BTC-100 User Manual - StoneAge Waterblast Solutions
Contents
1. STONEAGE ENGINEERING POWER WATER BOILER TUBE CLEANER BTC LIMITED RELEASE USER MANUAL a e 4 J a e k ES i RS S ET x ae PL 614 REV 10 06 15 TABLE OF CONTENTS MANUFACTURER S 3 ICA TIN 3 DESCRIPTION OF EQUIPMENT AND 3 WARNING AND SAFETY 5 4 OPERATOR TRAINING besser 4 PERSONAL PROTECTIVE EQUIPMENT 4 OVERVIEW 100 BOILER TUBE 5 OVERVIEW CB BTC CONTROL BOX 6 ASSEMBLY INSTALLATION AND 7 RAILS AND SUPPORT TO MUD DRUM 7 JOIN RAIL EXTENSIONS CLAMP TO MUD DUM 4 8 ROTATOR AND TRACTOR 9 10 11 uu u L 12 CONTROL BOX DETACHABLE 5 2 16 PNEUMATI2. DIRECTION CONTROL CONTROL BOX CONTROL BOX FRONT VIEW REAR VIEW aa 5 NE AIR SUPPLY PNEUMATIC DUMP FITTING CONTROL FITTING FOR OD TUBING COLOR CODED JIC FITTINGS WITH DUST CAPS DETACHABLE LEGS 866 795 1586 e WWW STONEAGETOOLS COM 6 E ASSEMBLY INSTALLATION AND CONNECTION BU 004 XX RAIL The slotted box with BTC 140 Support and BTC 120 Clamps act as the support for the 100 system components Rails are available to match the length of any mud drum he BTC will ship with standard stock rails or the BTC components can be customized to fit the dimensions of your mud drum interior and external obstructions BTC 140 SUPPORT 1 Before attaching to the rail set the BTC 140 Support in the drum Check the height of the bearing surface to be sure is is level with the manway Adjust the extendable feet if needed to level the support 6 15 24 cm below the drum centerline Attach to rail with rail slots positioned on the right and Spring Plungers on the left when looking into the mud drum Pull up on the ring of the Spring Plunger Pin to unlock the swivel mechanism of the BTC 140 Support Swivel the Support until it allows for insertion into the mud drum Insert the BTC 140 Support and the rail into the mud drum with the extendable feet facing down Swivel the Support so the feet touch the sides of the mud drum and lock t
3. r BLUE LOCTITE 5 SEE NOTE 4 BLUE LOCTITE 2 BLUE LOCTITE 6 SEE TABLE 1 FOR PART NUMBER OF SWIVEL TO USE Q 2 BLUE LOCTITE LONG FLAT SIDE OF PLATE INSTALLED FIRMLY AGAINST SIDE OF ELBOW ORIENTATION OF ELBOW WITH RESPECT TO THIS SLIT WILL BE RANDOM IN THIS EXAMPLE LOCKING PLATE NOT INSTALLED ON THIS SIDE OF ELBOW DUE TO SLIT NOT ALLOWING TWO SCREWS SECTION A A TO SECURE ELBOW LOCKING PLATE ORIENT TUBE SO HOSE WILL LAY FLAT ON BOTTOM OF DRUM ORIENT LEVER APPROXIMATELY AS SHOWN SLIDE FLANGE ONTO SWIVEL AS FAR AS POSSIBLE THEN TIGHTEN SCREW gt NOMINAL DRUM NOT SHOWN FOR CLARITY CONTINUED ON NEXT PAGE ORIENT SO WATER INLET IS ON FAR SIDE 866 795 1586 WWW STONEAGETOOLS COM 21 5 DIAGRAM HCS 100 Helix Hose Containment System CONTINUED TABLE 1 PART NUMBER OF SWIVEL ELBOW TUBE GLAND COLLAR HCS 100 P12TM9 24 SG P12K 62 90 HCS 105 HCS 108 AF 070 MP9 AF 071 MP9 HCS 100 MP12TM9 24 SG MP12K 62 90 HCS 105 HCS 108 AF 070 MP9 AF 071 MP9 ASSEMBLY NUMBER PART NUMBER QTY BR 055 SS ROLLER ASSY B 350 07 BOLT HEX 50 13 X 1 75 SS G GS 325 03 SHCS 25 20 X 75 SS GS 325 05 SHCS 25 20 X 1 25 SS G 5 GSB 331 03 BHCS 31 18 X 75 LG 1 D D 8 D Erza 1 HS 101 DRUM BASE PLATE WELOWENT 1
4. 10225 BOX RAL CUT AND TAPPED gt HOS 108 DRUM ADAPTER FLANGE HCS 115 RETRACTABLE SPRING PLUNGER HCS 120 ELBOW LOCKING PLATE PL 180 GENERIC STONEAGE DECAL 2 5X13 1 1 15 16 NOTES 1 BLUE G00P IS A SWAGELOK BRAND ANTI SEIZE AN EQUIVALENT ALTERNATIVE IS ACCEPTABLE 2 BLUE LOCTITE PN 242 0R EQUIVALENT 3 SWIVEL FLANGE DRUM ELBOW amp LOCKING PLATE INSTALLATION A SECURE SWIVEL WITHIN CLAMP ON BASE PLATE AT HEIGHT SHOWN IN SIDE VIEW B SLIDE ADAPTER FLANGE FULLY ONTO SWIVEL SHAFT PROFILED SIDE TOWARD SWIVEL AND TIGHTEN SECURELY C PLACE DRUM ON ADAPTER FLANGE 5 OF THE 6 HOLES WILL BE USED ATTACH DRUM TO ADAPTER FLANGE WITH ALL 5 SCREWS D CRITICAL TIGHTEN ELBOW ONTO SWIVEL CRITICAL E PLACE FLAT SIDE OF LOCKING PLATE UP AGAINST ONE OF THE SIDES OF ELBOW DETERMINE THE BEST SIDE AND ORIENTATION OF PLATE BY ASSURING 2 SCREWS CAN SECURE THE PLATE REMOVE THOSE 2 SCREWS PLACE PLATE FIRMLY AGAINST THE SIDE OF THE ELBOW ADD FLAT WASHERS AND REINSTALL SCREWS SEE SECTION VIEW A A SHOWING EXAMPLE OF PLATE INSTALLED 4 CLEAN ALL DEBRIS amp OILS BEFORE INSTALLING INSTALL AT APPROXIMATE ORIENTATION AND LOCATION amp AT ROOM TEMP 32 P STONEAGE 866 795 1586 WWW STONEAGETOOLS COM PARTS DIAGRAM HLXC 100 1 Helix Containment Drive Assembly WITHOUT SPROCKET KIT REPLACE STOCK KEY 090 GAP FOR GEARBOX PUSH CLEVIS PIN THRU SHEETMETAL C
5. 4 0 A Goa 2 ADD BLUE LOCTITE 242 THIS ONLY OIL FILL Ze MIN 3 63 THD LENGTH EXPOSED SEE NOTE k 13 2 BR052 2 0 90AXLE ZERK 3 BRO55ROLLERASSY 3 5 eNs37 LnYLokNUTSS 017 O RING INPUT 7 HLXR 035 10 1 5 THREADED ROD SS AT 001 AXLE OUTPUT 9 HLXT 002 SPUR GEAR OUTPUT H H 7 S e 16 1 1 CO NO 0 LXT 003 BUSHING OUTPUT 21 LXT 004 34 X 48 X 7 TC SEAL FINAL 22 HLXT 005 WORM GEAR OUTPUT 350 L 20 NYLOK NUT SS 7 GP 010 BLUE PLASTIC ID WASHER P8 GP 010 Y YELLOW PLASTIC ID WASHER P8 GP 025 P4SS HEX SOCKET PLUG 10 GS 325 03 SHCS 25 20 X 75 55 TB 050 11 GS 325 16 SHCS 25 20 X 4 00 SS GS 331 025 SHCS 31 18 X 62 SS HLXD 007 WOODRUFF KEY HLXD 012 KEYED BUSHING HLXT 018 WORM CAP INPUT HLXD 013 SEAL INPUT 26 STONEAGE 866 795 1586 WWW STONEAGETOOLS COM 2 3 3 1 1 1 1 2 2 2 2 ALT OO O ANG FINAL nomor ALT 16 WORM MAAN 3 4 5 6 T 8 9 30 31 32 PARTS DIAGRAM HLXD 100 1 Helix Drive Assembly WITHOUT SPROCKET KIT REPLACE STOCK KEY 17 KEY amp SET SCREW ARE PART OF INPUT AXLE NOTES LIP WITH SPRING TOWARD GEAR BOX ADD BLUE LOCTITE 242 1 ADD 1 0 OUNCES OF MOBIL SYNTHETIC OIL SCH 634 SA PART GP 146 1 2 THIS WO
6. HLXD 024 SPROCKET FLANGE CAP 1 8 HLXD 025 SPROCKET FLANGE BUSHING HLXD 025 SPROCKET FLANGE BUSHING 1 9 HLXD 031 5 33t IDLER GEAR HLXD 031 6 30t IDLER GEAR 4 10 HLXD 035 5 33t SPROCKET HLXD 035 6 30t SPROCKET 2 11 HLXD 038 LG BACK WASHER HLXD 038 LG BACK WASHER 1 12 HLXD 039 LG IDLER AXLE HLXD 039 LG IDLER AXLE 1 13 HLXD 042 FRONT WASHER HLXD 042 WASHER 1 14 HLXD 065 L 5mm SPLIT BUSHING LONG HLXD 066 L 6mm SPLIT BUSHING LONG 1 15 HLXD 065 S 5mm SPLIT BUSHING SHORT HLXD 066 S 6mm SPLIT BUSHING SHORT 1 16 LM 071 05 JE BEARING LM 071 05 JE BEARING 2 866 795 1586 WWW STONEAGETOOLS COM P STONEAGE 29 5 DIAGRAM HCS HLXC V Helix Containment System with Helix Containment Drive PART NUMBER TABLE 1 1 GSB 325 025 5 1 4 20 UNC X 0 625 L 4 HELIX DRIVE 2 GW 325 L HC WASHER LOCK HIGH COLLAR 1 4 SS 4 HCS HLXC 5 HCS 100 P12TM9 24 HLXC 100 5 HCS HLXC 6 HCS 100 MP12TM9 24 HLXC 100 6 SEE TABLE 1 FOR PART NUMBERS OF DRIVE AND CONTAINMENT ASSEMBLIES TO USE P lt 866 795 1586 5 PARTS DIAGRAM HCS 100 M Helix Hose Containment System HOSE SHOWN FOR REFERENCE ONLY 8 5 5 BLUE LOCTITE BLUE GOOP SEE TABLE 1 FOR PART NUMBER OF ELBOW TUBE a a GLAND AND COLLAR TO USE C Va EE NOTE 3
