HCT HelioJET C-30 Installation Operation & Maintenance Download Page 11

Start-up 

Preparing for Initial Calibration and Start-up 

After the HelioJET C-30 has been installed, complete the following steps before attempting to start the system. 
 

Precharge Reserve Tank 

Close 2” discharge ball valve.  This will prevent compressed air from entering the discharge piping that feeds the cleaning stations in 
your plant (pg. 12, fig. 6). 
 
Connect air hose line to the 1/4” tank air charge valve located at the rear of the reserve tank (fig. 6). 
 
Charge the reserve tank with air pressure (60-120 psi). 
 
Close 1/4” tank charge valve, remove air hose, and connect it to the air actuated steam valve (fig. 6).  Charging the tank is a one time 
procedure.  It should not be necessary to repeat except during times of maintenance. 
 

Pump Rotation

 

Be sure the manual steam valve is closed and the manual water supply valve is open.  Turn the power switch on and off quickly.  The 
pump shaft should turn in the direction of the arrow located on the pump housing. 
 

Pump Air Lock 

Remove any air that may be trapped in the pump by loosening the release plug on the upper portion of the pump body housing.  The 
pump may be off, but the manual water supply valve feeding the system must be open. 
 

Remove Condensate 

Be sure all condensate from the steam line has been purged and that the steam trap is working properly. 
 

Two Adjustments 

There are two adjustments on your HelioJET C-30.  You will make them during the initial calibration and start-up procedure in the 
next section.  Please refer to pages 7 and 12 to familiarize yourself with the location of the 

handwheel adjustment

 and the 

high-low 

pressure switch

.  After you have located these two components, you may begin the calibration and start-up procedure.  Please do not 

arbitrarily make adjustments. 
 
Follow proper procedures as covered in the initial calibration and start-up section below. 

Initial Calibration and Start-up 

Before attempting to start this system, be sure it has been installed in accordance with all previous instructions, and that the proper 
procedures have been followed.  If you have any questions, contact the HelioJET Technical Service Department at 1-800-444-3546. 
 
Please read all

 

of the following steps before beginning, and be sure to follow them in proper order: 

 

Step 1.

  Be sure the handwheel adjustment is turned clockwise to fully bottomed position. 

 

Step 2.

  Adjust pressure switch (upper dial) to 350 psi.  Note, if the maximum scale reading on your pressure switch is 600 psi, then 

adjust the upper dial to 575 psi (see pg. 12, fig. 5). 
 

Step 3.

  Open manually operated water and steam supply valves to system (be sure all condensate has been drained from the steam 

supply line). 
 

Step 4.

  Turn the HelioJET power switch on.  Water will flow to drain from the start-up/overflow. 

 

Step 5.

  Observe the start-up vacuum gauge, and begin turning the handwheel counter-clockwise.  At some point the gauge will 

suddenly read a vacuum.  Continue to turn the handwheel rapidly in the same direction until the vacuum reading is 

10 inches

.  The 

handwheel is now calibrated, do not continue to adjust it.  Observe the discharge pressure gauge.  Pressure will build in the reserve 
tank and the start-up/overflow will cease to discharge water to the drain until the system reaches its maximum pressure.  At that time 
one of the following two things will occur:   

 

 

 

              

                                                                             11 
 
 
 
A.  The reading of 10” on the start-up vacuum gauge

 

will go to 0, the system will continue to run, but water will again flow to the 

Summary of Contents for HelioJET C-30

Page 1: ...HelioJET Model Central Cleaning C 30 System HelioJET Cleaning Technologies 57 North Street Suite 120 LeRoy NY 14482 Tel 585 768 8710 Fax 585 768 9209 Installation Operation Maintenance M C030 03 ...

Page 2: ...of Contents Important Safety Precautions 3 How it Works 4 5 Installation 6 10 Start up 11 13 Trouble Shooting 14 15 Preventative Maintenance 16 19 Major Components and Spare Parts 20 22 Limited Warranty 23 2 ...

Page 3: ...ose 3 ALWAYS allow hose a minimum 9 inch bend radius 4 ALWAYS check hose for kinks or abrasions that may develop into a rupture 5 ALWAYS use hardware valves fittings quick disconnects etc which are rated for the maximum discharge pressure at which you could be operating REMEMBER The HelioPAC is a powerful fluid pressure amplifier and condenser which can multiply the inlet pressure several times Fo...

