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Listed below are some commonly asked questions and answers regarding the Ultra Clean Technologies Cleaning System. The most important factor when using the system is to exercise common sense at all times. If there is any chance a projectile may become lost in the system, do not attempt to fire one into the HTP (hose, tube or pipe).

Pour some water or spray a little WD40 down the HTP and operate the pneumatic launcher, without a projectile, from the other end and blow the projectile out. The water or WD40 will loosen the wedged projectile and allow it to continue its course. Make sure that the fluid you are using to lubricate and soften the projectile is compatible with the HTP application.

Place the launcher at the other end of the HTP and, without a projectile, fire the unit. This should remove the wedged projectile. Providing the restriction is not too great, fire a smaller projectile through to complete the cleaning process. If the restriction is too large, dismantling will need to occur.

Make sure the HTP is consistent in diameter for the full length. Fire the launcher without a projectile to make sure it is not blocked and there is good airflow. Fire a smaller than recommended projectile. If comfortable, use the recommended size. If after this process the projectile becomes lodged, fire the unit from the other end by using a flexible hose, tube or adapter. Continue to clean with a smaller projectile.

If the projectile does not expel from the nozzle, remove the nozzle with the projectile, turn and place the outlet of the nozzle onto the air hole on the launcher and depress the trigger. Make sure it is pointed in a safe direction prior to firing. Then select a smaller projectile or correct nozzle.

If a projectile emerges from the HTP and is broken up, it is an indication that the internal wall of the HTP is damaged. Dip the projectile in water and then fire through. If the projectile still appears shredded, it confirms this fact. The water adds a friction modifier as in some cases the HTP can become extremely dry, which in turn tends to shred the projectile. There could also be a sharp object such as a burr inside the pipe or tube. Hydraulic hose may have a broken wire protruding through the hose wall.

No. You never want to re-introduce contamination or used projectiles back into an assembly.

Ultra Clean and abrasive projectiles will not damage the surface, however, grinding projectiles may cause some scratching.

There isn’t a fast method for clearing a clogged HTP prior to cleaning with the system. Blow some air through to see if you have a passage. Once this has been established, send though a smaller than recommended projectile and upon its exit gradually increase the projectile size. If at the outset the contamination build-up is too great to obtain a passage through with air, a chemical may be introduced to soften the contamination. Once this has been established, continue in the normal way with the system.

In the case of a projectile not being able to enter the HTP, the length can be trimmed. It is important that the length is greater than the width so the projectile does not tumble.

Yes. Ultra Clean and abrasive projectiles will negotiate sweeping bends and the Ultra Clean projectiles will handle tight bends.

In past demonstrations, the projectile will travel thousands of feet depending on the ID of HTP and the pressure and volume of your gas source. As long as there is sufficient volume of air behind the projectile, it will keep traveling through the HTP.

Yes. This can be achieved using an Ultra Clean projectile, although, if the build-up has hardened; it will probably require an abrasive or grinding projectile.

Yes. Select the right nozzle to suit the coupling then select the correct Ultra Clean projectile and fire through the line.

Yes, however, this will only occur with full port ball and gate valves and similar designs. The projectile will not go through a non-return valve or butterfly valve or one of similar design.

Yes. There are some important rules when dealing with a tee section. The projectile must be fired into the cross section while at the same time blocking one end of the cross section. Next either reverse the blocked end on the cross section or open both ends of the cross section and block the tube going into the cross section.

Yes, providing the unit is operated down one end of the Y (with the other sealed) and then down the other end of the Y.

No, unless there is a method of blocking off the branch line.

No, the tube must have a consistent ID throughout. The projectile will simply jam onto the fin.

No, the HTP must be disassembled into the three sections to clean.

The projectile must be fired into the pipe going into the tee that is smaller than the cross section.