7. 100 Assembly feeds the hose through the rest of the 100 Assembly and provides 50 of pressure to push the chosen tool into the boiler tubes The step by step process on how to change and or setup the Sprocket and Helix Hose feed are shown on pages 12 through 15 The same process is followed to change Helix Hose sizes and their respective Gearpacks and Split Bushings Figure 2 The Helix Hose Containment System HCS 100 automatically collects and safely protects the operator from the high pressure Helix Hose Helix Containment System Helix Containment Drive Helix Containment Drum Helix Drive 18 mg s Gg FIGURE 2 SIDE VIEW OF BTC 100 ASSEMBLY PS Rail Lock 866 795 1586 e WWW STONEAGETOOLS COM STONEAGE GEARPACK REMOVAL INSTRUCTIONS GEARPACK REMOVAL NOTE This process will be typical all sizes of Gearpacks on the HLXD 100 and HLXC 100 Assemblies AWARNING Always de energize the system before servicing or replacing any parts Failure to do so can result in severe injury and or death Keep hands hair and clothing clear of rotating parts 1 Remove the protective Gearbox Cover Plates by unhinging the two Hinged Collar Assemblies and unscrewing the 4 socket head cap screws with flat washers Figure 1 The Socket head cap screw Assemblies stay with each Gearbox Cover Plate as they are held in by a Self Loc
8. 866 795 1586 WWW STONEAGETOOLS COM S7oncAgeE 15 ASSEMBLY INSTALLATION AND CONNECTION CB BTC CONTROL BOX The Control Box be operated with or without installing the detachable legs Remove the legs for portability or to operate the Control Box in smaller spaces 1 Remove the lower bolts and nuts from the Control Box frame 2 Install the detachable legs onto the tube inserts Install the lower bolts and nuts through the legs and tube inserts Use a 7 16 in wrench and socket to tighten the bolts CAMERA SCREEN MOUNTING HOLES TUBE INSERT 16 STONEAGE 866 795 1586 WWW STONEAGETOOLS COM ASSEMBLY INSTALLATION AND CONNECTION SUPPLY LINES T 2 3 Remove the dust caps from the Joint Industry Council JIC fittings of the Control Box and the BTC Connect and blow out the hoses remove the port cap then immediately apply the hose to the motor Connect the seven pneumatic supply lines to the Control Box and the BTC using the color coding on the JIC fittings Use a 7 8 in wrench to tighten the JIC Swivel nuts Test the Control Box before operating the BTC with high pressure water to verify the control valves move the hose in the intended direction and that the dump valve is working properly PNEUMATIC SUPPLY LINE COLOR CHART HLXC 100 HLXD 100 HELIX DRIVE HLXR 100 HELIX ROTATOR HLXT 100 HELIX TRACTOR HELIX CONTAINMENT DRIVE HOSE FEED my OSE FEED SPE
9. death STONEAGE 866 795 1586 e WWW STONEAGETOOLS COM OVERVIEW 100 BOILER TUBE CLEANER BTC 100 Boiler Tube Cleaner HLXR 100 HELIX ROTATOR The Helix Rotator aligns the Helix Hose and water jet tool with the boiler tubes The Helix Rotator is comprised of an air motor drive double worm gear reduction overload slip clutch elbow The Helix Hose and water jet tool exit the HLXR 040 Helix Rotator Elbow and enter the boiler tubes Helix Rotator extension tubes are available through StoneAge to match the internal dimension of the boiler tube The Helix Rotator and the Helix Tractor allow the operator to align the Helix Hose with each individual boiler tube before launching the Helix Hose HLXT 100 HELIX TRACTOR The Helix Tractor moves the entire Boiler Cleaner unit along the rail HLXD 100 HELIX DRIVE The Helix Drive will feed or retract the Helix Hose through the assembly into the boiler tube ports The Helix Drive can exert up to 50 Ibs 23 Kg of push when needed to clear plugged tubes or travel long distances HLXR 040 HELIX ROTATING ELBOW ASSEMBLY BIC 140 BOILER TUBE SUPPORT 120 CLAMP ASSEMBLY HELIX HOSE WITH PRO LANCE AND TYPE M SWIVEL BU 004 866 795 1586 WWW STONEAGETOOLS COM SLOTTED DRIVE RAIL HELIX HOSE The Helix Hose is a wire wrapped hose engineered to engage with the sprockets of the Helix Drive giving the operator pre
10. 19 L 24 NYLOK NUT SS GN 319 L 24 NYLOK NUT SS 6 3 GS 316 02 SHCS 16 32 X 50 SS HC 014 GS 316 02 SHCS 16 32 X 50 SS HC 014 4 4 GS 319 040 SHCS 19 24 X 1 00 SS GS 319 040 SHCS 19 24 X 1 00 SS 2 5 GSB 319 07 BHC 19 24 X 1 75 LG SS GSB 319 07 BHC 19 24 X 1 75 LG SS 6 6 HLXC 065 L 5mm SPLIT BUSHING LONG HLXC 066 L 6mm SPLIT BUSHING LONG 1 7 HLXD 023 SPROCKET FLANGE PLATE HLXD 023 SPROCKET FLANGE PLATE 1 8 HLXD 024 SPROCKET FLANGE HLXD 024 SPROCKET FLANGE CAP 1 9 HLXD 025 SPROCKET FLANGE BUSHING HLXD 025 SPROCKET FLANGE BUSHING 1 10 HLXD 031 5 33t IDLER GEAR HLXD 031 6 30t IDLER GEAR 4 11 HLXD 035 5 33t SPROCKET HLXD 035 6 30t SPROCKET 2 12 HLXD 038 LG BACK WASHER HLXD 038 LG BACK WASHER 1 13 HLXD 039 LG IDLER AXLE HLXD 039 LG IDLER AXLE 1 14 HAD 042 FRONT WASHER HLXD 042 FRONT WASHER 1 15 HLXD 065 5 5mm SPLIT BUSHING SHORT HLXD 066 S 6mm SPLIT BUSHING SHORT 1 16 LM 071 05 JE BEARING LM 071 05 JE BEARING 2 866 795 1586 e WWW STONEAGETOOLS COM P STONEAGE 35 TERMS AND CONDITIONS 36 1 Acceptance of Terms and Conditions These Terms and Conditions shall operate as Seller s acceptance of Buyer s purchase order and such acceptance is made expressly conditional on assent by Buyer to the Terms and Conditions Such assent shall be deemed to have been given unless written notice of objection to any of such Terms and Conditions including inconsistencies between Buyer s purchase order and this acceptan
11. 37 16 X 1 25 GB 550 14 BOLT HEX 50 13 X 1 50 GN 550 L NYLOCK NUT N po F9 gt gt 22 STONEAGE 866 795 1586 e WWW STONEAGETOOLS COM PARTS DIAGRAM HLXR 04077 Elbow Assembly NOTES 1 ALIGN ELBOW STOP VERTICALLY TO ELBOW AS SHOWN 2 ASSEMBLY TO BE SUPPLIED WITH 1 HLXR 050 TOOL SEE NOTE 1 SEE NOTE 2 PART NUMBER QTY 1 HLXR 010 ELBOW WELDMENT 2 HLXR 011 KNURLED NUT 3 HLXR 012 WAVE SPRING ELBOW 4 5 AH 013 STOP ELBOW HLXR 014 U BOLT CLAMP sesch HLXR 015 XX FLARE XX LENGTH XX LENGTH 866 795 1586 WWW STONEAGETOOLS COM lt 23 5 DIAGRAM CAM 100 Camera System en Io cs camera ca ASSEMBLY 24 P STONEAGE 866 795 1586 WWW STONEAGETOOLS COM 5 DIAGRAM 1007 Helix Rotator 10 24 15 FOR OPTIONAL ACCESSORIES USE SCREW FOR PLUG KEYS ARE PART OF MID DRIVE AXLE 2 ADD BLUE LOCTITE 242 THIS END ONLY MIN 1 88 THD LENGTH EXPOSED ADD BLUE LOCTITE 242 LIP WITH SPRING TOWARD GEAR BOX KEY amp SET SCREW ARE PART OF INPUT AXLE OIL FILL PLUG SEE NOTE 1 SET ON BENCH IN THIS POSITION TO FILL HLXR 030 HOUSING HLXR 031 SPLIT CLAMP HLXR 033 50 13 THREADED ROD SS 2 HLXT 015 A
12. C SUPPEY LINES 17 OPERATION 18 CONTROL EE 18 PNEUMATIC DUMP CONTROL AND AIR SUPPLY 18 PRE RUIN RR dE EE 19 TEST RUN 19 STORAGE TRANSPORTATION AND 19 20 MANUAL TUBE LOCATION 20 PARTS DIAGRAM a 2 100 BOILER TUBE 21 BTC 120 CLAMP AND 140 22 HLXR 040 ELBOW ASSEMBLY AND HLXR 015 23 CAMERA SYS 24 PEAR TOO 25 FLAT T00 PEUX TRAG TOR E 26 PEXD 1T00 1 BLD DAVE WITRAOUT SPROCKET 27 HLXD BTC 100 HELIX DRIVE WITH SPROCKET KIT CHANGE 28 DRIVE SPROCKET EE 29 HCS HLXC HOSE CONTAINMENT SYSTEM WITH 24 0 90 30 5 100 HOSE CONTAINMENT SYSTEM 31 HLXC 100 1 HOSE CONTAINMENT DRIVE WITHOUT SPROCKET 33 HLXC 100 HELIX CONTAINMENT 2 009292 34 HLXC 60X HELIX CONTAINMENT DRIVE SPROCKET
