PEINEMANN 1-XS User manual

PEINEMANN
1-XS
MANUAL MAY 2023
PEINEMANNEQUIPMENT.COM

2PEINEMANN EQUIPMENT - USER MANUAL1-XS
Dear Customer,
© Copyright 2023 Peinemann Equipment. All rights reserved.
Peinemann is a registrated trademark. This publication is the property of, and contains information proprietary
to Peinemann Equipment. Accordingly, no parts of this publication may be reproduced or copied in any form, or
by any means, including electronic, mechanical, photocopying, recording or otherwise, without the prior written
permission of Peinemann Equipment.
All products, brands or trade names used in this publication are their respective owners’ trademarks or registered
trademarks. Information in this manual is subject to change without notice.
No rights can be obtained from this document.
Thank you for acquiring the Peinemann Equipment 1-Xs. Please read this manual
thoroughly and in completeness before installation or conducting operations. Information
in this manual is essential for the safe and correct usage of the machine. Please get in
touch with Peinemann Equipment B.V. when questions concerning safe installation and
operation arise.

3
PEINEMANN EQUIPMENT - USER MANUAL 1-XS
CONTENT
1. GENERAL INFORMATION............................................................................................................ 5
1.1 Intended audience................................................................................................................ 5
1.2 Special information.............................................................................................................. 5
1.3 Illustrations........................................................................................................................... 5
1.4 Safety requirements............................................................................................................ 5
1.5 Personell training.................................................................................................................. 5
1.6 Recommend tools................................................................................................................ 5
1.7 General system safety practices....................................................................................... 6
1.8 Replacing components....................................................................................................... 6
1.9 Routine maintenance.......................................................................................................... 6
1.10 Limited warranty................................................................................................................. 6
1.11 Hose sizes and pressure.................................................................................................... 6
1.12 SIR Regulations.................................................................................................................... 7
1.13 Accountability....................................................................................................................... 7
1.14 General terms and conditions.......................................................................................... 7
2. SAFETY INSTRUCTIONS............................................................................................................. 8
2.1 General.................................................................................................................................... 8
 2.2Steellanceand/orexlance............................................................................................ 8
3. CRIMP FITTING, NOZZLE, STOP SLEEVE, AND HOSE CATCHER CONFIGURATION........ 9
4. GENERAL SPECIFICATIONS....................................................................................................... 11
 4.1Technicalspecications...................................................................................................... 11
4.2 Components......................................................................................................................... 12
5. INSTALLATION.............................................................................................................................. 13
5.1 Check items........................................................................................................................... 13
5.2 Filling the oil lubricator...................................................................................................... 13
5.3 Adjusting the oil lubricator................................................................................................ 13
5.4 Mounting the motor............................................................................................................ 13
5.5 Connecting the air hose..................................................................................................... 14
5.6 Setting the air pressure..................................................................................................... 14
5.7 Greasing the chain............................................................................................................... 14
6. OPERATIONS................................................................................................................................ 15
6.1 Operating the 1-Xs manually............................................................................................... 15
6.1.1 Installing the lance and hose catcher.................................................................... 15
6.1.2 Setting the friction..................................................................................................... 17
6.1.3 Setting the friction for horizontal use................................................................... 17
6.1.4 Mounting the end stop.............................................................................................. 18
6.1.5 Carrying strap............................................................................................................. 19
 6.2UsageincombinationwiththeOrionIndexer............................................................... 20
6.2.1 Required equipment.................................................................................................. 20
6.2.2 Installing the adapter............................................................................................... 21
6.2.3 Installing the automatic motor and adjustable tube guide............................ 21
  6.2.4Settingupthe1-XsandOrionIndexer................................................................. 21
6.3 High-pressure hose reel (option)..................................................................................... 22

4PEINEMANN EQUIPMENT - USER MANUAL1-XS
77 CONTENTS
7. MAINTENANCE............................................................................................................................ 23
7.1 Daily maintenance................................................................................................................ 24
7.1.1 Replacing friction blocks.......................................................................................... 24
7.2 Major maintenance............................................................................................................. 24
8. DECISION TREE.......................................................................................................................... 25
9. WARRANTY................................................................................................................................... 27
10. APPENDIX................................................................................................................................... 29
10.1 Schematic drawings
10.2 Parts list
 10.3Certications
10.4 Declaration of Conformity