Yes. The projectile will travel through any configuration such as knots, but the hose must not be kinked more than 40% to 60% (depending on whether it is hose, tube or pipe). If it is kinked too much, the projectile will stop at that point and the launcher will need to be fired from the other end using air only to remove the projectile from the end it entered.

Yes providing the restriction is not too great. This will depend on the size of the tube and the projectile. The smaller the tube, the less tolerance there will be. Also the constriction cannot occur at the beginning of the tube where the projectile is entering. The projectile must already be in the tube to cope with this condition. A coupling projectile would be our recommendation depending on the type of internal contamination.

When copper tube is cut, the end is often burred or the opening is compressed from the cutting process. It is important the tube or pipe is square cut and deburred accordingly.

Try using a hose nozzle and insert it into the tube or pipe rather than over it and use the appropriate projectile for the application.

Yes providing they can all be sealed off and the projectile will enter the tee the correct way every time.

If the HTP does not accommodate a standard nozzle, try the next sized smaller nozzle. Insert the recommended projectile to suit the HTP, but before firing into the HTP, fire it through the nozzle only to ensure it comes out of the nozzle. (Make sure the pneumatic launcher is pointed in a safe direction).

To make sure an oversized projectile will initially leave the nozzle. This does not mean it will go through the HTP.

Yes, normal operating pressure is 80 psi to 140 psi and it is recommended that 140 psi not be exceeded. A higher pressure can assist in problem contamination.

If the pipe or tube has an uneven cut, and this can’t be rectified by re-cutting, or there is weld splatter, wrap a piece of rubber sheet or cloth around the nozzle and seal the pipe or tube.

Yes, these may assist the cleaning task when there is an excessive build up of contamination. One or two projectiles should follow this up. With regular maintenance using the system, no further chemicals should be required.

This will depend on the chemicals in question. The best method is to soak a projectile in the chemical and see the result prior to using on an application.

Yes, providing no breakdown occurs, it can assist the projectiles task, e.g., in paint lines, the projectiles must be soaked in thinners prior to cleaning lines.

Check that the faceplate is secured properly and safety bar/release mechanism is locked in position. Check for restrictions in the air hose and the gas is turned on.

If gas pressure is too low, the correct sized projectile will possibly become lodged in the HTP. As smaller projectile will need to be used resulting in greater use of projectiles than is necessary.

The distance the projectile will travel is reduced and the time taken for the projectile to clean will be increased. Any restrictions in the HTP will probably cause the projectile to jam when normally it would overcome these easily. Overall, it reduces the effectiveness of the system.

If the gas pressure is too high, the valve and trigger in the launcher may not operate properly, e.g., difficult to depress trigger and release gas, or the trigger does not close and therefore gas is difficult to turn off. If the trigger does not close, follow one of the following procedures:

  • Disconnect quick release coupling from the launcher.
  • Tap the launcher lightly against nearest firm object.
  • Turn off gas supply source at most convenient point.

2 to 3 minutes depending on ambient shop temperatures.

2 to 3 seconds depending on the size. Larger capsules take slightly longer to shrink than smaller ones.

Depends on the size. Assemblies up to ½” ID can fit 3 to 4 lines at a time depending on fitting configuration.

The 230v Clean Seal System will heat up quicker than a 120v ac unit and it draws half the amperage. This efficiency consistently outperformed the 120v models during tests.

The UC-HG-STAND flexible suction-pump stand was designed specifically for use with the UC-HL1910E heat gun. It is not recommended for use on any other industrial heat gun.

The Clean Seal Capsule size is directly related to the hex OD by measuring from point-to-point (not the flats!) on the hex fitting. There is a sizing chart on the Ultra Clean Website and in our Clean Seal System brochures and Product Manual. You may also call our customer service at 800-791-9111 to request copies.

Measure the largest part of the fittings outside diameter (OD). When measuring, go from hex-point to hex-point and not from flat side to flat side to get an accurate measurement.

Yes.