13. E POSITION HOSE SPEED 2 IPS TO 18 IPS CONTROLLED BY NEEDLE VALVE SPEED CONTROLS DESCRIPTION OF EQUIPMENT AND KEY FEATURES INTENDED USE Cleans vertical and horizontal tubing The Boiler Tube Cleaner was developed as a safe and efficient alternative to manual cleaning requiring vessel entry and cleaning of tube bundles such as steam generator tubes in fossil fueled boilers Specifically designed for the mud drum of small package Optional Camera System can be mounted to the BTC 100 gives boilers that are used for process steam in chemical and petroleum the operator the ability to quickly align with each boiler tube inside refining plants The Boiler Tube Cleaner can be adapted to fit other of the mud drum types of boilers by modifying the size of a few components Removes thin hard scale and corrosion Will work with manways as small as 16 inches wide Can be paired with any StoneAge rotary pipe or tube cleaning tool StoneAge recommends utilizing the 2 Badger or the Banshee Beetle Rotating Nozzle for boiler tube cleaning Both tools are capable of navigating the bends commonly found in boiler tubes This system automates the cleaning process increasing both safety and efficiency yet remains flexible portable and fast Tool Benefits e Safely operated from outside the water blast zone e Requires a single operator to run 866 795 1586 WWW STONEAGETOOLS COM STONEAGE 4 WARNING AND SAFETY INSTRUCTIONS OPERATOR
14. ED FORWARD HOSE FEED SPEED REVERSE SHROUDED HOSE ASSEMBLY CONNECTIONS TO CONTROL BOX ___ HELIX DRIVE HELIX TRACTOR HELIX ROTATOR CONNECTIONS TO BTC 100 ASSEMBLY 866 795 1586 WWW STONEAGETOOLS COM STONEAGE OPERATION 18 CB BTC CONTROL PANEL The TRAVEL CONTROL moves the BTC 100 Assembly in and out of the mud drum along the The OFF position is at the 12 O clock position The HOSE DIRECTION CONTROL will move the hose in the forward feeding and reverse retracting directions The OFF position is at the 12 O clock position NOTE Ensure that the elbow is lined up with a boiler tube before advancing the hose Use remote camera to line up elbow A manual tube locating instruction is in the Maintenance section of this manual The HOSE FEED SPEED CONTROLS will move the hose in the forward direction at 9 50 ft min and independently in the reverse direction at 9 50 ft min The control acts on the motor exhaust in the return hoses Turn the controls clockwise to decrease the feed rate and counter clockwise to increase the feed rate The ROTATION CONTROL rotates elbow There is a stop on the Elbow that will contact the rail and activate the internal slip clutch if you over rotate the elbow to either side This prevents damage to the tool Adjust the elbow length so you can see the tool move out of the tube and there is a gap between the elbow and the tube MOMENTARY PNEUMATIC DUM
15. KIT 24 22 35 TERMS AND CONDITIONS a 36 2 P STONEAGE 866 795 1586 WWW STONEAGETOOLS COM MANUFACTURER S INFORMATION StoneAge Inc 466 Skylane Drive Durango 81303 Phone 970 259 2869 Toll Free 866 795 1586 www stoneagetools com This manual must be used in accordance with all applicable national laws The manual shall be regarded as a part of the machine and shall be kept for reference until the final dismantling of the machine as defined by applicable national law s SPECIFICATIONS Weight Pressure Flow Speed Dimensions Connections Helix Hose 5mm 0 35 lb per foot 20 ksi 5 49 inch OD Inlet M 9 16 16 ko per meter Lenoth up to Outlet 3 8 MP RH 75 ft Helix Hose 6mm 0 40 Ib per foot 20 ksi 10 gom 64 inch OD Inlet M 9 16 18 kg per meter Outlet 3 8 MP RH Helix Drive 2016 9 20 cfm 2 18 IPS 1 inch extension clamped to HLXT 100 Helix Tractor 20 9 kg 10 cfm 14 70 IPM Rollers on Box Rail Helix Rotator 20 9 kg 10 cfm 1 4 RPM Rollers on Box Rail Helix Takeup AO 18 kg 24 inch Position Held by Pin diameter x 12 inch high Control Panel 30 19 6 kg 90 psi air 20 cfm Video Camera 2 lb 9 kg 5 7 inch display 12v Battery or 120v AC TRAVEL 18 IPM TO 90 IPM CONTROLLED BY VALVE HANDLE POSITION ROTATION 1 RPM TO 4 RPM CONTROLLED BY VALVE HANDL
16. LIP EXTERNALLY PUSH CLEVIS PIN THRU SHEETMETAL amp COLLAR CLIP EXTERNALLY 866 795 1586 WWW STONEAGETOOLS COM lt 5 5 DIAGRAM HLXC 100 Helix Containment Drive Assembly WITH SPROCKET KIT SPROCKET KIT SEE CHART HLXC DRIVE ASSY SEE CHART ORIENT WASHER FLAT AGAINST TAB SPROCKET KIT DETERMINED BY SEE CHART PROCKET PACK PUSH CLEVIS PIN THRU BUSHING amp SHEETMETAL CLIP EXTERNALLY PUSH CLEVIS PIN THRU BUSHING SEE NOTE 1 SHEETMETAL amp COLLAR CLIP EXTERNALLY SPROCKET KIT CHART ASSEMBLY NUMBER HOSE SIZE HLXD DRIVE ASSEMBLY SPROCKET KIT HLXC 100 5 5mm HLXC 100 1 HLXC 605 HLXC 100 6 6mm HLXC 100 1 HLXC 606 aa 5 366 795 1586 e WWW STONEAGETOOLS COM NOTES 1 ASSEMBLE IDLER GEARS WITH ENGRAVED FACING OUTWARD BOTH SIDES HLXC 60X Helix Containment Drive Sprocket Kit THIS IS SHOWN AS THE HLXC 605 5mm SEE NOTE 3 SEE NOTE 3 2 PACKAGE SPROCKET ASSEMBLIES AND BUSHINGS TOGETHER 3 ADD BLUE LOCTITE 242 TO NOTED THREADED HARDWARE 4 BLUE GOOP IS A SWAGELOK BRAND ANTI SEIZE AN EQUIVALENT ALTERNATIVE IS ACCEPTABLE SEE NOTE 4 SEE NOTE 4 PARTS DIAGRAM 605 PART NUMBERS 606 PART NUMBERS 1 GB 337 04 BOLT 37 16 X 1 00 SS GB 337 04 BOLT HEX 37 16 X 1 00 SS 2 2 GN 3
17. May be required refer to job specific risk assessment AWARNING Operations with this equipment can be potentially hazardous Caution MUST be exercised prior to and during machine and water jet tool use Please read and follow all of these instructions in addition to the guidelines in the WJTA Recommended Practices handbook available online at www wita org Deviating from safety instructions and recommended practices can lead to severe injury and or death e Do exceed the maximum operating pressure specified for any component in a system The immediate work area MUST be marked off to keep out untrained persons connections are tight and free of leaks Inspect the equipment for visible signs of deterioration damage and improper assembly Do not operate until repaired Make sure all threaded Users of the Boiler Tube Cleaner BTC MUST be trained and or experienced in the use and application of high pressure technology and cleaning as well as all associated safety measures according to the WJTA Recommended Practices for the use of High pressure Waterjetting Equipment The Control Box should be located in a safe location where the operator has good visibility of the mud drum entrance The Boiler Tube Cleaner BTC and Control Box MUST be supervised at all times and should never be left unattended e Always de energize the system before attempting to service or replace any parts Failure to do so can result in severe injury and or
18. N ALL DEBRIS amp OILS BEFORE INSTALLING 2 LOOSEN TOP BAR KNOBS RAISE UPPER CLAMP SLIDE HLXD SPLIT BUSHING INTO HLXT CLAMP INSTALL AT APPROXIMATE ORIENTATION AND TIGHTEN BAR KNOBS LOCATION AT ROOM TEMPERATURE 3 LOOSEN TOP BAR KNOBS SET HLXR ASSEMBLY OVER BU 004 RAIL TIGHTEN BAR KNOBS DISCARD U BOLT BRACKET AND REPLACE WITH LED ASSEMBLY DETAIL A SCALE 1 4 FLARE SEE NOTE HLXR 015 DISCARD 10 24 BUTTON HEAD SCREW REPLACE WITH SHOULDER BOLT W CAMERA ASSEMBLY SEE NOTE 4 LXD BTC 100 XX DRIVE _ H SEE CHART 1 12 le E 1 RAIL SEE NOTE 5 866 795 1586 WWW STONEAGETOOLS COM exonur er 21 5 DIAGRAM BTC 1201 Clamp 8 315 2 OTTEN Se PART NUMBER QTY 4 BTC 123 ACME NUT 2 1 BR 060 D RAIL CLAMP DRILLED 2 5 BTC 124 SUPPORT PLATE 1 2 BTC 121 CLAMP WELDMENT 1 6 GB 537 04 BOLT 37 16 X 1 00 4 3 BTC 122 ACME WELDMENT 2 7 GB 550 06 BOLT HEX 50 13 X 1 50 1 NOTE 1 DO NOT TIGHTEN COMPLETELY ASSEMBLY MUST ROTATE FREELY 6 GW 550 F FLAT WASHER 7 BTC 143 PIVOT PLATE 8 BTC 144 SPRING PLUNGER 9 BTC 141 TUBE OUTER WELDEMENT 10 BTC 142 TUBE INNER WELDMENT PART NUMBER QTY BR 060 D RAIL CLAMP DRILLED GB 537 04 BOLT HEX 37 16 X 1 00 GB 537 05 BOLT HEX
