StoneAge AUTOSTROKE AST-200-V2, User Manual

Page 1: ...AUTOSTROKE AST 200 V2 FOR USE WITH THE AUTOBOX PRODUCT LINE USER MANUAL PL 629 V2 REV E 02 2019 ...

Page 2: ... SAFETY CHECK 7 SYSTEM ASSEMBLY OVERVIEW 8 ABX 2L AND ABX 2L V2 MANIFOLD UPGRADE 10 AUTOSTROKE AIR MANIFOLD CONVERSION OVERVIEW 10 REMOVAL OF MANIFOLD AND INSTALLATION OF CONVERSION 11 SPLICING THE TUBING FOR THE T FITTINGS 12 ABX 2L AND ABX 2L V2 AUTOSTROKE SET UP 13 ABX 3L AND ABX 3L V2 AUTOSTROKE SET UP 15 OPERATION 17 MAINTENANCE 18 STORAGE TRANSPORTATION AND HANDLING 18 AIR MOTOR GENERATOR RE...

Page 3: ...line with Autobox ABX 2L ABX 2L V2 ABX 3L and ABX 3L V2L forward reverse and clamp airlines with two additional signal lines from the ABX unit SPECIFICATIONS AutoStroke AST 200 V2 Weight 18 lbs 8 2 kg AutoStroke AST 200 V2 Dimensions 16 9 Long x 11 7 Tall x 7 9 Wide 429 mm x 297mm x 201mm Air Pressure 40 to 125 psi 2 8 to 8 6 bar Air Consumption 3 CFM 5 m hr StoneAge Inc 466 S Skylane Drive Durang...

Page 4: ...f machinery General principles for design Risk assessment and risk reduction 2011 65 EU Restriction of Hazardous Substances RoHS2 Directive EN 61326 1 2013 Electrical equipment for measurement control and laboratory use EMC requirements Part 1 General requirements The Technical File for AutoStroke AST 200 V2 is maintained at StoneAge Incorporated 466 South Skylane Drive Durango CO 81303 USA and wa...

Page 5: ...5 866 795 1586 WWW STONEAGETOOLS COM NOTES This page is intentionally left blank ...

Page 6: ...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 IMC...

Page 7: ...0 V2 with high pressure water to verify the control valves move the hose in the intended direction and that the dump valve and hose clamp are working properly See the Operation section of this manual for adjustment settings Always de energize the system before opening the door to service or replace any parts Failure to do so can result in severe injury and or death PRE RUN SAFETY CHECK Refer to WJ...

Page 8: ...PEN END BOX WRENCH 3 4 JIC FITTING ASSEMBLIES ON MANIFOLD OPEN END BOX WRENCH 7 8 1 2 JIC FITTINGS ON HOSE ENDS LOCTITE 567 PIPE DOPE OR TAPE ALL NEW OR REPLACED TAPERED PIPE FITTINGS NOTE THIS COLOR CODE SYSTEM IS USED THROUGH THE SYSTEM FOR TUBE AND HOSE CONNECTIONS AND COLOR I D FORWARD REVERSE DESCRIPTION QTY 1 AST 277 25 AUTOSTROKE UMBILICAL ASSEMBLY 1 2 AST 301 V2 AUTOSTROKE BOX WITH GENERAT...

Page 9: ...RVIEW AUTOSTROKE AST 275 MANIFOLD ASSEMBLY AUTOSTROKE AST 200 V2 ASSEMBLY AUTOSTROKE AST 200 V2 HOSE FORWARD AUTOSTROKE AST 200 V2 HOSE REVERSE 1 4 TUBING LINES COME BUNDLED IN NYLON SHEATH AUTOSTROKE AST 200 V2 SHOWN WITH AUTOBOX ABX 2L AND CB ABX ASSEMBLY ...

