The UltraTrak 850s Smart Analog Ultrasound Sensor (UltraTrak 850S), engineered and manufactured by UE Systems Inc. (USA), is an advanced ultrasound sensor and transmitter featuring state-of-the-art on-board digital signal processing designed to detect early-onset equipment failures in industrial manufacturing machinery.

The UltraTrak 850s allows maintenance and reliability teams to incorporate the diagnostic power of high-frequency ultrasound directly into their existing plant control and automation systems (PLC, SCADA, DCS) with an installation time of under 10 minutes. Rather than acting as a simple passive probe, the 850s functions as a self-contained intelligent field transmitter: it continuously monitors high-frequency stress waves generated by mechanical friction, impacting, and turbulent fluid leakage, processing detected decibel amplitudes into a scaled linear analog mA output that wires directly into standard analog input cards.

Key Engineering Features & Operational Advantages:
- Patented Auto-Sensitivity Adjustment: The sensor autonomously optimizes its internal gain across the entire 0 dB to 100 dB measurement dynamic range. This hands-free feature eliminates manual dial adjustments, complex gain-setting procedures, and sensor saturation, providing continuous plug-and-play reliability.
- Scaled Linear mA DC Output: Delivers a demodulated/heterodyned DC current output spanning from 0.500 mA to 16.280 mA DC (at 0.158 mA per dB of ultrasonic signal change). The linear relationship is governed by the standardized transfer function: dB Output = + 6.321 x (Current Output Reading mA) - 2.917 dB. This allows automation engineers to establish standardized multi-tier alarms in the PLC: Lubrication Required (Baseline + 8 dB), Early Onset Failure (Baseline + 16 dB), and Catastrophic Failure (Baseline + 35 dB).
- Universal Bearing Support (Down to 1 RPM): While conventional mechanical accelerometers suffer from poor signal-to-noise ratios on slow-turning shafts, the UltraTrak 850s detects microscopic stress-wave friction pulses at rotational speeds as low as 1 RPM, making it the premier choice for slow-speed rotary kilns, heavy agitators, and continuous casting rollers.
- Condition-Based Precision Lubrication (CBL): Eliminates both over-lubrication (which ruptures bearing seals and causes motor burnouts) and under-lubrication. Sensor data can directly command automated single-point or centralized lubricators to dispense grease only when acoustic friction levels elevate.
- Valve Leakage, Steam Trap & Cavitation Diagnostics: Continuously monitors shut-off valves for unseated blow-by, identifies stuck-open or blowing steam traps, and flags centrifugal pump impeller cavitation long before mechanical damage occurs.
- Heavy-Duty IP67 / NEMA 6P Stainless Steel Enclosure: Machined from solid industrial stainless steel to resist mechanical impact, water submersion, corrosive chemical washdowns, and heavy industrial dust. Equipped with an RF-shielded housing and a detachable, shielded 3-wire cable designed for harsh industrial operating environments.

Typical Industrial Applications:
- 24/7 continuous health monitoring of critical electric motor bearings, large slurry pumps, boiler draft fans, air compressors, and heavy gearboxes.
- Slow-speed rotary asset monitoring: Clinker kilns in cement manufacturing, chemical batch mixing tanks, mineral ball mills, and primary mining conveyor drive pulleys.
- Boiler feed pump and chemical transfer pump cavitation detection.
- High-pressure steam trap failure monitoring and isolation valve seat bypass detection in power plants and petrochemical refineries.

• Manufacturer: UE Systems (UE Systems Inc.)
• Country of Origin: USA
• Product Line: UltraTrak Series Smart Analog Ultrasound Sensors
• Model Designation: UltraTrak 850s (850S)
• Sensor Category: Smart Analog Ultrasound Sensor & Transmitter
• Transducer Technology: Precision Piezoelectric crystal element
• Frequency Detection Bandwidth: High-frequency ultrasound range spanning 20 kHz to 100 kHz (Optimized around 30 kHz peak mechanical friction and turbulence response)
• Dynamic Measurement Range: 0 dB to 100 dB (Decibels)
• Sensitivity Adjustment: Patented Auto-Sensitivity Adjustment across the full 0 dB to 100 dB output span
• Signal Output Type: Demodulated / Heterodyned Milliamp DC current output
• Current Output Response: Linear, proportional to 0 dB to 100 dB change in detected ultrasonic signal
• Current Output Range: 0.500 mA DC to 16.280 mA DC @ 0.158 mA/dB of signal change
• Current Output Compliance Voltage: 3.3 VDC
• dB Output Transfer Function: dB Output = + 6.321 x (Current Output Reading mA) - 2.917 dB
• Current Output Accuracy: Less than ±1 dB of reading, typical
• Power Supply Voltage: 23 VDC to 26 VDC (+23 VDC minimum at sensor terminals after line drop)
• Current Consumption: Quiescent draw ~12 mA; Operational draw 30 mA DC maximum typical
• Connection Cable: Detachable 3-wire with braided RF shield; lengths available: 3 m (10 ft), 20 m (66 ft), or 30 m (100 ft)
• Cable/Housing Connector: Heavy-duty harsh environment connector, RF shielded
• Mounting Thread: 10/32 UNF female mounting hole
• Housing Metallurgy: Heavy-duty Stainless Steel construction
• Ingress Protection Class: Meets or exceeds IP67 and NEMA 6P (dust-proof and water-resistant / submersible)
• Standard Operating Ambient Temperature: -20°C to +60°C (-4°F to +140°F)
• Extended Operating Ambient Temperature: -30°C to +80°C (with high-temperature cable assembly)
• Sensor Weight: Approx. 250 g (8.8 oz).