Page 4: ... This transfer causes a significant increase in the temperature and velocity of the incoming water The HelioPAC converts this velocity to pressure increasing the pressure of the incoming water up to 10 times 4 Liquid Vapor Secondary Inlet Optional Start up Overflow Discharge High Velocity Stream Water Supply Steam Supply Start up Overflow to Drain High Velocity Hot Water Supersonic Steam Flow Velo...

Page 5: ...3 and the stabilizer pump 4 which sends cold water through the water inlet line to supply the HelioPAC 7 The flowing water closes the flow switch circuit 5 which energizes the air actuated steam valve 6 allowing steam to flow to the HelioPAC where it encounters the incoming water The HelioPAC starts and fills the reserve tank to the desired pressure as set by the pressure switch When the pre set p...

Page 6: ... from supply mains increase pipe diameters feeding the unit Avoid the use of restrictive devices in piping such as regulators etc Before actually connecting supply lines thoroughly flush them to remove any debris that may plug orifices within the system and impede start up Steam Supply The HelioJET C 30 requires a 1 1 2 dedicated steam supply line Install a manual shut off valve steam strainer pre...

Page 7: ...rge Line to Plant 2 NPT 10 Thermometer 4 Start up Overflow to Drain 1 1 4 NPT 11 Handwheel Adjustment 5 Electrical Control Box 12 Power Switch 6 Steam Trap 3 8 or 1 2 NPT sold separately 13 High Low Pressure Switch 7 Pressure Reserve Tank 120 Gallon A S M E rated 600 psi MWP Figure 3 10 48 74 7 5 13 1 4 2 12 9 HelioPAC 11 8 3 10 7 6 ...

Page 8: ...ly The standard C 30 system is wired to accept a 3 phase 460 volt supply This can be modified to customer specification before shipment All internal control wiring and components such as starter overload etc are included in the package Caution Never run a permanent air line to the reserve tank always disconnect after charging High Pressure Discharge Piping To supply pressurized hot water to spray ...

Page 9: ...Steam Probe Drwg D00350 Three Phase 460V Alarm Light Condensate Indicator 8 6 2 4 7 1 3 5 High Probe Reference Probe Ground Tank if metallic may be used instead of reference probe Solid State Relay Module 9 10 11 Steam Probe Relay Push to Test 1 1 2 6 7 2B Pressure Switch Discharge Solenoid Water Solenoid Steam Solenoid Flow Switch Main Switch 9 9 9 3 4 5 1 ...

Page 10: ... Air Supply Valve 9 Foaming Nozzle 10 S 10 Spray Gun up to 8 GPM 11 1 2 Hose Swivel 12 3 4 Quick Disconnect Fem 13 3 4 Quick Disconect Male 14 3 4 Foam Hose 15 1 2 Spray Hose 16 3 4 X 1 2 Bushing 17 Detergent Pick up Tube Note Items 12 and 13 are optional and serve to make the spray gun and hose mobile 17 16 14 15 S 10 Spray Gun Typical Hot Foam Sanitize Installation and Rinse Station 10 Figure 4 ...

Page 11: ...ave located these two components you may begin the calibration and start up procedure Please do not arbitrarily make adjustments Follow proper procedures as covered in the initial calibration and start up section below Initial Calibration and Start up Before attempting to start this system be sure it has been installed in accordance with all previous instructions and that the proper procedures hav...

Page 12: ...on and start up only Once the handwheel and pressure switch have been adjusted it is only necessary to follow the routine start up and shut down procedure described below During times of clean up the HelioJET can be left on It will cycle on and off as pressurized hot water is used for clean up purposes If the system is to be turned off until the next clean up period follow these routine start up a...

Page 13: ...ter Tank Air Charge Valve Steam In To Spray Stations 2 Discharge Ball Valve System On Off Switch Start Up Overflow Initial Calibration Start up High low Pressure Switch Figure 5 High Setting upper dial Low Setting lower dial C 30 System Figure 6 Power Switch Discharge Pressure Gauge Discharge Thermometer Start Up Vacuum Gauge Set at 10 vacuum Start Up Overflow Drain Air Actuated Steam Valve Steam ...

