Elliott RECON 2500 Manual

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

4 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
[phone] toll free (USA only) or [phone], or fax us at [phone] for immediate
service.

R ECON 2500 Tube Leak Test Gun 5
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
!
CAUTION
!
Pinching Hazard located between Backup Washer
and Cylinder Nose. Do not place ngers in this
location during operation.

6 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

R ECON 2500 Tube Leak Test Gun 7
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

8 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

R ECON 2500 Tube Leak Test Gun 9
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.

10 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

R ECON 2500 Tube Leak Test Gun 11
TUBE LEAK TEST GUN - PRESSURE
TTP2500-100

12 RECON 2500 Tube Leak Test Gun
ITEM
NO. PART NAME NO. REQ
PART
NUMBER
1 CYLINDER NOSE 1 TTP2500-120
2SOCKET HEAD CAP SCREW, #8-32 X 3/4 8 P8302-20
3 O-RING, AS568 - 114 1 P8309-12
4 PISTON 1 TTP2500-123
5 CYLINDER BODY 1 TTP2500-121
6 O-RING, AS568 - 330 1 P8309-330
7 GASKET 1 TTP2500-140
8 PIPE TEE 1 TTP2500-185
9BUTTON HEAD CAP SCREW 2 TTP2500-178
10 LEVER 1 TTP1250-160
11 CHECK VALVE 1 TTP2500-275
12 BUTTON VALVE 1 TTP1250-176
13 SPRING PIN, 3/32 X 7/8 1 P8381-14
14 SPRING 1 37-72190
15 ADAPTER TEE 1 TTP1250-174
16 ELBOW 2 TTP2500-161
17 CYLINDER CAP 1 TTP2500-122
18 VALVE ACTUATOR 1 TTP2500-176
19 POPPET VALVE 1 TTP2500-175
20 BUTTON HEAD CAP SCREW 4 TTP1250-173
21 HANDLE HALF 1 TTP2500-250
22 LONG NIPPLE 1 TTP1250-182
23 1/4 NIPPLE 1 41-6534K18
24 HANDLE HALF 1 TTP2500-153
25 GASKET 1 TTP2500-141
26 HANDLE HALF 1 TTP2500-152
27 BUTTON HEAD CAP SCREW 8 TTP1250-170
28 SUPPORT BRACKET 4 TTP1250-171
29 BLEED VALVE 1 TTP1250-177
30 HANDLE HALF 1 TTP2500-251
31 PRESSURE GAUGE 1 TTP2500-190
32 LABEL 1 ETTLBL1800A
33 ELASTIC LOCKNUT, #4-40 6 546GSS
34 THREADED STUD (NOT SHOWN) 1 TTP2500-138
35 LABEL ( NOT SHOWN) 1 TTP2500LBL-2
36 TUBING (NOT SHOWN) 12 41-5156K87
37 NEEDLE ROLLER (NOT SHOWN) 4 P8573-17
TUBE LEAK TEST GUN - PRESSURE
TTP2500-200

R ECON 2500 Tube Leak Test Gun 13
TUBE LEAK TEST GUN - PRESSURE
TTP2500-200

14 RECON 2500 Tube Leak Test Gun
TROUBLESHOOTING GUIDE
Seal slips out of tube.
1. The tube is not clean of debris/lubrication.
a.) a.) It is always very important to properly clean tubes before testing them. Debris/
lubrication can inhibit the seal from seating correctly in the tube.
b.) Check how much PSI is being supplied to the gun. DO NOT exceed the MAX PSI
rating of 125 PSI. If there is too much pressure being supplied to the tube(s) being
tested, the excess PSI will force the test guns out of the tube. Use the provided air
regulator to ensure you are within the specied PSI range (40 - 125 PSI, 2.7 - 8.6
bar).
Tester will not create a seal.
1. The seal set being used is not the proper size for the tube.
2. Proper air pressure is not being used.
a.) Test guns operate on air pressure ranging from 40 to 125 psi (2.7 to 8.6
Bar). Use the provided air regulator to ensure you are within the specied
PSI range.

R ECON 2500 Tube Leak Test Gun 15
WARRANTY
Should any part, of Seller’s own manufacture, prove to have been defective in material or workmanship
when shipped (as determined by Seller), Seller warrants that it will, at its sole option, repair or replace
said part f.o.b., point of manufacture, provided that Buyer noties, in writing, of such defect within
twelve (12) months from date of shipment from the manufacturing plant.
On request of Seller, the part claimed to be defective will be returned, transportation, insurance, taxes
and duties prepaid, to the factory where made, for inspection. Any item, which has been purchased by
Seller, is warranted only to the extent of the original manufacturer’s warranty to Seller.
Seller shall not be liable for any damages or delays caused by defective material or workmanship.
No allowance will be made for repairs or alterations made by others without Seller’s written consent or
approval. If repairs or alterations are attempted without Seller’s consent, Seller’s warranty is void.
THE WARRANTIES PROVIDED IN THE OBLIGATIONS AND LIABILITIES OF SELLER HEREUNDER,
AND THE RIGHTS AND REMEDIES OF BUYER HEREUNDER ARE EXCLUSIVE AND IN
SUBSTITUTION FOR, AND BUYER HEREBY WAIVES ALL OTHER WARRANTIES, GUARANTEES,
OBLIGATIONS, CLAIMS FOR LIABILITIES, RIGHTS AND REMEDIES, EXPRESS OR IMPLIED,
ARISING BY LAW OR OTHERWISE, INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTY
FOR MERCHANTABILITY AND FITNESS FOR PURPOSE.
Seller’s total liability is limited to the lower of the cost of repair or replacement.

Elliott Tool Technologies, Ltd.
1760 Tuttle Avenue
Dayton, Ohio 45403-3428
Phone: [phone] • [phone]
Fax: [phone]
www.elliott-tool.com
Printed in the USA
©09/2020 Elliott Tool Technologies, Ltd.
TM-116
PL-101
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