19. P BTC TRAVEL CONTROL AIR SUPPLY FITTING A universal AIR SUPPLY FITTING Chicago style is located on the back of the Control Box Connect a compatible compressed air line not included according to the manufacturer s instructions If another pneumatic connection is preferred this fitting can be removed any male 72 in NPT fitting may be used PNEUMATIC DUMP CONTROL FITTING AND LINE MOMENTARY PNEUMATIC DUMP CONTROL TOGGLE is located on the control panel and should be set up to control air actuated dump valve Install 1 4 in OD nylon tubing not included by pushing the tubing into the fitting to connect the PNEUMATIC DUMP CONTROL FITTING to the pneumatic dump valve NOTE Do not travel or rotate while the hose extended into a boiler tube This can damage hose Always retract the tool into the elbow before moving the Helix Tractor or Helix Rotator controls To use the MOMENTARY PNEUMATIC DUMP CONTROL TOGGLE hold it in the HIGH PRESSURE ON position to route the high pressure water to the tool Release the toggle to the OFF position to release the high pressure water away from the tool NOTE Ensure that the tool end is inside a boiler tube before going to high pressure To pause the system turn the HOSE DIRECTION CONTROL to the OFF 12 O clock position and release the MOMENTARY PNEUMATIC DUMP CONTROL TOGGLE to the OFF position This will stop the assembly from moving and reroute the high pressu
20. QUIREMENTS Use of Personal Protective Equipment PPE is dependent on the working pressure of water and the cleaning application Managers Supervisors and Operators MUST carry out a job specific risk assessment to define the exact requirements for PPE See Protective Equipment for Personnel Section 6 of WJTA IMCA s Recommended Practices For The Use Of High pressure Waterjetting Equipment for additional information Hygiene Operators are advised to wash thoroughly after all waterjetting operations to remove any waterblast residue which may contain traces of harmful substances First aid provision users MUST be provided with suitable first aid facilities at the operation site The risk assessment MUST consider potential material or substance hazards including e Aerosols e Biological and microbiological viral or bacterial agents Combustible materials e Dusts e Explosion e Fibers e Flammable substances e Fluids e Fumes e Gases e Mists Oxidizing Agents PPE may include e Eye protection Full face visor e Foot protection brand or steel toe capped waterproof non slip safety boots e Hand protection Waterproof gloves e Ear protection Ear protection for a minimum of 85 dBA e Head protection Hard hat that accepts a full face visor and ear protection Body protection Multi layer waterproof clothing approved for waterjetting Hose protection Hose shroud e Respiratory protection
21. RM CAP WILL BOTTOM ON BEARING WILL NOT BOTTOM ON HOUSING WHEN TIGHTENED 2 avaso nnonwrss 3 GP 010 BK BLACK PLASTIC ID 1 WASHER P8 GP 010 P PURPLE PLASTIC ID 1 WASHER P8 GP 025 P4SS HEN 0 PLUG 2 GS 325 03 SHCS 25 20 X 75 SS TB 050 7 GSB 325 02 BHCS 25 20 X 50 LG SS 78 _ I x RING CLEVIS PIN 25 HLXD 061 GEARBOX BASE PLATE ASSY 26 HLXD 063 GEARBOX COVER NIN N 866 795 1586 e WWW STONEAGETOOLS COM OF OUPUT AXLE PUSH CLEVIS PIN THRU SHEETMETAL amp COLLAR CLIP EXTERNALLY OIL FILL PLUG PART ADD BLUE LOCTITE 242 WORM GEAR PUSH CLEVIS THRU SHEETMETAL CLIP EXTERNALLY A 080 HINGED COLLAR ASSY 1 HRS 573 FITTING 90 DEG 808 RJ 009 BEARING 1 SG 055 AIR MOTOR STONEAGE 27 5 DIAGRAM HLXD BTC 100 Helix Drive WITH SPROCKET KIT HLXD DRIVE ASSY HLXD SPROCKET KIT HLXD CLAMP TROLLEY HLXD CLEVIS PIN QTY 1 QTY 1 QTY 1 QTY 1 HLXD BTC 100 5 HLXD 100 1 HLXD 605 HLXD 046 HLXD BTC 100 6 om HLXD 100 1 HLXD 606 HLXD 046 HLXD BTC 100 XX HLXD SPROCKET KIT SEE CHART HLXD CLEVIS PIN SEE CHART HLXD CLAMP TROLLEY SEE CHART HLXD SPROCKET KIT SEE CHART PUSH CLEVIS PIN THRU BUSHING amp SHEETMETAL PUSH CLEVIS PIN THRU BUSHING SHEETME
22. TAL amp COLLAR CLIP EXTERNALLY PART NUMBER BR 052 2 0 90 AXLE ZERK 2X ADD BLUE LOCTITE 242 THIS END ONLY TIGHTEN TILL THREADS BOTTOM BR 055 ROLLER ASSEMBLY MIN 4 63 MAX 5 30 THD LENGTH EXPOSED HLXD 046 1 CLAMP TROLLEY BLOCK LEFT HLXD 046 2 CLAMP TROLLEY BLOCK RIGHT 2X ADD BLUE LOCTITE 242 HLXD 046 3 37 16 0 THREADED ROD 6 HLXT 037 BAR KNOB 38 28 STONEAGE 866 795 1586 WWW STONEAGETOOLS COM PARTS DIAGRAM HLXD 60X Helix Drive Sprocket Kit NOTES THIS IS SHOWN AS THE HLXD 605 5mm SECTION LIP FACES INWARD DETAIL B SCALE 1 1 1 ASSEMBLE IDLER GEARS WITH ENGRAVED FACING OUTWARD BOTH SIDES 2 PACKAGE SPROCKET ASSEMBLIES AND BUSHINGS TOGETHER 3 ADD BLUE LOCTITE 242 TO NOTED THREADED HARDWARE 4 BLUE GOOP IS A SWAGELOK BRAND ANTI SEIZE AN EQUIVALENT ALTERNATIVE IS ACCEPTABLE 605 PART NUMBERS 606 PART NUMBERS 1 GB 337 04 BOLT 37 16 X 1 00 SS GB 337 04 BOLT 37 16 X 1 00 SS 2 2 GN 319 L 24 NYLOK NUT SS GN 319 L 24 NYLOK NUT SS 6 3 GS 316 02 SHCS 16 32 X 50 SS HC 014 GS 316 02 SHCS 16 32 X 50 SS HC 014 4 4 GS 319 040 SHCS 19 24 X 1 00 SS GS 319 040 SHCS 19 24 X 1 00 SS 2 9 GSB 319 07 BHC 19 24 X 1 75 LG SS GSB 319 07 BHC 19 24 X 1 75 LG SS 6 6 HLXD 023 SPROCKET FLANGE PLATE HLXD 023 SPROCKET FLANGE PLATE 1 7 HLXD 024 SPROCKET FLANGE
23. TRAINING Managers supervisors and operators MUST be trained in Health and Safety Awareness of High pressure Water Jetting and hold a copy the Water Jetting Association WJA Code of Practice or equivalent see www waterjetting org uk Operators MUST be trained to identify and understand all applicable standards for the equipment supplied Operators should be trained in manual handling techniques to prevent bodily injury Operators MUST read understand and follow the Operational and Training Requirements Section 7 0 of WJTA IMCA s Recommended Practices For The Use Of High pressure Waterjetting Equipment or equivalent Operators MUST read understand and follow the Warnings Safety Information Assembly Installation Connection Operation Transport Handling Storage and Maintenance Instructions detailed in this manual StoneAge has designed and manufactured this equipment considering all hazards associated with its operation StoneAge assessed these risks and incorporated safety features in the design StoneAge WILL NOT accept responsibility for the results of misuse IT IS THE RESPONSIBILTY INSTALLER OPERATOR to conduct a job specific risk assessment prior to use Job specific risk assessment MUST be repeated for each different set up material and location The risk assessment MUST conform to the Health and Safety at Work Act 1974 and other relevant Health and Safety legislation PERSONAL PROTECTIVE EQUIPMENT RE
24. XLE INPUT 1 1 010 GREEN PLASTIC ID WASHER Pg 010 RED PLASTIC ID WASHER P8 ER GP 025 P4SS 0 PLUG GS 325 02 25 20 X 50 SS 11 GS 325 03 SHCS 25 20 X 75 SS TB 050 GS 325 16 SHCS 25 20 X 4 00 SS GSB 319 0125 BHCS 19 24 X 31 LG SS GW 325 F FLAT WASHER SS 19 HLXR 001 DRIVE TUBE 0UTPUT 1 WELDMENT NOTES 1 ADD 2 5 OUNCES OF MOBIL SYNTHETIC OIL SCH 634 2 LOT NUMBER TO BE ADDED BY STONEAGE TOOLS cen HLXT 040 16MM BALL STUD 31 32 33 34 35 36 37 38 39 41 42 43 866 795 1586 WWW STONEAGETOOLS COM lt 25 5 DIAGRAM 1007 Helix Tractor NOTES 1 ADD 1 5 ONCES OF MOBIL SYNTHETIC OIL SCH 634 SA GP 146 1 2 LOT TO BE ADDED BY STONEAGE TOOLS 3 THIS WORM CAP WILL BOTTOM ON BEARING WILL NOT BOTTOM TIGHTEN LOCK NUT TO 65 INCH POUNDS 48 5 KEY amp SET SCREW ARE PART OF INPUT AXLE ON HOUSING WHEN TIGHTENED OF MID DRIVE AXLE 4 ADD BLUE LOCTITE 24210 EACH END OF ALL THREAD AT 0222 SET DISTANCE SEE NOTE 4 SEALS MUST HAVE LIP WITH SPRING FACING GEAR BOX ORIENT BELLVILLE WASHERS WHERE CONCAVE SURFACES FACE EACH OTHER SEE NOTE 2 KEYS PART OF OUTPUT AXLE ADD BLUE ech LOCTITE 242 5 3 2 ADD BLUE LOCTITE 242 THIS END ONLY 1 38 THD LENGTH EXPOSED P
