preheater presentation 1

7/28/2019 Preheater Presentation 1

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03800B RAIL PREHEATER


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General Safety Precautions

REMEMBER ALL PPE

TOOL OPERATORS AND MAINTENANCE PERSONNEL MUST ALWAYS

COMPLY WITH THE SAFETY PRECAUTIONS GIVEN IN THE MANUAL, AND

WITH ALL STICKERS AND TAGS ATTACHED TO THE TOOL AND HOSE. ALL

SAFETY PRECAUTIONS ARE GIVEN FOR YOUR SAFETY. READ OPERATER

MANUAL TO UNDERSTAND AND FOLLOW ALL SAFETY, MAINTENANCE

AND OPERATION INSTRUCTIONS.

THE CUSTOMER MUST ASSUME RESPONSIBILITY FOR THE TOOLS

SUITABILITY FOR A PARTICULAR FUNCTION, FOR ANYONE USING THE

TOOL OR MAINTAINING THE TOOL REGARDING THEIR FITNESS TO USETHE TOOL OR REPAIR THE TOOL, UNDERSTANDING OF THE OPERATION

AND SAFETY AND MAINTENANCE MANUAL, INTELLIGENCE TO USE GOOD

JUDGMENT NECESSARY TO WORK SAFELY AND EFFICIENTLY WITHOUT

ENDANGERING THEMSELVES OR BYSTANDERS IN THE WORK AREA.


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General Description

FLOW10 gpm(38 lpm)

HydraulicPRESSURE2000 PSI (140 BAR)

RPM

3400

DIMENSIONSL - 18 (457 mm)W - 16 (406 mm)H - 13-1/2 (343mm)

WEIGHT

83 lbs.(33 kg)

03800B Rail Pre-Heater


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General Description03800B Rail Pre-Heater Torch / Inox Burner


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General DescriptionPre-Heater Torch Hoses (HPAP50)

AIR- 3/4 Inside Diameter- 50 ft. MAX LENGTH

PROPANE- 3/8 Inside Diameter- 50 ft. MAX LENGTH

NEVER USE OVER 50 FT. OF HOSE OR SPLICE HOSE LENGTHS TOGETHER!

AIR

PROPANE


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General DescriptionRail Pre-Heater Settings

AIR PROPANE- 3-5 PSI 11 - 12 PSI

TORCH HEIGHTEven with mold

chamber

NEVER USE OVER 50 FT. OF HOSE OR SPLICE HOSE LENGTHS TOGETHER!


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General DescriptionConnections and Knobs / Valves

AIR Torch Hose

&Gage

PROPANETorch Hose

Propane TankFlex-Hose

HYDRAULICPower Source

HYDRAULIC Control

Valve Knob

PropaneRegulator Valve &

Gages


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Pre-Heater Setup

1. Make sure the power source is turned off.

2. Make sure all knobs are turned to the OFF position on the Pre-Heater.

3. Connect all the hoses, ensuring a proper fit.

4. Loop the service hose in the work area in such a way to relieve stresson the hose and quick disconnect fittings while working. Be aware ofhose location at all times.


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Pre-Heater Setup

5. Turn the hydraulic power source to the on position to supply 10 gpm.

6. Start the pre-heater unit by turning hydraulic control valve to the ONposition.

LET THE BLOWER RUN 2 OR 3

MINUTES TO ALLOW UNIT TO

WARM UP, THEN TURN THE

HYDRAULIC CONTROL VALVE

TO THE OFF POSITION

TURN HYDRAULIC POWER

SOURCE OFF AT THIS TIME.


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Pre-Heater Setup

7. Connect the propane flex-hose from the regulator/propane tank to the

pre-heater.8. The inox heating nozzle must be aligned in the molds so that the flat

piece just above the nozzle is no higher than the top of the inside ofthe mold (where the diverter plug fits in). The nozzle must be alignedin such a way that the tip of the nozzle is straight up and downperpendicular to the rail.


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Pre-Heater Setup

9. Prior to starting the rail pre-heater, the nozzle needs to be tilted all theway back so the nozzle is pointing to the side of the mold. This isnecessary to help start the flame.

The torch stand pivots upand down for this purpose.

Original alignment Position for lighting flame


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Pre-Heater Setup

10. Make sure the propane regulator valve (located on the Rail pre-heater)is turned all the way out (counterclockwise).

11. Turn the hydraulic power source to the on position to supply 10 gpm.

12. Turn hydraulic control valve knob clockwise, on the rail pre-heater, toactivate the blower.

13. With the rail pre-heater unit

operating, open the shut off valve

on the propane tank all the way.

HYDRAULIC ControlValve Knob

PropaneRegulator Valve


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Pre-Heater Setup14. With the propane shut-off valve located on the inox burner completely

open, adjust the propane regulator to 11-12 psi.

15. With the rail pre-heater unit operating, open the air bypass valvelocated at the inox burner to adjust air pressure for ease of lighting theburner. To light the inox burner open the propane shut off valve to turn. The burner can be lit with a torch or a striker.

Air Bypass Valve

Propane shut-off valve

PropaneRegulator Valve &

Gages


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Pre-Heater Setup

Air Bypass Valve

Propane shut-off valve


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Pre-Heater Setup

16. After lighting slowly close air by-pass valve. Let the flames warm themolds for 30-45 seconds, slowly position the nozzle in the mold so it isstraight up and down, perpendicular to the rail. Look at the flames in themold, the flames should be down in the rail area not just in the risers.Flames should be 6 to 8 inches coming out of the risers. If the flames areonly in the risers and not in the rail area, turn the nozzle to the side andslowly straighten again. It will be necessary to adjust the flame at thepropane on-off valve to fine-tune the flame. You should not hear a lot ofpopping or spitting, rather you should hear a sound similar to that of aturbine or jet engine.


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Pre-Heater Setup

17. Once the flame is fine tuned, start the preheat time.

During pre-heat the flame will burn more efficiently. More propanecan be added just to flutter and backed off to sound like turbine.

A.) PREHEAT ALL 5-1/2 BASE RAIL FOR 5-6 MINUTES.B.) PREHEAT ALL 6 BASE RAIL FOR 6-7 MINUTES.C.) PREHEAT ALL W.G.W. WELDS FOR 6-1/2 MINUTES.

DO NOT HEAT RAIL ENDS MORE THAN 8 MINUTES.

AT THE END OF PREHEAT THE TOP OF THE BASE OF THE RAIL

SHOULD BE 450 DEGREES F MINIMUM AT 2-1/2 INCHES FROM

THE RAIL ENDS, TESTED WITH A TEMPSTICK.18. After preheating the rail remove the inox nozzle from the mold. Next,completely close propane on-off valve. Before shutting rail pre-heaterunit down.Note: should operating experience prove that blower capacity is toohigh for the actual air requirements, any excess may be blown off

continuously through the manual unloading valve located on theinox burner.


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If working with a weak Hydraulic system,

it may be necessary to adjust the flow toreach desired RPM


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CLIP- Adjusting the torch (1 Weld)


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CLIP- Lighting the Torch (1 Weld)


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CLIP- Preheat / Flame (1 Weld)


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QUESTIONS?

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