Elliott RECON 2500 Handbuch

www.elliott-tool.com

Tube & Pipe Cleaners Tube Testers Tube Plugs Tube Removal Tube Installation

Tube Leak Test Gun - Pressure

Operating and Maintenance Instructions

2500

TABLE OF CONTENTS

Introduction .......................................................................................................... 4

Safety Guidelines ................................................................................................. 5

General Information.............................................................................................. 6

Operation Instructions.......................................................................................... 8

Seal Sets & Support Tubes .................................................................................. 8

Technical Information ........................................................................................... 9

Parts List & Diagrams........................................................................................... 9

Maintenance Instructions ................................................................................... 10

Troubleshooting Guide ....................................................................................... 14

Warranty ............................................................................................................. 15

RECON 2500 Tube Leak Test Gun

INTRODUCTION

Thank you for purchasing this Elliott product. More than 100 years of experience have been employed

in the design and manufacture of this control, representing the highest standard of quality, value and

durability. Elliott tools have proven themselves in thousands of hours of trouble-free eld operation.

If this is your rst Elliott purchase, welcome to our company; our products are our ambassadors.

If this is a repeat purchase, you can rest assured that the same value you have received in the past

will continue with all of your purchases, now and in the future.

The RECON 2500 Tube Leak Test Gun has been designed for the following types of equipment:

Heat Exchangers

Condensers

Chillers

Evaporators

Air Conditioners

If you have any questions regarding this product, manual or operating instructions, please call Elliott at

+1 800 332 0447 toll free (USA only) or +1 937 253 6133, or fax us at +1 937 253 9189 for immediate

service.

ECON 2500 Tube Leak Test Gun

SAFETY GUIDELINES

Read and save all instructions. Before use, be sure everyone using this tool reads and understands this

manual, as well as any labels packaged with or attached to the machine.

• CAUTION: Pinching Hazard located between Backup Washer and Cylinder Nose. Do not

place ngers in this location during operation.

• CAUTION: Operators should always wear safety glasses and a face shield when

operating this tool.

• Prior to testing, the tubes should be cleaned and any loose deposits or scale should

be removed. If the tubes have not been cleaned any foreign materials present may

be ejected during the testing operation and may damage the test guns or injure the

operators.

• Use Proper Accessories. Use Elliott accessories only. Be sure accessories are properly

installed and maintained.

• Maintain Labels and Nameplates. These carry important information and will assist you

in ordering spare and replacement parts. If unreadable or missing, contact an Elliott

service facility for a replacement.

Operators should always wear safety glasses and a

face shield when operating this tool.

CAUTION

Pinching Hazard located between Backup Washer

and Cylinder Nose. Do not place ngers in this

location during operation.

RECON 2500 Tube Leak Test Gun

GENERAL INFORMATION

RECON Series 2500 (TTP2500) Kit Includes:

Tube Leak Test Gun Set – Pressure

Support Tube Assembly (TTPST4)

Washers to support up to 2.456” (62.4mm) Seals (BW1700, BW2090, BW2600)

Tool Case

Start-Up

If the tubes have been chemically cleaned, please check with Elliott Tool regarding the compatibility of

the test gun seals with the cleaning agent.

Make sure the test guns have the correct size Seal and Washer Set on them for the tubes being tested

(see chart above). Seal and washer sets contain two seals and four washers. The seals and washers

are considered to be correctly sized if the OD of the seal is between 0.030” to 0.050” (0.76 mm to 1.27

mm) smaller than the actual tube ID. Using seals that are too small may cause the following: premature

seal wear, jamming of the test gun in the tube, or expulsion of the test gun from the tube end. Using

seals that are improperly sized may cause inability to pull a vacuum on tube end.

Range

Support Tube

Assembly

Part Number

Support Tube Washer Set

1.240” - 1.630” (31.5 mm - 41.1 mm) TTPST4 TTPST4 BW1700

1.640” - 2.030” (41.6 mm - 51.6 mm) TTPST5 TTPST4 BW2090

2.040” - 2.456” (51.8 mm - 62.4 mm) TTPST6 TTPST4 BW2600

ECON 2500 Tube Leak Test Gun

GENERAL INFORMATION

Installing Replacement Seals

Replacement seals for the RECON 2500 test guns are always supplied with the corresponding size

washers. Always replace the seals and washers on both guns at the same time. Under optimum

testing conditions you should be able to test between 500 to 1000 tubes per replacement Seal and

Washer set.

1. Remove the locknut from the end of the Support Tube and set it aside.

2. Remove the Seal and Washer Set from the Support Tube. Discard if worn.

NOTE: If you are changing the Seal and Washer Set to test a different size tube, it may be

necessary to change the back-up washer as well.

