Frequently Asked Questions
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.
Until the operator is familiar with HTP sizes, simply match the internal diameter of the HTP and nozzle by eye. Use the projectile sizing charts to select the recommended nozzle and projectile.
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 it 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 the safety bar/release mechanism is locked in position. Check for restrictions in the air hose and ensure the gas is turned on.
If gas pressure is too low, the correct sized projectile may become lodged in the HTP. A smaller projectile will need to be used, resulting in greater use of projectiles than 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 likely 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., the trigger might be difficult to depress or release gas. If the trigger does not close, follow these steps: Disconnect the quick release coupling from the launcher. Tap the launcher lightly against a firm object. Turn off the gas supply at the nearest convenient point.
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. 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".
a. Capsules are made from heat-shrinkable PVC film and they are recyclable.
a. The UC-CSS-230v is a brushless unit designed for continuous use.
CLEAN SEAL FLANGE:
a. The UC-CSS-230v is a brushless unit designed for continuous use.
Standard vents or breather caps do not prevent the most harmful elements from entering your system. Ultra Clean® breathers remove particles of 2 micron and larger before they cause harm. They also remove airborne water vapor which causes chemical changes, sludge, corrosion, and more.
Water is present in three forms: dissolved, emulsified, and free. Even if you don't see it, it’s still there and causing damage like rust, sludge, acids, and corrosion, shortening fluid life and damaging equipment.
Both are necessary. Downstream filters remove contaminants already in the system, while breathers prevent contaminants, like abrasive particles and water, from entering the system.
Airflow in and out of the tank determines the breather size, not the tank size. The D-Series handles up to 35 cfm (260 gpm), while the Steel Breather Model M-107 handles up to 300 cfm (2250 gpm).
Breathers should be mounted vertically or at a 45º angle to ensure proper airflow. In a horizontal position, air could bypass the silica gel, allowing wet air to enter the tank.
Breathers can be mounted remotely using tubing or pipes, but ensure there is no obstruction or leaks in the line to maintain proper airflow.
The return on investment is substantial. By extending fluid life and preventing expensive equipment failures, Ultra Clean® breathers save more money than they cost.
The lifespan of a breather depends on factors like frequency of breathing, silica gel quantity, and ambient humidity. Generally, breathers last 3 to 6 months in industrial settings.
Each Ultra Clean model has a maximum water capacity that depends on the amount of silica gel inside. Silica gel can hold up to 40% of its weight in water under ideal conditions.
The silica gel turns from gold to dark green/blue when it reaches capacity. If the gel is fully saturated, it’s time to replace the breather.
It’s unlikely. The 2-micron filter cloth self-cleans through a process called 'backflushing,' where particles are expelled when air flows out of the tank.
Check local regulations for solid waste disposal. If the breather is used with regulated fluids, it should be disposed of according to the same guidelines.
No, unless water is sprayed directly upwards into the top cap. Normal washing and splashing won’t reduce breather life.
It’s possible. While the breather is sturdy, dropping it from a height could crack the acrylic tube, allowing contaminants to enter. Replace any damaged breathers.
No. The design of the breather makes it impossible to replace the silica gel without breaking the unit.
The wide variety of applications requires different adapters for easy installation. Sales sheets describe the use of each adapter.
Yes. Ultra Clean breathers are designed for rugged environments, including the 'R-Series' for severe vibration and 'Steel Breathers' for harsh conditions.