5
PEINEMANN EQUIPMENT - USER MANUAL 1-XS
1. GENERAL INFORMATION
1.1 Intended audience
Thismanualisintendedforeldengineering,installation,operation,andrepairpersonnel.
Everyeorthasbeenmadetoensuretheaccuracyoftheinformation.However,Peinemann
Equipment will not be held liable for errors in this manual or consequences arising from the
misuse of this manual.
1.2 Special information
Detailed descriptions of standard procedures, safety principles and service operations
are not included. Please note that this manual contains warnings about procedures which
could damage equipment, make it unsafe, or cause PERSONAL INJURY. Anyone using service
procedures or tools, whether or not recommended by Peinemann Equipment, must be
thoroughlysatisedthatneitherpersonalsafetynorequipmentsafetywillbejeopardized.
All information in this manual is based upon the latest product information available at any
time of printing. We reserve the right to make changes at any time without notice.
1.3 Illustrations
Illustrations (gures) represent equipment components for use in identifying parts or
establishingnomenclature.Theseguresmayormaynotbedrawntoscale.
1.4 Safety requirements
The 1-Xs is installed and operated in a controlled environment involving hazardous situations.
Proper maintenance is essential for safe and reliable operation. Procedures outlined in
Peinemann Equipment manuals are the recommended methods for performing operations
and maintenance.
1.5 Personnel training
All personnel performing installation, operations, repair, or maintenance procedures on the
equipment, or those in the vicinity of the equipment, should be trained accordingly to ensure
their safety.
! Personnel should wear protective gear during installation, maintenance, and operations.
1.6 Recommend tools
Serviceoperationsmayrequireusingtoolsdesignedspecicallyforthepurposedescribed.
PeinemannEquipmentrecommendsthatonlythosetoolsspeciedbeusedwhenstated.
Ensure that personnel and equipment safety is not jeopardized when following service
procedures.
77

6PEINEMANN EQUIPMENT - USER MANUAL1-XS
1. GENERAL INFORMATION
1.7 General system safety practices
The equipment discussed in this manual may require or contains one or more utilities, such
as electrical, hydraulic, pneumatic, or oil.
• Isolate energy sources before beginning work.
• Avoid performing maintenance or repairs while the equipment is in operation.
• Wear proper protective equipment during equipment installation, maintenance, or repair.
! Read and follow the guidelines below before installing equipment or performing maintenance.
1.8 Replacing components
• Verify that all components, such as cables and hoses, are tagged and labelled during
assembly and disassembly of equipment to ensure correct installation.
• ReplacefailedordamagedcomponentswithPeinemannEquipmentcertiedparts.Failure
to do so could result in equipment damage or injury to personnel.
• Onlyusepartsthataresuitableforhighpressureandcarryavalidtestcerticate.
1.9 Routine maintenance
Equipment must be maintained on a routine basis. See Ch.7 for maintenance guidelines.
! Failure to conduct routine maintenance could result in equipment damage or injury to
personnel.
1.10 Limited warranty
Warranty provided will be void if the 1-Xs or parts were either:
• Unauthorizedmodiedrepairedorserviced.
• Not properly maintained.
• Replacement parts not manufactured by Peinemann Equipment were utilized.
1.11 Hose sizes and pressures
The1-Xsissuitableforusewithvarioushosesizesandpressures.However,themaximum
throughput of the 1-Xs is Ø27 milimeter (1.06 in). The most common hose sizes (3/2 - 6/2),
hosecatchers,nozzlesandendstopsareavailablefromstock.Dierentlengthsandshapes
for the front lances are also available.

7
PEINEMANN EQUIPMENT - USER MANUAL 1-XS
1. GENERAL INFORMATION
1.12 SIR Regulations
The 1-Xs is a semi-automatic high-pressure ex lance transit machine, and current SIR
regulations regarding high-pressure cleaning apply (or the applicable rules in the country
where you are currently working). It is recommended to comply with SIR regulations. The
general safety regulations apply, just as for other high-pressure cleaning activities. The
nozzles to be used must align with the cleaning activity’s nature. It is advised to refrain from
usingnozzlesthatexertamajorpushorpullforce.
1.13 Accountability
Peinemann Equipment B.V. cannot be held accountable for any material and non-material
damage caused during the installation and operation of the 1-Xs. Therefore, users must
carefully read this manual and handle the machine with care.
1.14 General terms and conditions
“Alloers,orders,assignmentsandagreementsforthelease,saleand/ordeliveryofservices
by Peinemann Equipment B.V. are subject to Peinemann’s General Terms and Conditions
as lastly led with the Chamber of Commerce and Industry in Rotterdam under number
24175469. The General Terms and Conditions can also be found on Peinemann.nl. Any other
generaltermsandconditionsareexpresslyrejected.”

