03800B RAIL PREHEATER

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 TOOL’S SUITABILITY FOR A PARTICULAR FUNCTION, FOR ANYONE USING THE TOOL OR MAINTAINING THE TOOL REGARDING THEIR FITNESS TO USE THE 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.

General Description 03800B Rail Pre-Heater DIMENSIONS L - 18” (457 mm) W - 16” (406 mm) H - 13-1/2” (343mm) WEIGHT 83 lbs. (33 kg) FLOW 10 gpm (38 lpm) Hydraulic PRESSURE 2000 PSI (140 BAR) RPM 3400

General Description 03800B Rail Pre-Heater Torch / Inox Burner

NEVER USE OVER 50 FT. OF HOSE OR SPLICE HOSE LENGTHS TOGETHER! General Description Pre-Heater Torch Hoses (HPAP50) AIR PROPANE 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!

General Description Rail Pre-Heater Settings AIR PROPANE - 3-5 PSI 11 - 12 PSI TORCH HEIGHT Even with mold chamber NEVER USE OVER 50 FT. OF HOSE OR SPLICE HOSE LENGTHS TOGETHER!

General Description Connections and Knobs / Valves HYDRAULIC Control Valve Knob Propane Regulator Valve & Gages HYDRAULIC Power Source AIR Torch Hose & Gage Propane Tank Flex-Hose PROPANE Torch Hose

Pre-Heater Setup Make sure the power source is turned off. Make sure all knobs are turned to the “OFF” position on the Pre-Heater. Connect all the hoses, ensuring a proper fit. Loop the service hose in the work area in such a way to relieve stress on the hose and quick disconnect fittings while working. Be aware of hose location at all times.

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 “ON” position. 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.

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 of the mold (where the diverter plug fits in). The nozzle must be aligned in such a way that the tip of the nozzle is straight up and down perpendicular to the rail.

Position for lighting flame Pre-Heater Setup 9. Prior to starting the rail pre-heater, the nozzle needs to be tilted all the way back so the nozzle is pointing to the side of the mold. This is necessary to help start the flame. Original alignment Position for lighting flame The torch stand pivots up and down for this purpose.

HYDRAULIC Control Valve Knob Propane Regulator Valve 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, to activate the blower. 13. With the rail pre-heater unit operating, open the shut off valve on the propane tank all the way. HYDRAULIC Control Valve Knob Propane Regulator Valve

Propane Regulator Valve & Pre-Heater Setup 14. 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 valve located at the inox burner to adjust air pressure for ease of lighting the burner. To light the inox burner open the propane shut off valve ½ to ¾ turn. The burner can be lit with a torch or a striker. Propane shut-off valve Propane Regulator Valve & Gages Air Bypass Valve

Pre-Heater Setup Air Bypass Valve Propane shut-off valve

Pre-Heater Setup 16. After lighting slowly close air by-pass valve. Let the flames warm the molds for 30-45 seconds, slowly position the nozzle in the mold so it is straight up and down, perpendicular to the rail. Look at the flames in the mold, 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 are only in the risers and not in the rail area, turn the nozzle to the side and slowly straighten again. It will be necessary to adjust the flame at the propane on-off valve to fine-tune the flame. You should not hear a lot of popping or spitting, rather you should hear a sound similar to that of a turbine or jet engine.

Pre-Heater Setup 17. Once the flame is fine tuned, start the preheat time. During pre-heat the flame will burn more efficiently. More propane can 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-heater unit down. Note: should operating experience prove that blower capacity is too high for the actual air requirements, any excess may be blown off continuously through the manual unloading valve located on the inox burner.

If working with a weak Hydraulic system, it may be necessary to adjust the flow to reach desired RPM

CLIP- Adjusting the torch (1” Weld)

CLIP- Lighting the Torch (1” Weld)

CLIP- Preheat / Flame (1” Weld)

QUESTIONS?