3. Assemble the Support Tube and Seal and Washer Set as shown below.

NOTE: When replacing the locknut on the support tube do not use a wrench, screw it on

nger tight only. A small space between the locknut, seal and washer set, and back-up

washers is normal. There will be enough stroke in the air cylinder to compensate for this

space.

Other Replacements and Repairs

Under no conditions should you attempt to service the air cylinders. Any attempt will void any and all

remaining warranties, implied or otherwise.

Seal

Part number varies.

See chart on page 9.

Washers

Part number varies.

See chart on page 9.

Backup Washer

TTPST4 Assembly: BW1700

TTPST5 Assembly: BW2090

TTPST6 Assembly: BW2600

Locknut

Support Tube

TTPST3-030

RECON 2500 Tube Leak Test Gun

OPERATION INSTRUCTIONS

The RECON 2500 Test Guns come as a set. This set is comprised of: an air injection gun and a

plugging gun. The air injection gun can be differentiated from the plugging gun because it incorporates

the valve block and air regulator.

1. Attach air supply to both guns. The RECON 2500 test guns will be operational on plant air

supplies ranging from 40 to 125 psi (2.7 to 8.6 Bar) at a minimum of 5 cfm. The maximum

test pressure of the tube is dependent on the tube ID and the air supply pressure (see

Table 1).

2. On the air injection gun, turn the adjusting nut on the air regulator counterclockwise to set

the tube testing pressure to zero.

3. Insert the air injection gun into one end of the tube to be tested and the plugging gun into

the other end. The seal should be fully into the tube and the backup washer should be

against the tube end.

4. Press the the top button for actuating the cylinder of the air injection gun, and press the

air control valve on the plugging gun and hold until the guns are rmly held in the tubes.

Release both buttons.

5. Press the the bottom button for pressurizing the tube on the air injection gun and adjust

the air regulator clockwise until the desired tube test pressure is achieved (use Table 1 for

maximum tube test pressures available).

NOTE: The air pressure regulator must be readjusted if testing different size tubes or if air

supply pressure changes.

6. Both injection gun and plugging gun operators should observe the pressure gage on their

respective guns. Any decrease in the pressure will indicate a leaking tube.

7. Press the bleed valve on the injection gun between the gage and the cylinder body to

bleed off the air pressure in the tube. After the tube test pressure has bled to zero, press

the bleed valve on both guns to release the pressure in the cylinder and relax the seals.

8. Remove the test guns and move on to the next tube. Mark each leaking tube encountered

for repair. The total operation should be completed in 5 to 10 seconds. Your actual testing

time will depend on the amount of time you choose to hold the pressure test.

9. Repeat steps 3 through 8 for each tube to be tested.

TABLE 1 – Maximum Tube Test Pressure Versus Air Supply Pressure And Tube ID

Nominal

Tube Size

Air Supply Pressure - PSI

40 60 80 100 125

Maximum Test Pressure - PSI

1-1/4” 40 60 80 100 125

1-1/2” 30 40 50 60 75

1-3/4” 20 30 40 50 60

2 15 20 25 30 35

2-1/4” 10 15 20 25 30

2-1/2” 5 10 15 20 25

ECON 2500 Tube Leak Test Gun

SEAL SETS & SUPPORT TUBES

Replacement Support Tube Sets & Optional Extensions

Tube ID Range

4” (Std.)

(101.6mm)

Part #

12”

(305mm)

Part #

24”

(610mm)

Part #

36”

(914mm)

Part #

48”

(1,219mm)

Part #

0.282”-0.510”

(7.2-13mm) TTPST1 TTPST1-12 TTPST1-24 TTPST1-36 TTPST1-48

0.532”-0.856”

(13.5-21.7mm) TTPST2 TTPST2-12 TTPST2-24 TTPST2-36 TTPST2-48

0.857”-1.230”

(21.8-31.2mm) TTPST3 TTPST3-12 TTPST3-24 TTPST3-36 TTPST3-48

1.240”-1.630”

(31.5-41.4mm) TTPST4 TTPST4-12 TTPST4-24 TTPST4-36 TTPST4-48

1.640”-2.030”

(41.6-51.6mm) TTPST5 TTPST5-12 TTPST5-24 TTPST5-36 TTPST5-48

2.040” - 2.456”

(51.8-62.4mm) TTPST6 - - - -

For larger seal and washer sizes, contact factory. Support Tubes are backwards-compatible. Extensions for TTPST6 available upon

request.