No, not when following Ultra Clean’s capsules-shrinking procedures. The capsules and O-ring style fitting should not be in the Clean Seal System (heat shrink machine or gun) more than 5 seconds maximum when heating unit is at optimum temperature. Fittings and capsules are generally cool to the touch immediately after the capsule is sealed onto the fitting.

Yes, minimum quantities start at 100,000pcs per size per production run. Special tooling for putting your logo, part number, etc. onto the capsules will also need to be purchased.

First, Clean Seal Capsules are easier to install and remove than traditional injection-molded caps and plugs. They fit loosely over the fitting end and conform to the fitting OD when heat is applied. They will not fall off during transportation or handling and they are easy to remove because of the unique built-in tear strip feature. b. Second, Clean Seal Capsules are cleaner than regular caps and plugs. They come pre-stacked so the inside of the capsule is always clean compared to loose caps and plugs that can become contaminated from airborne particles. Sharp male or female threads can cut or shear off pieces of plastic when injection-molded caps or plugs are pushed in or over the threads. The plastic pieces will fall into the inside of the hose or tube creating additional internal contamination that must be removed. The shaving off of plastic can also occur when removing tight fitting caps or plugs.

The heating elements have a 500-hour warranty. With proper usage and maintenance, the heating element can last up to 1,000 hours.

The UC-CSS-230v has a one year warranty on all parts except the heating element. The heating element and the UC-HL1910E heat gun are warranted for 500 hours.

Clean Seal Capsules can be shrunk onto a smooth round surface but you run the risk of the capsule sliding off prematurely. Capsules work best with a fitting shape as they conform to the fittings’ OD making it impossible for them to fall off.

Millimeters make it easy for part numbering and sizing. However, our sizing chart for the Clean Seal Capsules is in both metric and nominal inch.

It is much easier to shrink a capsule onto a fitting with the diffuser. It provides a gentle 360° airflow for even shrinking around the capsule. The force of air coming out of a normal heat gun may blow the capsule off the fitting.

Yes, but it is highly recommended that you use a diffuser. They are available with both a 1½” and 2″ ID connections to attach to your gun and are adjustable +/- to 1/8″.

Capsules are made from heat-shrinkable PVC film and they are recyclable.

The UC-CSS-230v is a brushless unit designed for continuous use.

The universal design of the flange seal means that they will work on all code 61, code 62, Caterpillar and Komatsu flanges as well as round hydraulic hose and tube flanges.

Standard vents or breather caps do not prevent the most harmful elements from entering your system. Most standard breather caps are intended to cover the filler opening on a tank or reservoir and to keep out rain and large solid particles. Most of these are only capable of stopping particles of about 100 micron or larger. Studies have shown that to have a significant effect on abrasive wear, particles of 10 micron or less must be kept out of the system. Ultra Clean® breathers remove particles of 2 micron and larger before they cause the silent destruction of your equipment. Most importantly, standard filler/breather caps do not remove airborne water vapor which causes chemical and physical changes resulting in loss of additive performance, sludge, bacteria growth, and corrosion. Ultra Clean® breathers remove water vapor before it enters the tank or reservoir.

It’s there, even if you don’t see it – and it’s costing you money.

There are three states of water contamination in lubricants, hydraulic fluid, insulating oil, etc.:

DISSOLVED WATER – these molecules are dispersed one-by-one throughout the oil like humidity;

EMULSIFIED WATER – these microscopic globules of water are suspended in the oil like fog;

FREE WATER – settles to the bottom of the tank like rain. All forms of water are generators of other contamination: rust, sludge, acids, soot, bacteria, varnish, and ice. All of these shorten the life of the oil or fluid and the equipment serviced by it.

