PANDROL HFP 36V Operation And Maintenance Manual Download Page 3 | Manualshive

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| S0000473 | January 2022 rev6

© Pandrol 2022

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Content

EXPLANATION OF SYMBOLS

GENERAL SAFETY INSTRUCTIONS

INSTRUCTION FOR USE

Personal Protective Equipment

Safety checks before welding commences

Handling the HFP

Handling the HFP box

Handling the HFP unit

Positioning the preheater

Installation of the gas line

Ignition of the HFP preheater

Keyboard and display

HFP preheater operating cycle

Stopping and removing the HFP

Storing the HFP

LAYOUT ON THE TRACK ACCORDING TO NF EN 13977

Installation of the gas line

Replacing the nozzle

TROUBLESHOOTING GUIDE

TECHNICAL CHARACTERISTICS

Dismantling and disposal

CONFIGURATIONS OF THE HFP

LIST OF SPARE PARTS AVAILABLE FOR MAINTENANCE

DECLARATION OF CONFORMITY

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Summary of Contents for HFP 36V

Page 1: ...Preheater HFP 36V OPERATION AND MAINTENANCE MANUAL ENGLISH S0000473 January 2022 rev6 Instruction video ...

Page 2: ...translation remove e V4 08 12 2021 ND Updated weight added type DIN9 line V5 15 12 2021 ND Added the list of all HFP set up Added instruction when when using the HFP with strong wind V6 21 01 2022 ND Modification of several spare parts code Added instruction to replace the nozzle and handling the HFP Added QR code for online training video ...

Page 3: ...llation of the gas line 14 4 4 6 Ignition of the HFP preheater 16 4 4 7 Control panel 18 4 4 8 Keyboard and display 19 4 4 9 HFP preheater operating cycle 19 4 4 10 HFP Operation 20 4 4 11 Stopping and removing the HFP 20 4 4 12 Storing the HFP 21 5 LAYOUT ON THE TRACK ACCORDING TO NF EN 13977 22 6 MAINTENANCE 23 6 1 1 Installation of the gas line 23 6 1 2 Replacing the nozzle 24 7 TROUBLESHOOTING...

Page 4: ...ad the instruction manual carefully before operating or any maintenance Disconnect the HFP preheater before any maintenance Risk of contact with parts with electrical current inside the HFP Accessible parts that may remain hot after using the HFP especially the tip of the torch ...

Page 5: ...e which must be operated by a single user practical training should be given to any new user Use and maintenance must be carried out by qualified personnel The operator must wear the necessary PPE for preheating operations goggles gaiters overalls gloves etc Handling and positioning of the HFP can be done by one person The operator must ensure that his working area is clear People animals electric...

Page 6: ...tions the instructions and instructions given in this instruction manual must be observed Wearing Personal Protective Equipment PPE is advised In the event of use in a confined space or of small volume or enclosed in a low point such as for example a tunnel forced ventilation should be implemented in this room This ventilation will be arranged so as to ensure the permanent evacuation of burnt gase...

Page 7: ...t work clothing preferably cotton or similar material covering the legs and arms A pair of high top safety shoes with good heat resistance A pair of handling gloves adapted to the risk of burns category 3 A pair of safety goggles suitable against projections of hot particles white glass with side shields or Welding goggles Approved hearing protection In the event of a fire shut off the gas supply ...

Page 8: ...installation procedure The unit is composed of The Preheater which integrate a variable speed air blower powered by battery a propane gas injection device a control panel a control unit The HFP is equipped with a connector for the gas connection Protections are installed to protect the gas connector against shocks and the batteries against rain A carrying handle is installed on the top of the box ...

Page 9: ...10 17 mm length 5 meters a STAUBLI type RBE female coupler a bleeding tube of the HFP preheater and its STAUBLI RBE connection A support to be screwed onto the rail allowing the HFP preheater to be placed in the working position A specific storage case for this set The fitted suitcase weighs approximately 46 kg It is used to store a second set of battery and a charger Sold separately Its closed ov...

Page 10: ...lasses suitable for the protection against hot particles white glass with side sheilds Shaded Welding goggles Ear Protection This list is a prerequisite it is likely to be modified with regard to the constraints specific to each particular environment that each site constitutes This remains the choice and decisions of the user 4 3 Safety checks before welding commences Make sure that the propane g...

Page 11: ...onditions are not met the HFP must be immediately removed from service 4 4 Handling the HFP To preserve health and wellbeing of the users the following rules must be followed when handling the HFP 4 4 1 Handling the HFP box 1 The full HFP set is sold with a transport box The box weight 49kg 2 To reduce stress on the user body the users must avoid when possible to carry the HFP a Use lifting equipm...