RECON 1250 & 2500 Seal Sets

Tube OD

BWG

8-9 10-11 12-13 14-15 16-17 18-19 20-24

1/2” (12.7mm) - - TTPS250 TTPS300 TTPS340 TTPS370 TTPS400

5/8” (15.9mm) TTPS270 TTPS340 TTPS370 TTPS440 TTPS470 TTPS500 TTPS530

3/4” (19.1mm) TTPS400 TTPS440 TTPS500 TTPS530 TTPS590 TTPS620 TTPS650

7/8” (22.2mm) TTPS530 TTPS590 TTPS620 TTPS690 TTPS720 TTPS750 TTPS780

1” (25.4mm) TTPS650 TTPS690 TTPS750 TTPS800 TTPS840 TTPS870 TTPS900

1-1/8” (28.6mm) TTPS780 TTPS840 TTPS870 TTPS940 TTPS970 TTPS1000 TTPS1030

1-1/4” (31.75mm) TTPS900 TTPS940 TTPS1000 TTPS1070 TTPS1090 TTPS1120 TTPS1150

1-3/8” (34.9mm) TTPS1050 TTPS1090 TTPS1120 TTPS1190 TTPS1230 TTPS1250 TTPS1280

1-1/2” (38.1mm) TTPS1150 TTPS1190 TTPS1250 TTPS1310 TTPS1340 TTPS1370 TTPS1400

1-5/8” (41.3mm) TTPS1280 TTPS1340 TTPS1370 TTPS1440 TTPS1470 TTPS1500 TTPS1530

1-3/4” (44.5mm) TTPS1400 TTPS1470 TTPS1500 TTPS1550 TTPS1590 TTPS1620 TTPS1650

2” (50.8mm) TTPS1650 TTPS1700 TTPS1750 TTPS1800 TTPS1840 TTPS1840 TTPS1900

2-1/4” (34.9mm) TTPS1900 TTPS1950 TTPS2000 TTPS2050 TTPS2090 TTPS2120 TTPS2150

2-1/2” (63.5mm) TTPS2150 TTPS2200 TTPS2250 TTPS2290 TTPS2340 TTPS2370 TTPS2400

Seal sets contain two seals and four washers. Seal sets TTPS250 through TTPS440 contain 4 seals and 4 washers.

Standard seal material is neoprene. Seals are backwards-compatible.

RECON 2500 Tube Leak Test Gun

ITEM

#PART DESCRIPTION NO.

REQ

PART

NUMBER

1 CYLINDER NOSE 1 TTP2500-120

2 PISTON 1 TTP2500-123

3 O-RING, AS568 - 114 1 P8309-12

4 CYLINDER BODY 1 TTP2500-121

5SOCKET HEAD CAP SCREW, #8-32 X 3/4 8 P8302-20

6 GASKET 1 TTP2500-140

7 PIPE TEE 1 TTP2500-185

8BUTTON HEAD CAP SCREW 2 TTP2500-178

9 O-RING, AS568 - 330 1 P8309-330

10 VALVE BLOCK 1 TTP2500-187

11 SPRING 1 37-72190

12 BLEED VALVE 2 TTP1250-177

13 ADAPTER TEE 1 TTP2500-174

14 ELBOW 1 TTP2500-161

15 CYLINDER CAP 1 TTP2500-122

16 TEE 1 TTP2500-163

17 VALVE ACTUATOR 1 TTP2500-176

18 POPPET VALVE 1 TTP2500-175

19 HANDLE HALF 1 TTP2500-150

20 BUTTON HEAD CAP SCREW 4 TTP1250-173

22 PRESSURE GAUGE 1 TTP2500-190

21 PRESSURE REGULATOR 1 TTP2500-179

23 LABEL 1 ETTLBL1800A

24 ELASTIC LOCKNUT, #4-40 6 546GSS

25 GASKET 1 TTP2500-141

26 HANDLE HALF 1 TTP2500-153

27 HANDLE HALF 1 TTP2500-152

28 BUTTON HEAD CAP SCREW 8 TTP1250-170

29 SUPPORT BRACKET 4 TTP1250-171

30 HANDLE HALF 1 TTP2500-151

31 1/4 NIPPLE 1 41-6534K56

32 CHECK VALVE 1 TTP2500-164

33 1/8 NPT PLUG 1 P548015

34 MALE CONNECTOR 1 TTP2500-162

35 LABEL (NOT SHOWN) 1 TTP2500LBL-1

36 TUBING (NOT SHOWN) 12 41-5156K87

37 THREADED STUD (NOT SHOWN) 1 TTP2500-138

38 NEEDLE ROLLER (NOT SHOWN) 4 P8573-17

TUBE LEAK TEST GUN - PRESSURE

TTP2500-100

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