Downstream filters and dessicant breathers are both important parts of a contamination control system. Harmful contaminants, both abrasive particles and water, enter an enclosed system from three sources: BUILT IN – this is debris from manufacturing and service of the equipment. It includes dirt and dust, burrs, contaminated fluids, etc.; GENERATED – such as mechanical wear, additive precipitation, hose fibers, etc.; INGESTED – which enters the tank or reservoir from the atmosphere. The breather prevents the ingested material from entering the tank and causing harm to the fluids and the equipment. The downstream filter removes contaminants that are already in the system before they do additional harm.

The size of the tank or reservoir does not determine the model of breather to use. The airflow BOTH in and out of the tank, reservoir, or gearbox determines the model to choose. Two factors create airflow. They are temperature variations (which cause very low airflow rates) and fluid volume changes caused by the stroking of hydraulic cylinders or by tanks being filled and emptied.

The D-Series (D-100, D-101, D-102) are rated at 35 cfm airflow. This is the amount of airflow created by 260 gpm of fluid level change. At this airflow rate or fluid level change rate the pressure drop through these breathers will be approximately 1 psi. Pressure drop is an important concern because if there is too much pressure drop created by the resistance to airflow through the breather, the sides of the tank will be subjected to stress and could fracture, creating an implosion or explosion.

Because the hole in the Mini Breathers (Z-131, Z-132, Z-133, Z-134) is smaller (1/2″ female NPT), they are rated for 10 cfm or 75 gpm.

For larger airflow requirements the D-108, which has a 2″ opening, will handle 100 cfm (750 gpm). The Steel Breather Model M-107 has a 3″ standpipe and is rated at 300 cfm (2250 gpm).

Breathers should be mounted in the vertical position, or at least no more than a 45º angle. Even though the Ultra Clean® Breathers are vibrated during assembly to assure maximum filling, the silica gel settles during shipping, creating an air passage above it when the unit is in the horizontal position. Air, like people, takes the path of least resistance, and in this case it would miss the silica gel and would enter the tank undried.

Breathers can be mounted remote from the tank or reservoir. In many applications it is desirable to mount the breather away from the tank for better visibility or better access for changing the units. Remote mounting can be accomplished using tubing or pipes for the air to flow from the breather to the tank. Care must be taken to insure that there is no airflow obstruction in the line and that there are no air leaks after the clean dry air has left the breather. Piping can also be used to achieve a vertical mounting position for the breather where space limitations exist on the tank or reservoir.

The return on investment for any Ultra Clean® breather is very good.

A major bearing manufacturer has stated that bearings can have an infinite life when small particles are removed from the lubricant. Hydraulic fluid will last three, even four times as long if water vapor is kept out of it. A power outage when a transformer fails is staggering. An Ultra Clean   model D-102 will hold up to a pint of water and will filter out 2 micron abrasive particles. The price of a breather is well below the cost of changing hydraulic fluid three times, or rebuilding a gearbox or cylinder, or having electrical shorting in a transformer.

There is no set time frame that an Ultra Clean breather will last. The size of the breather, as well as the environment it is in, will determine the life span of a breather. Generally speaking, a small Mini breather will not have the same life expectancy as a larger Disposable Breather. The useful life of a breather has three variables. They are: Frequency of Breathing means how often does a new batch of wet air pass through the breather. Each time this happens, water vapor is retained and the breather life is shortened. Examples of the extremes would be a storage tank that has fluid drawn out once a day and a hydraulic cylinder stroking every 30 seconds. Quantity of Silica Gel: The water holding capacity of a breather is directly proportional to the amount of silica gel in the breather. Silica gel has the capability to remove up to 40% of its own weight in water. Ambient Humidity in the Work Area: Most users believe that the ambient humidity is the major factor in the life of the breather. However, humidity works for us, as well as against us. As each load of wet air passes through the breather, the air with more humidity brings more water vapor to adsorb, but the silica gel can adsorb more at the higher humidity level. The end result is a small decrease in the life of the breather at higher work area humidity levels, but this is not as significant as the other two life factors. Most breathers in industrial applications will last 3 to 6 months, if sized properly. The first breather put on a tank or reservoir that has been in operation for a period of time will usually have a shorter life than subsequent breathers because it is having to dry air leaving the reservoir as well as coming in. Our customers have used Ultra Clean breathers in nearly every climate possible. Some breathers will last 2 months on a fluid storage tank; some will last over a year. When the silica gel changes from gold to green, it is time to replace the breather.