25. at the time of shipment Prices are subject to increase for inclusion of any and all taxes which are applicable and which arise from the sale delivery or use of Seller s products or services and for the collection of which Seller is or may be responsible to any governmental authority unless acceptable exemption certificates are provided by Buyer in accordance with law Buyer shall pay all charges for transportation and delivery and all excise order occupation use or similar taxes duties levies charges or surcharges applicable to the equipment or services being purchased whether now in effect or hereafter imposed by any governmental authority foreign or domestic 3 Warranty Subject to the limitations and conditions hereinafter set forth Seller warrants to the original Buyer that its products are free from defects in workmanship and material for a period of one 1 year months from shipment Seller s obligation under this warranty shall be limited to repairing replacing or issuing a credit for at Seller s option any products or services it finds to be defective in material or workmanship In no event shall Seller be liable for any incidental consequential or indirect damages of any kind THIS WARRANTY SHALL BE IN LIEU OF ANY OTHER WARRANTY EXPRESSED OR IMPLIED INCLUDING ANY WARRANTY FOR MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE No statement or recommendation made by Seller or its representative to Buyer or User sha
26. ce is given by Buyer to Seller promptly on receipt hereof Seller desires to provide its Buyer with prompt and efficient service However to negotiate individually the terms of each sales contract would substantially impair Seller s ability to provide such service Accordingly products furnished and services rendered by Seller are sold only on the Terms and Conditions stated herein Notwithstanding any Terms or Conditions on Buyer s order Seller s performance of any contract is expressly made conditional on Buyer s agreement to Seller s Terms and Conditions of sale unless otherwise specifically agreed to in writing by Seller In the absence of such agreement commencement of performance shipment and or delivery shall be for Buyer s convenience only and shall not be deemed or construed to be an acceptance of Buyer s Terms and Conditions PRODUCTS SOLD BY SELLER ARE DESIGNED AND INTENDED TO BE USED AT HIGH PRESSURES AND SPEEDS AND MAY BE DANGEROUS IF OPERATED IMPROPERLY OR WITHOUT THE USE OF APPROPRIATE SAFETY DEVICES AND GUARDS BUYER IS CAUTIONED TO CAREFULLY READ AND UNDERSTAND THESE TERMS AND CONDITIONS AS THEY HAVE IMPORTANT LEGAL CONSEQUENCES 2 Payment Prices Unless other arrangements have been made in writing between Seller and Buyer payment for product delivered shall be made upon receipt of invoice The prices shown on the face hereof are those currently in effect Prices invoiced shall be per price list in effect
27. cise control over forward and reverse travel This allows for consistent cleaning throughout the length of the tube The spring coils provide strength protection and flexibility The Helix Hose is available in 5mm 6mm and 8mm hose sizes and are specified by flow limits and the tool being used NOTE If there is any question about the appropriate hose size for the flow limit or water jet tool being used please contact your StoneAge Customer Service Representative 1 866 795 1586 HLXC 100 HOSE CONTAINMENT DRIVE The Helix Hose Containment Drive is a hose drive with an air motor directly driving sprocket that engages the Helix Hose HCS 100 HOSE CONTAINMENT SYSTEM The Helix Hose Containment System is designed to keep the Helix Hose managed and protected Aluminum drum water swivel rolls along rail and locks into position HLXR 100 HELIX ROTATOR HLXT 100 HELIX TRACTOR HLXD 100 HELIX DRIVE HLXC 100 HELIX HOSE CONTAINMENT DRIVE HCS 100 HELIX HOSE CONTAINMENT SYSTEM 7 gt gt mee E E KEISER e j yee STONEAGE ROTATION CONTROL OVERVIEW CB BTC CONTROL BOX Bie N ELBOW TRAVEL CONTROL TRAVEL ROTATE LEFT RIGHT HIGH PRESSURE a a ON Zi 5 e OFF HOSE FEED SPEED HOSE FEED REV FWD FWD REV HOSE FEED SPEED CONTROLS
28. ck that the air hoses are properly connected and tight Check all hoses and accessories for damage prior to use Do not use damaged items Only high quality hoses intended for waterblast applications should be used as high pressure hoses Ensure that operators never connect disconnect or tighten hoses adaptors or accessories with the high pressure water pump unit running Test the Control Box before operating the Boiler Tube Cleaner BTC with high pressure water to verify the control valves move the hose in the intended direction and that the dump valve is working properly Check that the Boiler Tube Cleaner BTC is anchored securely for the application and pressure of the waterjet tool being used Check all high pressure threaded connections for tightness Check air supply attachment high pressure pump function air controlled dump function INSERTING ASSEMBLY THROUGH MANWAY Using the Pin Spanner supplied a 5 16 diameter pin or your hand loosen the collar that holds the elbow onto the Helix Rotator sufficiently so that the elbow may be pulled toward the center of the rail clearing the man way and entering the mud drum as the BTC 100 is rolled forward on the rail Once the elbow is inside the mud drum the elbow will return to it s operating position Tighten the collar to the minimum needed to hold the elbow in position IMPORTANT The end of the elbow will be about 2 1 2 from the inside surface of the 24 mu
29. cts If any litigation is commenced between Seller and Buyer or their personal representatives concerning any provision hereof the party prevailing in the litigation shall be entitled in addition to such other relief that is granted to a reasonable sum as and for their attorneys fees and costs in such litigation or arbitration STONEAGE TRADEMARK LIST View the list of StoneAge s trademarks and service marks and learn how the trademarks should be used Use of StoneAge trademarks may be prohibited unless expressly authorized http www StoneAgetools com trademark list STONEAGE PATENT DATA View the list of StoneAge s current U S patent numbers and descriptions http www sapatents com STonNEAGE NOTES This is intentionally left blank 38 STONEAGE 966 795 1586 9 WWW STONEAGETOOLS COM NOTES This page is intentionally left blank 866 795 1586 WWW STONEAGETOOLS COM 5 39 STONEAGE ENGINEERING POWER OF WATER 1 866 795 1586 www STONEAGETOOLS com 2014 StoneAge Inc All Rights Reserved