8PEINEMANN EQUIPMENT - USER MANUAL1-XS
2. SAFETY INSTRUCTIONS
2.1 General
• Use this machine only for the purpose it was developed and as instructed in the
manual.
• Thismachinemayonlybeusedbyqualiedandtrainedpersonnel.
• Theareaaroundtheworkshouldbecordonedotoexcludeuntrainedindividuals.
• All personnel in the vicinity must wear appropriate protective clothing and eye and ear
protection,perthespecicrequirements.
• Inspect the equipment for apparent damage or incorrect assembly. Wait to use the
machineuntilthishasbeenxed.
• Rinseoutthehosesbeforethenozzlesarettedtoavoidanyblockages.
• Check that all threaded connections are assembled tightly and leak-proof. Use stainless
steel thread grease to avoid thread galling.
• Check that there are no blockages in the nozzles. If the nozzles are blocked, they must
be cleaned or replaced.
• This machine must always be used with a foot pedal and/or dump valve that has been
checked by an inspector and that automatically releases any water pressure when
released.
• Water spray nozzles create a strong reactive force, and these forces can become
unbalanced if a nozzle gets stuck. Use the equipment correctly to resist these forces.
• Check that all operating functions are working correctly before commencing high-
pressure activities.
• Increase the pressure gradually when starting up the machine to ensure that everything
is working correctly and that the equipment is appropriately balanced and positioned.
• Usettingsmarkedwiththemaximumworkingpressureandcoveredbyavalid
certicate.Staywithinthemaximumworkingpressureforeachcomponentinthe
system.
2.2 Steel lance and/or ex lance
• Thefarthest end ofthe bundle to be cleaned should be cordoned owith a 6 meter
(19.69”in)radius.Ifthereareotherworkersnearby,ascreenshouldbeused.
• The person closest to the nozzles must control the high pressure.
• The lance machine should be safeguarded against the reactive force of the water spray
and the possibility of hydraulicking.
• The operator must take a position where he can see the pipe plate, but is far enough away
not to be troubled by rebounding water spray during cleaning.
• Mechanicalendstopsmustbettedtoensurethattheexlancedoesnotescapefrom
theheatexchanger.
• The length of a nozzle, including the end stop, on a high-pressure hose, must be the same
or larger than the pipe’s internal diameter to be cleaned to prevent the lance from turning.
If not, a lead pipe must be installed between the end of the holes and the lance.
• It is recommended to use an anti-withdrawal device so that the machine cannot be
pushed from the tube plate.
• When cleaning blocked pipes with small diameters, use a lance and hose diameter of
less than 2/3 of the pipe diameter so that the waste water can escape. In addition, it is
recommended to use an anti-withdrawal device to protect the operator against the hose
being pushed back out of the pipe.
• High-pressure cleaning can damage pipes if the nozzles are not moved under pressure.
Therefore,alwaysensurethatthereisacleaningprotocolstatingmaximumwaterpressure.

9
PEINEMANN EQUIPMENT - USER MANUAL 1-XS
3. CRIMP FITTING, NOZZLE, STOP SLEEVE, AND HOSE CATCHER
CONFIGURATION
AllPeinemannexlancefeederssuchastheTLE,(X)LTC,TLXandXsseriesmustbeoperated
withacorrectnozzle,crimptting,stopsleeveandhosecatcherconguration.Therefore,
before starting operations, review the steps below to ensure a correct and safe operating
conguration.
First,always useanozzlewiththe sameorlargerdiameterthanthecrimpttingonthe
hose.Whenthenozzlehasasmallerdiameterthanthecrimptting,theriskofhydraulicking
arises.
Second, always use a hose with a stop sleeve (safety sleeve) at 5 centimeter (2 in) before the
crimpttingonthehose.Checkthatthestopsleevehasalargeenoughdiametertobesafely
stopped by the hose catcher. If a stop sleeve cannot be used (not recommended), then make
surethatthecrimpttinghasalargeenoughdiametertobesafelystoppedbythehose
catcher. There is a risk of the hose coming through the hose catcher or getting stuck in the
hosecatcherwhenthestopsleeveand/orcrimpttingdiameterisnotsignicantlylarger
thanthehosecatcherdiameter.Thestopsleeveand/orcrimpttingishighlyrecommended
to have at least a 3 millimeter (0.12 in) larger diameter than the hose catcher (=+1.5 mm
around).Ifthisisnotthecase,werecommendusingadierentconguration.
Nozzlediametersmallerthancrimptting
diameter = incorrect
Nozzle diameter the same or larger than crimp
ttingdiameter=correct