Page 14: ...If the flow switch does not function properly it may prevent the opening of the steam valve Refer to page 15 Flow Switch Maintenance in the Preventative Maintenance section of this manual Problem I turned the power switch off while the system was in the midst of a cycle building pressure in the reserve tank When I turned it on again it started to overflow and would not stop Solution Reduce the pre...

Page 15: ...piping routed overhead It should be at a declining level to the drain for proper start up D Is start up overflow line at least 1 1 4 in diameter and completely free from obstructions Never plug restrict or valve off the overflow E Inspect the internal condition of the overflow check valve If check valve seat is lodged or damaged it can obstruct the overflow line This may prevent start up disturb t...

Page 16: ...ir actuated steam valve When water supply to the HelioJET is adequate the flowing water lifts the metering disc which raises the magnet The magnet completes the circuit allowing power to the steam valve If the flow switch does not function properly it will affect steam valve operation Inspect the magnet and other components to be sure they are intact Body Housing Bonnet Assembly Flow Switch 5 1 2 ...

Page 17: ...noid Does air continuously leak from the solenoid even when the system is not running If so replace the solenoid Air Actuated Steam Valve 1 2 3 4 Valve Body Actuator Head Assembly Steam out Steam in Steam Valve Part Components Number Complete Valve Assembly S AVP 1 1 2 01 Actuator Head Assembly ACT 12 Pilot Assembly S PV 01 1 Conduit Plug CP 01 2 Solenoid SOL 01 3 Adapter ADA 01 4 Valve Seat 17 RK...

Page 18: ...psi If it is less you may have lost some of the charge If no air discharges from the gun at all the air cushion has been depleted and it must be replenished B Excessive noise can also be caused by a faulty overflow check valve If the overflow check valve does not seat properly it can actually cause excessive air intake through the start up overflow line This can result in increased noise level If ...

Page 19: ...he air cushion in the reserve tank may become depleted A reduction in air intake as a result of low vacuum is usually accompanied by an increase in noise B Plugged Air Intake The air nozzle and air check valve must be clean and open in order for the HelioJET to properly draw in air from the atmosphere To check whether or not the air intake is clean and open for free air flow be sure the start up v...

Page 20: ...ber 1 Handwheel 200189 375 2 Dowel Pin 615008 3 Shaft 100135 4 O Ring 611002 5 Plug 200469 6 O Ring 611024 7 Bracket 100122 121 8 Water Jet 200434 XXX 9 Dowel Pin 615004 10 O Ring 611019 11 Body 400051 12 O Ring 611041 13 Mixing Chamber 100134 14 Amplifier 100137 15 O Ring 611042 16 O Ring 611043 17 Manifold 300101 18 Lockwasher 6 613001 19 Screw 6 612023 20 Hex Nut 614011 21 Lockwasher 613008 22 ...

Page 21: ...HelioJET Major Components C 30 21 8 7 6 4 3 2 5 1 19 17 18 14 13 12 11 10 9 26 27 20 21 23 24 22 28 25 15 Front View Rear View 16 ...

Page 22: ...ower Switch 629091 15 Air Check Valve CV 1 4 03 16 Air Nozzle 100054 0016 17 Quick Disconnect Nipple steam valve air supply 631001 18 Air Actuated Steam Valve S AVP 1 1 2 01 19 Start up Vacuum Gauge 620037 20 Tank Check Valve 1 CV 1 02 21 Tank Check Valve 2 CV 1 02 22 Tank Air Charge Valve BV 1 4 01 23 Safety Relief Valve RV 600 04 24 Quick Disconnect Nipple tank air charge 631001 25 Quick Disconn...

Page 23: ...ructions To obtain service under this warranty the defective product must be returned to HCT s factory in LeRoy New York together with proof of purchase failure date and supporting installation data Any defective products to be returned to the factory must be sent freight prepaid documentation to support the warranty claim and or a Return Material Authorization must be included if so instructed HE...

Page 24: ...57 North Street Suite 120 LeRoy NY 14482 Tel 585 768 8710 ...

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