30. d drum The boiler tubes typically project about 1 2 so there is a 2 clearance between the end of the elbow and the tubes Depending on field conditions you may need to shorten or lengthen the elbow This can be easily done by replacing the entire elbow or saw off and form flare StoneAge has HLXR 015 Flares available in custom lengths Traverse way deploy elbow and tighten collar TEST RUN PROCEDURE Adjust the hose feed speed controls Proper forward and reverse speeds will vary depending on the type of material being removed Adjustment of the hose feed speed controls may be necessary during operation in order to optimize cleaning and overall productivity Operate the high pressure water at full pressure and use the MOMENTARY PNEUMATIC DUMP CONTROL TOGGLE to verify that the dump valve is working properly When storing the unit use compressed air to blow out the air lines to remove debris and moisture Use mild soapy water to clean the machine in order to remove corrosive materials Store unit in a clean and dry area Apply a small amount of air tool oil directly into the motor forward and reverse fittings Then briefly operate the controls at slow speed for a short duration in each direction to coat the interior parts of the motor Install the dust caps onto all three fittings to keep moisture and dirt out 866 795 1586 WWW STONEAGETOOLS COM STONEAGE 19 MAINTENANCE Maintenance Item Freq
31. e drive gear onto the shaft Install the two 10 24 Socket head cap screws into the two positions shown in Figure 2 and tighten until the Sprocket Flange engages securely Install the Follow Gear with Back Washer and 3 8 Nut above the Plate Stop on the Gearbox Base Plate Do not tighten at this point to allow for installation of the Helix Hose Figure 3 w f S 5 4 Install the Lower Cover Plate with the appropriate Split Bushing halves attached Tighten the 2 socket head cap screws with flat washers Figure 4 SOCKET HEAD CAP SCREWS WITH FLAT WASHERS 2 FIGURE 4 pr 866 795 1586 WWW STONEAGETOOLS COM GEARPACK INSTALLATION INSTRUCTIONS 5 Install the Helix Hose End onto the Gearpack and through the Back Out Preventer Slide the Follow Gear down onto the Helix Hose Figure 5 Ensure the gears on both Sprocket Packs engage the Helix Hose Figure 5 1 and the Back Washer indicates the appropriate hose size in the 12 O Clock position and before tightening the 3 8 Bolt Figure 5 2 3 8 BOLT PROPER POSTION FOR 5 6 AND 8 mm HELIX HOSE GEAR ENGAGEMENT WITH HELIX HOSE 6 Fasten the Upper Cover Plate with Hinged Collars with the two 10 24 socket head cap screws Then fasten the hinged collars with the hex bolt thumb screw Figure 6 COMPLETE BACK VIEW FIGURE 6 1 P FRONT VIEW PAURES FIGURE 6 2
32. g a flexible tape measure 1 Align the end of the tape measure with the center of the flange on the top end of the elbow Fasten the tape where it lies on the HLXR 100 Rotator to the square head cap screw and washer on the HLXR 100 Rotator It should measure approximately18 at the washer 2 Zip tie the end of the tape measure back onto itself so that it does not get caught up in the assembly 3 Once the tape is fastened to the HLXR 100 Rotator drape the other end over the frame of the control box and clip it to the frame The distance measurement should be checked at the face of the mud drum For a tutorial on this procedure go to the YouTube page below stoneAge Boiler Tube Cleaner BTC 100 Training httos www youtube com watch v 1 7SZ34so09L4 DRAPE TAPE MEASURE OVER CONTROL BOX FRAME FASTEN TAPE MEASURE HERE AND ZIP TIE IT BACK ONTO ITSELF 2 STONEAGE 366 795 1586 e WWW STONEAGETOOLS COM 5 DIAGRAM 100 Boiler Tube Cleaner with Camera BU 004 6 BOX RAIL EXTENSION NOTES 4 SNAP HLXT 041 SOCKET ONTO HLXT 040 BALL ON BTC 100 XX CAM HLXD BTC 100 XX 1 LOOSEN SIDE BAR KNOBS ENGAGE GEAR IN RAIL HLXT AND HLXR ASSEMBLY BTC 100 5 CAM HLXD BTC 100 5 SLOTS TIGHTEN BAR KNOBS MAKE SURE ROLLER 5 HOSE FLARE amp RAIL PER CUSTOMER BTC 100 6 CAM HLXD BTC 100 6 GROOVES ENGAGE RAIL SPECIFICATIONS TO SUIT BOILER 6 CLEA
33. he Spring Plunger Pin in place 5 The distance you insert the rail into the mud drum is dependent on the length of the mud drum If the span exceeds 20 ft 6096 mm use two supports evenly spaced NOTE If the manway is than 12 30 48 cm block up the rail to center the HLXR 100 Rotator BU 004 RAIL SPRING PLUNGER SWIVEL LOCK AND RELEASE BTC 140 SUPPORT 20 6096 mm use Two SUPPORTS FOR LONGER DRUMS 700000000000000000000000000000000000 rem CES a 000 EFAN A END 140 SUPPORT INSIDE MUD DRUM MUD DRUM WITH EXTENDED FEET TOP VIEW 866 795 1586 WWW STONEAGETOOLS COM STONEAGE ASSEMBLY INSTALLATION AND CONNECTION JOINING RAILS Additional rail length may be needed when the assembly is slid into the inside of the mud drum Tighten the wedge bolts evenly to synchronize the rail slots 1 Slide Rail Extension over the Splice Tube When joining multiple rails it is important to align the drive slots as illustrated 2 Make sure the slots are clear to allow the gears of the Boiler Tube Cleaner to engage freely 3 Install Wedge Bolt through both Rail and Splice Tube and tighten the bolt to expand the diameter and secure the rails together Make sure the rail edges are matche to allow rollers to travel freely across joints 4 There must be at least 6 ft 1829 mm of rail outside the manway
34. he roller grooves engage the rail and the Chasis Clamp is completely closed There is a clutch to allow the Tractor gear to rotate on the gearbox output shaft with 5016 of thrust applied in the direction of travel Check this by forcing the Tractor forward and back See NOTE below for adjustment 2 Connect the link coupler from the tractor to the rotator NOTE Tighten to 65 in lbs Do not over tighten ORIENT BELLVILLE WASHERS WHERE CONCAVE SURFACES FACE EACH OTHER 866 795 1586 WWW STONEAGETOOLS COM STONEAGE ASSEMBLY INSTALLATION AND CONNECTION HELIX HOSE INSTALLATION The Helix Hose is a spring wrapped hose precisely engineered to engage with the sprockets of the Helix Drive and Helix Containment Drive giving the operator precise control over forward and reverse travel This allows for consistent cleaning throughout the length of the tube The spring coils provide strength protection and flexibility The Helix Hose Split Bushings and Gearpacks are labelled with size 5 mm or 6 mm Make sure all parts match NOTE If there is any question about the appropriate hose size for the flow rate or tool being used please contact your StoneAge Customer Service Representative 1 866 795 1586 1 Keep cap or protective covering onto the Pro Lance MP6R end of the Helix Hose to protect the sealing surface and threads and keep debris out of the hose N 2 Insert the Helix Hose end into the Helix Tractor He
35. ility of the other portions hereof 8 Disputes Buyer and Seller shall attempt in good faith promptly to resolve any dispute arising under these Terms and Conditions by negotiations between representatives who have authority to settle the controversy If unsuccessful Buyer and Seller shall further attempt in good faith to settle the dispute by nonbinding third party mediation with 866 795 1586 WWW STONEAGETOOLS COM TERMS AND CONDITIONS fees and expenses of such mediation apportioned equally to each side Any dispute not so resolved by negotiation or mediation may then be submitted to a court of competent jurisdiction in accordance with the terms hereof These procedures are the exclusive procedures for the resolution of all such disputes between the parties All sales agreements for sale offers to sell proposals acknowledgments and contracts of sale including but not limited to purchase orders accepted by Seller shall be considered a contract under the laws of the State of Colorado and the rights and duties of all persons and the construction and effect of all provisions hereof shall be governed by and construed according to the laws of such state A state or federal court located within the State of Colorado shall have sole and exclusive jurisdiction over any litigation concerning any such matters as well as any alleged defects of any products or equipment covered thereby or damages sustained as a result of such alleged defe