10 PEINEMANN EQUIPMENT - USER MANUAL1-XS
3. CRIMP FITTING, NOZZLE, STOP SLEEVE, AND HOSE CATCHER
CONFIGURATION
Third, always physically check that the hose catcher stops the stop sleeve and/or crimp
tting(notrecommended)onthehose.Donotonlyrelyonthesizeengravedontothecrimp
tting,stopsleeve,andhosecatcher.Itisalsorecommendedtomeasureifthecrimptting
and/or stop sleeve has a 3 millimeter (0.12 in) or larger diameter than the hose catcher (=+1.5
mm around).
Special warning
PeinemannEquipmentB.V.espesciallyadvisesnottoworkwithsocalled“Blast-Pro”or“Pro-
lance”crimpttingswithoutthepreviouslydescribedstopsleevesttedonthehose.These
specialcrimpttingsareknowntohaveasmalldiametercrimpttingwhichcouldgetstuck
in the hose catcher and in worst case scenarios could pass the hose catcher if it returns in
theexlancecleanerathighspeeds.Alwaysaddacorrectstopsleevetothehoseifworking
witha“Blast-Pro”or“Pro-lance”coupling.Double-checkthatthestopsleevediameteris
minimally 3 millimeter (0.12 in) larger than the hose catcher after clamping the stop sleeve
to the hose (=+1.5 mm around). The diameter of the stop sleeve might have decreased in the
clamping process.
Stop sleeve diameter too small for the hose
catcher = incorrect
Stop sleeve diameter large enough for the hose
catcher (stop sleeve diameter is min. 3mm
larger then hose diameter (=+1.5mm around)) =
correct
Typical“Blast-Pro”crimpttingthatcouldpass
through the hose catcher
Alwaysuseastopsleevewhenusing“Blast-Pro”
or“Pro-Lance”crimptting

11
PEINEMANN EQUIPMENT - USER MANUAL 1-XS
4. GENERAL SPECIFATIONS
4.1 Technical specications (approx.)
General
Length (drive unit) 28.0 cm (11.0 in)
Width (drive unit) 30.0 cm (11.8 in)
Height (drive unit) 19.0 cm (7.5 in)
Weight (drive unit) 6.0 kg (13.2 lb)
Hose feed rate 40 - 70 cm/s (15.7 - 27.6 in/s)
Max.push/pullforce  50kg(110lb)
Pitch adjustment range N.a.
Motor
Motor model Atlas Copco LZB33-ML-AR009-001
Max.outputpermotor  0.62kW(0.83hp)
Min. air pressure 3.0 bar (43.5 psi)
Operating air pressue 6.3 bar (91.4 psi)
Max.airpressure   7.0bar(101.5psi)
Max.airconsumption  14l/s(29.7cfm)
Stall torque per motor 32 Nm (23.3 ft lb)
Vane type Lubrication free
Hose specications
Hose size 3/2 - 6/2
Hose outer diameter 7 - 11.5 mm (0.28 - 0.45 in)
Max.hosecouplingdiameter 27mm(1.06in)

12 PEINEMANN EQUIPMENT - USER MANUAL1-XS
4. GENERAL SPECIFATIONS
4.2 Components
Friction control
Clamps
Motor
Quick connector
Protective hood
Friction roller
Bridge
Friction block
Chain
Blocking clip

13
PEINEMANN EQUIPMENT - USER MANUAL 1-XS
5. INSTALLATION
5.1 Check items
Check whether all required items are present. The following items should be present.
• 1-Xs heart
• Oil lubricator
• Lubricator oil
• Special chain grease
• Optional products
5.2 Filling the oil lubricator
Fillthedrumoftheoillubricatorwiththesuppliedoil.Theoildrumislocatedontheexit
side of the oil lubricator. Unscrew the drum by turning it counterclockwise, after which it
canbelledalongtheopenside.Screwthedrumbackintotheblockandtightenitrmly
withoutadditionaltools.Alwaysusethesuppliedoilforinitialusage.Forrelling,pleaseuse
oilthatisspecicallyintendedforpneumatictools.
5.3 Adjusting the oil lubricator
The oil lubricator can be adjusted using a screwdriver. Unscrewing the screw will cause drops
tobereleasedmorefrequently.Unscrewtheregulatingscrewtosuchanextentthat1drop
per 5 seconds is released.
5.4 Mounting the motor
Mountthemotorontothemachine.First,ensurethemachine’saxleisalignedwiththesmall
forkoftheairmotor.Thenpushthemotorovertheaxle,turnitcounterclockwiseandblock
it using the blocking clip.