Page 10: ...allow the AutoStroke AST 200 V2 to function with the Autobox ABX 2L and ABX 2L V2 THE AUTOSTROKE AIR MANIFOLD CONVERSION PARTS KIT The parts below are included in the AST 275 AutoStroke Air Manifold Conversion Kit ORIGINAL AIR MANIFOLD ABX 2L AND ABX 2L V2 BEFORE ABX 2L AND ABX 2L V2 AFTER AUTOSTROKE AIR MANIFOLD AUTOSTROKE Air Manifold Assembly Quick Disconnect Fittings NOTICE The Autobox ABX 3L ...

Page 11: ...h Remove and retain the top 3 JIC fitting assemblies and disconnect the 3 air tubes from the bottom of the Air Manifold Discard the old manifold FIGURE 3 FIGURE 2 INSTALLING THE AUTOSTROKE AIR MANIFOLD CONVERSION 1 Install the 3 JIC fitting assemblies to the new AutoStroke Air Manifold Use pipe dope or tape on the NPT tapered threads Re attach the air manifold using the 2 hex head bolts that were ...

Page 12: ...ack tubes with the T fittings from the manifold to the fittings on the left side of the flow controls Connect the other end of the T fittings to the end of the cut tubing The tubes from the manifold assembly should lie between the flow control knobs FIGURE 3 3 Attach the Top Plate and close the Side Door Assembly FIGURE4 4 Install the two Quick Disconnect Fittings to the brass elbows using pipe do...

Page 13: ...sembly off of the Mounting Pole and put aside Figure 1 2 Slide the AutoStroke Assembly onto the Mounting Pole and hand tighten the Thumb Screw Then slide the Control Assembly back onto the Mounting Pole Align the Thumb Screw with the top hole on the Mounting Pole and hand tighten Figure 2 3 Connect the air hose from the FRL to the back of the Control Assembly Figure 3 DISCONNECT FIRST THUMB SCREW ...

Page 14: ...ck fittings on the right side of the AutoStroke Push the opposite ends of each tube into the color labeled press lock fittings on the manifold atop the ABX 2L or ABX 2L V2 Connect the BLACK and RED 1 2 lines to the right side of the AutoStroke marked Forward and Reverse and connect the opposite ends to the manifold on the ABX 2L or ABX 2L V2 Figure 2 3 3 Skip to the OPERATIONS page of this manual ...

Page 15: ...sembly aside Figure 1 2 Slide the AutoStroke Assembly onto the Mounting Pole with the Decal side facing away from the FRL Then hand tighten the Thumb Screw Then slide the Control Assembly back onto the Mounting Pole Then hand tighten the Thumb Screw to secure the Control Assembly to the Mounting Pole Figure 2 3 Connect the air hose from the FRL to the back of the Control Assembly Figure 3 DISCONNE...

Page 16: ...verse connections on the back of the CBX ABX Connect the SHORT 1 4 I D Hose to the fitting marked CLAMP on the left side of the AutoStroke to the CLAMP fitting on the Control Box Figure 1 2 Connect the LONG 1 4 I D Hose to the fitting marked CLAMP on the right side of the AutoStroke and the opposite end to the CLAMP fitting on the ABX 3L or ABX 3L V2 Insert the ends of the 1 4 BLACK and RED tubing...

Page 17: ...ower light comes on To setup the AutoStroke turn the SENSITIVITY knob all the way in the counter clockwise direction Increase turn clockwise Decrease turn counter clockwise Next position your nozzles so they hit the tube sheet face and run them into the tube sheet While holding the feed in lever increase the sensitivity until it just starts to peck at the tube sheet face Adjust the RETRACT DISTANC...

Page 18: ...ns located in this manual All Air Fittings After each use Reinstall all dust caps to protect from dirt and moisture Air Lines Before each use Blow out before making connections to the AutoStroke Electrical Connections Frequently Visually inspect for corrosion MAINTENANCE NOTICE Electronic components are not user serviceable If troubleshooting the system fails it must be sent back to StoneAge Tools...

Page 19: ...ne connections should be removed at least 10 minutes before servicing to allow time for stored electrical energy to dissipate 1 Using a flat screwdriver turn the quarter turn latches counterclockwise 90 degrees and open the AutoStroke enclosure 2 Disconnect the 2 air tubes from the air motor generator AST 200 V2 AUTOSTROKE shown without cover Air Motor Generator location 3 Depress the tab on the b...

