance and
Troubleshooting
A.

TRANSDUCER AND CABLE

Check the cable for cuts or punctures.

Check if the
connectors are secure. If the UTG-1 always indicates an echo
when the transducer is connected, a piece of metal may be
lodged in the cross talk barrier of the transducer. The cross
talk barrier is the line separating the two halves of the
transducer.

B.

KEYPAD

The keypad is a matrix type switch. Due to physical damage

or excessive wear, one key may remain struck closed or one
entire row or column may cease to function. The keypad can
easily be replaced.

C.

DISPLAY

The LCD is made of glass and is one of the most fragile

components of the UTG-1. It may break if dropped. This LCD
must be replaced by a factory trained technician.
While the LCD is made of glass, the front surface of the
display contains a plastic polarizer. DO NOT clean the
surface of the display with any solvents or abrasives.

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6. Specifications
6.1 Instrument Specifications
Operating Principle:
Ultrasonic pulse/echo
V-Path Correction:
Automatic, microprocessor controlled
Measuring Range:
.040 - 19.999 (1 - 500mm)
depending on probe,
material, surface condition,
and temperature
Displayed Resolution:
.001 inches
.01 up to 199.99mm, .1mm above
.199.99mm
Measurement Update Rate:
4 Hz
Material Velocity Range:
From less than 0.999 inches per
micro-second
Display Type:
4 1/2 digit LCD, .4 (10.2mm) high,
electroluminescent backlight

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Power Supply:
4 ea. 1.5V AA alkaline cells
Battery Life (operating time):
Up to 300 hours typical use;
80 hours continuous use with
backlight
Auto-Shut-off:
After 4 minutes of non-use
Size (L x W x D):
4.5 x 2.5 x 1.25
(114.3mm x 63.5mm x 31.8mm)
Weight:
11 oz. (312 g) including batteries

NOTE: Specifications subject to change without notice.

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6.2 Probe Specifications

Model, Designations, Probe Cable,
Contact Diameter, Measuring Range
in Steel, Temperature Range

BKK680, General-purpose Fingertip,

Potted, .38 (9.6mm), .040 - 6.0
(1 - 150mm), <130F (<54C)

KBA560, General-purpose, KBA531, .625

(15.9mm), .060 - 8.0
(1.5 - 200mm), <450F (<230C)

KBA560V, Elevated Temperature, KBA531,

.700 (17.8mm),
.060 - 8.0 (1.5 - 200mm),
750F (399C)

FH2E-WR, Wear Resistant Fingertip,

Potted, .550 (14.0mm), .040 - 2.0
(1 - 50mm), 130F (54C)

KBA560-WR, Wear Resistant

General-Purpose, KBA531,
.700 (17.8mm), .060 - 8.0
(1.5 - 200mm), 450F (230C)

KB550FH, Fingertip, Potted, .375 (9.5mm),

.060 - 2.0 (1.5 - 50mm), <130F (54C)
22

KB550BTH, Studded Boiler Tube,

C-BTH, .375 (9.5mm), .060 - 2.0
(1.5 - 50mm), <130F (54C)

FH2E, High Sensitivity Fingertip, Potted,

.38 (9.6mm), .040 - 2.0
(1 - 50mm), <130F (<54C)

NOTE: Specifications subject to change without notice.

23

Appendix A
Table for Typical Sound Velocity (Longitudinal Wave)
in Various Materials)
in/
mm/
in/
sec
sec
sec
Aluminum
.25
6.3
Nylon
.10

mm/
sec
2.5

Beryllium

.51

12.9

Phenolic

.056

1.4

Brass

.17

4.3

Platinum

.16

4.1

Cadmium

.11

2.8

Plexiglas

.11

2.8

Cast Iron

.18

4.6

Polyethylene

.07

1.8

Copper

.18

4.7

Polystyrene

.093

2.4

Glass(Crown)

.22

5.6

Porcelain

.22

5.6

Glass(Window)

.27

6.8

Rubber(Butyl)

.073

1.9

Gold

.13

3.3

Rubber(Vulc)

.09

2.3

Inconel

.22

5.6

Silver

.14

3.6

Lead

.085

2.2

Steel

.23

5.8

Magnesium

.23

5.8

Tin

.13

3.3

Molybdenum

.25

6.3

Titanium

.24

6.1

Monel

.21

5.3

Zinc

.16

4.1

Neoprene

.063

1.6

Zircaloy 2

.19

4.7

Nickel

.22

5.6

The information is supplied for the convenience of the user and the
manufacturer assumes no responsibility for inaccuracies. Actual
velocities depend on exact composition, temperature, and
processing of each material.

24