14 PEINEMANN EQUIPMENT - USER MANUAL1-XS
1 2 3 4
A
B C DEF
5. INSTALLATION
5.5 Connecting the air hose
Blow through the input air hose and connect it to the air supply unit and oil lubricator.
Connect the output hose to the oil lubricator and motor.
5.6 Setting the air pressure
Settheairpressurebetweenaminimumof3barandamaximumof6.3bar.
5.7 Greasing the chain
Grease the chain by injecting the supplied special chain grease.
G

15
PEINEMANN EQUIPMENT - USER MANUAL 1-XS
6. OPERATIONS
6.1 Operating the 1-Xs manually
6.1.1 Installing the lance and hose catcher
Remove the air supply hose from the machine. Open the hood of the machine by relieving
the clamps at the front of the machine. Then relieve the friction control by turning it
counterclockwise. Finally, topple the friction control to the front, enabling the bridge with
friction rollers to hinge upwards.
Attachthenozzleandthestingertotheexiblelance.Guidetheexlanceintotheback
hoseinputuntilithaspassedthefrontofthemachinebyapprox.30centimeter(11.81in).
Next,mountthecorrectsizehosecatcherandguidetubetothefrontofthe1-Xs.Checkthat
the hose collar cannot pass through the hose catcher. Pull the high-pressure hose to check
whether the hose catcher is functioning.
! If the hose catcher is not attached correctly, the ex lance may pop out of the machine
under high pressure.

16
6. OPERATIONS
Close the bridge, tighten the friction control and close the protective hood. If there is too
muchslipontheexlancesduringoperations,thenadjustthefrictioncontrol.
! Too much friction can damage the ex lances or the 1-Xs.
! The chain is automatically kept at the correct tension. Always check the chain for wear
and damage before usage. Also, check before use whether the chain runs smoothly without
the motor. The clearance should be approx. 5 milimeters (0.20 in) when you pull the friction
blocks up.

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PEINEMANN EQUIPMENT - USER MANUAL 1-XS
6. OPERATIONS
6.1.2 Setting the friction
There are multiple ways of setting the correct friction tension on the 1-Xs. Peinemann
Equipment recommends the following method. Hold the 1-Xs vertically and activate the
motor.Whenthemotorisactivated,thehoseispushedagainsttheoor.Turnthefriction
controluntilthemachinealmostdetachesitselffromtheoor.Themachinewillnowstart
slippingassoonasareactiveforcehigherthanapprox.10kg(22.05lb)isproduced.
6.1.3 Setting the friction for horizontal use
Follow the instructions in Ch.6.1.2 to set the initial friction tension. Then hold the 1-Xs
horizontally against the tube plate and perform a quick test against the tube plate. You
caninstantlyndoutwhethertheforceisnottoostrong.Theforceistoostrongwhenthe
operator is pushed away from the bundle.
! Always check the friction setting before starting operations.

18 PEINEMANN EQUIPMENT - USER MANUAL1-XS
6. OPERATIONS
6.1.4 Mounting the end stop
Themaximumreachofthelancecanbesetbyscrewingtheendstopontotheexlance.
The correct position of the end stop can be determined by manoeuvring the hose in one
ofthebundlepipes untilthe nozzleextendsbeyondthetube plate.Byscrewingtheend
stopagainsttherearhoseinputontheexlance,thelengthoftheexlancewillneverbe
too long, meaning that the nozzle will never protrude too far out of the pipe and create a
potentially hazardous situation.
If the end stop touches the back of the machine during cleaning, the machine will start
to slip, and the reverse movement can be started (check whether the end stop is actually
touching the back of the machine). The reverse movement can be stopped if the reducer
sleeveontheexlancetouchesthehosecatcherinthemachineandthe1-Xsstartstoslip.
When working with the 1-Xs, it is advised to use a stinger.
! When cleaning a “U bundle” using a small hose with no stinger, this must be adjusted so
that it cannot leave the pipe.
Incorrect Correct

19
PEINEMANN EQUIPMENT - USER MANUAL 1-XS
6. OPERATIONS
6.1.5 Carrying strap
It is possible to operate the 1-Xs by carrying it over your shoulders using a carrying strap.
! It is advised to use the 1-Xs with a balancer and anti-withdrawal device. This will take the
weight of the machine out of your hands.

20 PEINEMANN EQUIPMENT - USER MANUAL1-XS
Level
Drain
6. OPERATIONS
6.2 Usage in combination with the Orion Indexer
6.2.1 Required equipment
Checkwhethertherequiredequipmentforcombiningthe1-XsandOrionIndexerispresent.
• Adjustable tube guide
• Automatic motor
• Adapter
Adjustable tube guide Automatic motor
Adapter