The “Ultra Clean Maximum Water Capacity Chart by Model” shows how much water vapor each Ultra Clean model holds under ideal conditions; ideal conditions are approximately 70° F and 80% humidity, which, of course, seldom happens consistently. At this combination of humidity and temperature the silica gel will hold approximately 40% of its own weight; therefore, the major factor in a given application is the quantity of silica gel in the breather.

Ultra Clean gives an easy to read indication when it is saturated. As the Ultra Clean adsorbs water the silica gel turns from gold to very dark blue/green. In fact, it looks black to most people. Seeing a light green color throughout the gold is not a signal to replace the breather. When all of the silica gel has changed color, to the very dark blue/green, the breather should be replaced. A breather that still has a small amount of gold color, or even light green color, showing is just as good as a new breather.

In a typical industrial application, it is unlikely that the 2-micron filter cloth will become clogged before the breather has reached its full capacity of water. The filter cloth is a patented polyester knit with the two sides made differently. The side that is placed in the “up” position in the breather is knitted with a loose pile surface that closes to 2-micron when hit by incoming air. When air is expelled from the tank, it goes back through the filter and the knit opens back up (loose) throwing off the particles collected on the top surface. In the filter industry this is called “backflushing.” These particles flow out of the breather with the expelled air creating a self-cleaning process. In extreme situations, such as breathers being constantly covered with dust and a customer is concerned, the Ultra Clean C-Series is available with a 25-micron filter cloth.

Always check local regulations for solid waste disposal. Ultra Clean breathers are manufactured with all materials that can be disposed of as solid waste as defined by local regulations. However, if a breather is used on a tank that contains regulated fluids, the breather must be disposed of in the same manner as required for the fluids.

No, not unless you spray water directly upwards into the top cap of the Ultra Clean breather. Because of the design of our breathers, water cannot enter the breather under normal conditions. Unlike some competing breathers, normal splashing of fluids will not enter the breather. Washing equipment is safe and will not reduce the breather life.

It is possible. Our breathers are made of rugged ABS plastic caps and a high quality acrylic tube, held together by Weld-On glue. While they are sturdy enough to withstand most environments, the acrylic tube can crack if dropped from the top of an 8-ft ladder onto a shop floor. If the tube cracks or breaks, solid particles and water can enter the breather through the crack. It is best to replace any breather that is cracked or broken. We do offer our Steel Breather line of Contamination Control Breathers for harsh environments. These breathers are made of steel plates and hoods and are able to stand up to heavy vibration and extreme conditions.

No. Because of the design of our Disposable breathers, you cannot remove the top or bottom cap of the breather without breaking the breather. Our caps do NOT come off and the silica gel cannot be replaced by the end user.

The wide variety of applications for breathers requires us to make installation for our distributors and customers as easy as possible. (1) A sales sheet describes the application for each of the adapters for the D-Series models. (2) Standard fittings are available to adapt the Mini Breathers to many different male or female connections. (3) The Ultra Clean Splash Sentry adapters are designed for off-road Steel Breather applications where fluid might be splashed into the breather. (4) A sales sheet describes a typical application for the Bypass adapter.

Ultra Clean breathers are designed for rugged environments. Two groups of Ultra Clean products are designed for these applications. The “R-Series” breathers were designed in cooperation with a major U.S. railroad for applications with severe vibration. There is a metal reinforcing plate in the bottom cap and the connection to the reservoir is made with a steel pipe nipple. The Steel Breathers are designed for applications where the units may be used as a step to enter a cab or hit by flying objects or other equipment. They are designed with a 16 gauge steel body.

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