36. king Retaining Ring and Spring Mechanisms Figure 1 1 HINGED COLLAR SOCKET HEAD CAP SELF LOCKING SCREWS WITH FLAT RETAINING RING AND WASHERS A SPRING MECHANISMS 2 Slide the Upper and Lower Cover Plates off in opposing directions and set all parts aside Figure 2 3 Remove the Follow Gear by removing the 3 8 bolt from the Back Washer Keep these parts together for reinstallation Figure 3 BACK WASHER 3 8 BOLT FIGURE 2 FIGURE 3 2 STONEAGE 365 755 1586 WWWSTONEAGETOOLS COM GEARPACK REMOVAL INSTRUCTIONS 4 Remove the two 10 24 socket head cap screws and replace them into the holes two positions in the counter clockwise direction Figure 4 5 Thread them in until the Sprocket Flange within the Drive Gear Releases the Sprocket Pack Figure 5 SPROCKET FIGURE 5 GEARPACK INSTALLATION INSTRUCTIONS GEARPACK INSTALLATION NOTE This process will be typical all sizes of Gearpacks on the HLXD 100 and HLXC 100 Assemblies AWARNING Always de energize the system before servicing or replacing any parts Failure to do so can result in severe injury and or death Keep hands hair and clothing clear of rotating parts 1 Install the Follow Gear with Back Washer and 3 8 bot and Drive Gear from the 5mm Gearpack Figure 1 FIGURE 1 866 795 1586 e WWW STONEAGETOOLS COM lt 13 GEARPACK INSTALLATION INSTRUCTIONS 14 2 Find the keyway and slide th
37. lix Rotator and Helix Rotator Elbow Loosen the bar knobs above the clamp in the Helix Tractor Helix Hose End Helix Rotator Eloow Helix Rotator Helix Tractor 3 Thread the Swivel End of the Helix Hose onto the tube connection inside the Hose Containment Drum and coil the remaining hose inside the drum apts te he R Ma Swivel End Elbow Swive Tube Connection TOP VIEW Hose Containment Drum SE Coiled Hose inside the Hose Containment Drum amp 855 795 158 WWW STONEAGETOOLS COM ASSEMBLY INSTALLATION AND CONNECTION HLXD 100 HELIX DRIVE AND HLXC 100 HELIX CONTAINMENT DRIVE Before the Helix and Helix Containment Drives can be installed they must be opened in order to feed and engage the Helix Hose Both are shown below for identification purposes Figure 1 The Helix Containment Drive retracts the Helix Hose from the BTC 100 Assembly The Helix Drive on the 100 Assembly feeds the hose through the 100 Assembly and provides up to 50 of force and inserts the hose into the containment drum to push the chosen tool into the boiler tubes FIGURE 1 HLXD 100 Helix Drive TOP VIEW HLXC 100 Helix Containment Drive on the 100 Assembly on the HCS 100 Hose Containment System HELIX HOSE INSTALLATION INTO HLXD 100 HELIX DRIVE AND HLXC 100 HELIX CONTAINMENT DRIVE The Helix Drive on the
38. ll constitute a warranty by Seller or a waiver or modification to any of the provisions hereof or create any liability for Seller All warranty claims are subject to the exclusions and limitations set forth below a The warranty shall not apply if the product or service 1 has been subject to misuse negligence or accident 2 has not been installed or STONEAGE operated accordance with Seller s recommendations 3 has been operated under more severe conditions than those specified for the particular product or service 4 has been operated beyond the rated capacity of the product or 5 has been repaired or altered outside Seller s facilities or in any way so as Seller s judgment to affect its stability or reliability b Products that Seller furnishes but does not manufacture carry only the warranty of the manufacturer of such products Where other manufacturers or suppliers products used Seller s products or services prove defective Seller s liability shall exist only to the extent that Seller is able to recover from such manufacturers or suppliers for such defects c Any warranty granted by Seller to the Buyer shall be deemed void if any goods covered by such warranty are used for any purpose not recommended or permitted In addition the Buyer shall indemnify Seller and hold Seller harmless from and against any and all claims damages losses costs expenses and other liability of whatever nature
39. make delivery by a specified date but will always use its best efforts to make delivery within the time requested All deliveries are based on F O B Seller s factory unless specifically agreed otherwise and Buyer shall pay all shipping costs and insurance from that point Seller in its sole discretion will determine and arrange the means and manner of transportation of the products Responsibility of Seller shall cease and Buyer assumes all risk of loss or damages upon Seller s delivery to and receipt by a common carrier Carriers shall be responsible for goods lost or damaged in transit and Buyer shall immediately notify the carrier in writing of such loss or damage At Buyer s request Seller will offer its assistance THE PROPOSED SHIPMENT DATE IS AN ESTIMATE UNDER NO CIRCUMSTANCES SHALL SELLER HAVE ANY LIABILITY WHATSOEVER FOR LOSS OF USE OR FOR ANY DIRECT OR CONSEQUENTIAL DAMAGES RESULTING FROM DELAY REGARDLESS OF THE REASON S Shortages or errors must be reported within fifteen 15 business days from receipt of shipment to secure adjustment No merchandise may be returned without securing written approval from Seller Seller will notify Buyer promptly of any material delay and will specify the revised delivery date as soon as practicable Seller shall not be liable for any delay in delivery or performance or for any failure to manufacture deliver or perform due to a any cause beyond its reasonable control b any act of G
40. n safe operating practices on the part of its personnel In no event shall Seller be responsible for any injuries to persons or property caused by defects in any equipment including by way of illustration and not limitation any pumps compressors fittings connections components piping or hoses up to the point that same are connected to the product Buyer agrees to indemnify and to save Seller harmless from any and all liability or obligation incurred by or against Seller including costs and attorneys fees to or by any persons injured directly or indirectly in the operation of the equipment furnished under the following conditions a if Buyer fails to purchase and use necessary and appropriate safety devices and guards as determined and or recommended by Seller b if Buyer fails to maintain in good working order such safety devices and guards as are purchased from Seller c if Buyer adds omits repairs modifies replaces or substitutes any components on the equipment without permission from Seller 866 795 1586 e WWW STONEAGETOOLS COM d if Buyer exceeds at any time the maximum safe loads pressures speeds recommended by Seller for the equipment furnished hereunder without the specific written consent of Seller or e if Buyer otherwise fails to operate the product or equipment in accordance with Seller s printed instructions or otherwise negligently operates the equipment 5 Delivery Seller is not obligated to