Page 20: ...he Air Motor Generator from the AutoStroke enclosure AIR MOTOR GENERATOR REMOVAL INSTRUCTIONS CONTINUED AIR MOTOR GENERATOR INSTALLATION INSTRUCTIONS 1 Install the replacement Air Motor Generator into the AutoStroke enclosure as shown 2 Install the four screws securing the air motor generator with a 9 64 Hex Key 3 Carefully reconnect he electrical connection ...

Page 21: ...LATION INSTRUCTIONS CONTINUED Correct Air Motor Generator location inside the AST 200 V2 AUTOSTROKE 4 Connect the 2 air tubes from the air motor generator 5 Close the AutoStroke lid with a flat screwdriver Turn the quarter turn latches clockwise 90 degrees and tighten the cover onto the AutoStroke ...

Page 22: ...UTOSTROKE UMBILICAL ASSEMBLY 1 2 AST 301 V2 AUTOSTROKE BOX WITH GENERATOR 1 3 AST 340 AUTOSTROKE HOSE BUNDLE ASSY 1 AUTOSTROKE AST 200 V2 AUTOMATIC BLOCKAGE SENSOR NOTICE This color code system is used throughout the AutoStroke AST 200 V2 Autobox and Control Box Assembly PARTS DIAGRAM ...

Page 23: ...4 29 BR 168 DUST CAP J4 2 30 CB 122 FITTING OUTLET P6J8 4 31 CB 314 3 LOBE KNOB 1 32 CB 328 001 POLE MOUNT 1 33 CB 351 FTG P4PL6 SWIVEL ELBOW 1 34 CB 354 FTG P4PL6 STRAIGHT 1 35 GN 325 L NYLOK NUT SS TB 044 1 2 36 GP 011 B BLUE ID BAND MED 2 37 GP 011 BK BLACK ID BAND MED 2 38 GP 011 R RED ID BAND MED 2 39 GPTB 0250 PUR95A BK 24IN 40 GPTB 0250 PUR95A RD 12IN 41 GPTB 0375 PUR95A BK 12IN 42 GPTB 037...

Page 24: ...275 MANIFOLD ASSEMBLY AUTOSTROKE AST 277 25 UMBILICAL ASSEMBLY PART NUMBER QTY 1 ABX 260 FTG P4M X PL8MMF 90 ELBOW 2 2 ABX 268 1 AST TUBE BK 8MM 1 3 ABX 268 2 AST TUBE RD 8MM 1 4 ABX 270 1 AST TUBE BK 250 1 5 ABX 270 2 AST TUBE RD 250 1 6 AST 276 ABX 2L MANIFOLD AUTOSTROKE AST 275 1 7 AST 278 FTG P2M QUICK DISCONNECT 2 8 AST 279 FTG P2MP2F ELBOW BRASS 2 9 AST 280 FTG P2MP2F 1 10 AST 281 FTG P2PL4 ...

Page 25: ...25 866 795 1586 WWW STONEAGETOOLS COM NOTES This page is intentionally left blank ...

Page 26: ...e product s from Seller s warehouse Order shortages or errors must be reported within fifteen 15 business days from receipt of shipment to secure adjustment No product s may be returned without securing written approval from Seller 5 Modification These Terms and Conditions are intended by Seller and Buyer to constitute a final complete and exclusive expression of agreement relating to the subject ...

Page 27: ...he Operator s Manual accompanying the Product 5 REQUIRED WARRANTY PROCEDURES To be eligible for warranty service the End User must 1 report the Product defect to the entity where the Product was purchased i e StoneAge or the Dealer within the Limited Warranty Period specified in this Limited Warranty 2 submit the original invoice to establish ownership and date of purchase and 3 make the Product a...

Page 28: ...1 866 795 1586 www STONEAGETOOLS com 2015 StoneAge Inc All Rights Reserved ...