41. od act of Buyer act of civil or military authority governmental priority strike or other labor disturbance flood epidemic war riot delay in transportation or car shortage or c inability on account of any cause beyond the reasonable control of Seller to obtain necessary materials components services or facilities In the event of any such delay the date of delivery or of performance shall be extended for a period equal to the time lost by reason of the delay 6 Technical Advice All technical advice recommendations and services of Seller are intended for use by persons having adequate skill at their own risk and Seller assumes no responsibility and Buyer hereby waives all claims against Seller for results obtained or damages incurred from the use of Seller s advice recommendations and services 7 Modification These Terms and Conditions are intended by Seller and Buyer to constitute a final complete and exclusive expression of agreement and cannot be supplemented or amended without Seller s prior written approval Seller s waiver of any breach or failure to enforce any of the Terms and Conditions at any time shall not in any way affect limit or waive Seller s right thereafter to enforce and compel strict compliance with every Term and Condition thereof If any provisions of these Terms and Conditions are held to be invalid or unenforceable such invalidity or unenforceability shall not affect the validity or enforceab
42. re water away from the Boiler Tube Cleaner BTC AWARNING Always turn off pump system before servicing or replacing any parts Failure to do so can result in severe injury and or death ELBOW TRAVEL ROTATE ROTATION IN CH SC CONTROL HOSE FEED HOSE FEED SPEED HOSE FEED SPEED REV CONTROLS gt gt DIRECTION CONTROL CONTROL BOX REAR VIEW ku PNEUMATIC DUMP CONTROL FITTING 1 4 IN OD TUBING NOT INCLUDED SUPPLY FITTING 866 795 1586 e WWW STONEAGETOOLS COM PRE RUN CHECK Refer to WJTA IMCA s Recommended Practices For The Use Of High pressure Waterjetting Equipment and or The Water Jetting Association s WJA Code of Practice for additional safety information STORAGE TRANSPORTATION AND HANDLING When moving the BTC BTC 100 lift with care to prevent bodily injury Complete a job specific risk assessment and act on the resulting actions Ensure the waterblasting zone is properly barricaded and that warning signs are posted Adhere to all site safety procedures Ensure no personnel are in the hydroblasting zone Ensure the work place is free of unnecessary objects e g loose parts hoses tools Ensure all operators are using the correct Personal Protective Equipment PPE Ensure whip checks hose whips and all other applicable safety devices are installed and set up properly Che
43. that Seller suffers or incurs by reason of any such unintended use d Notice of defective product or service must be given in writing to Seller by Buyer or User within fifteen 15 business days following receipt of goods Buyer or User shall keep such products or services in an unaltered condition for examination by Seller s representative No goods may be returned for credit or adjustment without prior written permission from Seller 4 Product Liability Buyer specifically acknowledges that the products being purchased may be operated at high speeds and or pressures and that as such they may be inherently dangerous if not used correctly Buyer shall be solely responsible for the safe operation of the products at all times and for determining the safety devices and guards that may be required for the safe operation of the products Buyer shall undertake to specify and order all safety devices and guards necessary for the safe operation of the equipment covered All safety devices and guards offered in Seller s quotations are recommended for purchase Seller may provide necessary safety devices and guards not offered in this quotation at an extra price in accordance with the specifications of Buyer Buyer shall at all times use and require its employees to use all necessary and appropriate safety devices guards and proper safe operating procedures Buyer shall not remove or modify any such devices guards or warning signs and shall insist o
44. to allow the Elbow Rotator Tractor Hose Drive and Hose Containment System to be assembled Setup on site in easier if all of these are already mounted on a rail section MUD DRUM DRIVE SLOTS SLOTTED RAIL DRIVE SLOTS EXPANSION L PARALLEL TO RAIL BR 008 WEDGE BOLT BTC 120 CLAMP 1 Place the BTC 120 Clamp under the rail at the point where the rail contacts the man way Make sure the clamp end is outside the manway and the hook end is inside the man way Hook the clamps inside the manway flange 2 Hand tighten the two Acme nuts onto the threaded rods to pull the BTC 120 Clamp against the face of the man way Use wrench to tighten the two clamps to 100 in lb 11 3 Nm 8 P 866 795 1586 e WWW STONEAGETOOLS COM ASSEMBLY INSTALLATION AND CONNECTION HELIX ROTATOR AND HELIX TRACTOR TO RAIL ASSEMBLY HLXR 100 HELIX ROTATOR 1 Install the Helix Rotator onto the rail Loosen the bar knobs position it on the and tighten the bar Knobs to 50 in Ibs 5 65 Nm Make sure the roller grooves engage the rail and the Chasis Clamp is completely closed Note the Helix Rotator can also be installed by sliding it over the end of the rail HLXR 100 ROTATOR ASSEMBLY CHASIS CLAMP ROLLERS HLXT 100 HELIX TRACTOR 1 Install the Helix Tractor onto the rail behind the Helix Rotator as illustrated Loosen the bar knobs position it on the rail and tighten the bar Knobs 50 in llbs 5 65 Nm Make sure t
45. uency Maintenance Required Gearbox oil level for HLXT 100 HLXR 100 Every 100 Hours of use Fill with Mobil and SCH 634 synthetic gear oil See individual and HLD 100 part diagram pages for gearbox fill orientations All air fittings Before each use Inspect threads for wear or damage Carriage rollers may continue to function normally after some wear Roller replacement is required when wear begins to affect the Drive movement in forward or reverse All air fittings After each use Apply small amount of air tool oil directly into the forward and reverse fittings Then briefly operate the controls at slow speed for a short duration in each direction to coat the interior parts of the motor Install the dust caps onto all three fittings to keep moisture and dirt out Carriage rollers Every 100 Hours of use Lubricate Zerks all Carriage Rollers using any multipurpose NLGI 2 grease Sprockets Often Inspect teeth for wear and repace if hose skips or jams Contact StoneAge for Safety Data Sheets for material usage a complete list of spare part numbers and service instructions for the Boiler Tube Cleaner BTC 100 and Control Box Mobil and SCH are registered trademarks and or trademarks of ExxonMobil Loctite and Blue 242 are registered trademarks of Henkel AG amp Co KGaA MANUAL TUBE LOCATION INSTRUCTIONS It is possible to track the distance location of each tube usin
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