Page 12: ...ixing screw Place the HFP on its support frame so that the spout of the HFP is positioned in the centre of the moulds When placing the HFP on the railhead stand face on perpendicular to the rail move the unit round in front of your body and lean forwards to place it on and off the rail Do not stand side on to the rail and bend sideways and or twist your torso when doing this task If necessary loos...

Page 13: ...move it and use a different one The HFP checks the battery voltage before starting each cycle If the voltage is too low to complete a cycle the HFP will not start and illuminate the low battery indicator see 4 4 6 Control panel To preserve the longevity of the batteries it is advisable to avoid using a full battery with an empty battery Charging a battery takes about an hour The autonomy of the HF...

Page 14: ... in good condition the glass not broken and the case not distorted do not touch the setting the hose must not be split cracked or cut the connections at both ends of the pipe must be properly tightened Remove the bleed hose from the retaining spring clip Connect the end of the gas line hose to the HFP fitting Clip the hose into the retaining spring clip Propane hose connected Connect the regulator...

Page 15: ...re gauge must indicate the pressure specified in the instructions during the entire preheating cycle Only adjust this pressure on the regulator if it s necessary to maintain this value The pressure regulator pressure gauge must indicate the pressure specified in the instructions during the entire preheating cycle Only adjust this pressure on the regulator if it s necessary to maintain this value T...

Page 16: ...eak with the help of a flame If a gas leak is suspected do not attempt to correct it by tightening the fitting but dismantle the fitting in search of a foreign particle inserted in the parting hose In the event of such discovery change the seal 4 4 6 Ignition of the HFP preheater Make sure that the nozzle of the HFP is correctly centered in the moulds Set the main switch to position I adjustment w...

Page 17: ...n buttons allow you to adjust the time in 30s increments Start the HFP preheater by pressing the START button The green RUN indicator lights up for the duration of the junction preheating cycle In the event of a fault or malfunction detected by the on board PLC the ERROR indicator light comes on and the HFP preheater goes off ...

Page 18: ...ary 2022 rev6 Pandrol 2022 18 sur 38 4 4 7 Control panel Keyboard and display Main switch Charge USB socket The USB port is used to recharge an external device Phone etc The HFP must be turned on for charging to work ...

Page 19: ...the final speed This phase is used to preheat the torch and the mold In this phase the flames reach about 60 cm high at the start and 20cm at the end 2 Full power for a period set by the previously set time delay In this phase the flames reach 20 to 25 cm in height The height increases during preheating On the timer the countdown of the remaining time is displayed In the event of a malfunction fir...

Page 20: ... the cycle before the maximum speed is reached After 20 seconds switch off the HFP and start again 4 4 11 Stopping and removing the HFP When the required operating time has elapsed the HFP will shut down on its own Close the gas supply valve on the cylinder Return the main switch to position O The following operations are carried out on very hot parts and objects sources of risk of serious burns W...

Page 21: ...gas by connecting the purge hose then remove it Disconnect the regulator from the cylinder replace the bottle cap Put it in the suitcase in the housing provided for this purpose Coil the hose over the regulator Coil the power adapter Close and remove the suitcase Take the propane cylinder to the transport vehicle and secure it from movement or to the next work location The securing of the gas cyli...

Page 22: ... S0000473 January 2022 rev6 Pandrol 2022 22 sur 38 5 LAYOUT ON THE TRACK ACCORDING TO NF EN 13977 ...

Page 23: ...elds wears down the torch nose The torch should be replaced when the nose is bent or nibbled The possible tripping of one of the circuit breakers protecting the electrical circuits is visible through the window for checking the status of these circuit breakers which you only need to raise to reset the faulty circuit breaker A second trip of the circuit breaker following a reset requires the device...

Page 24: ...ten the 4 nuts that hold the nozzle 4 Replace the nozzle 5 Put back the 4 nuts Do not tighten it so it stays loose 6 Align the perpendicularity with the ground To facilitate the operation the HFP should be put on a flat and horizontal surface 7 Tighten slightly the 4 nuts 8 Align the vertical and horizontal perpendicularity Those perpendicularities are obtained by adjusting the compression level o...

Page 25: ... S0000473 January 2022 rev6 Pandrol 2022 25 sur 38 ...

Page 26: ... does not create a flame The gas supply is not connected or the gas cylinder is not opened Check the gas supply The solenoid valve is damaged Listen if the solenoid valve is functioning or if gas is coming out Damaged high voltage generator Check that a cracking noise can be heard within the first 5 seconds after pressing START If no noise contact the after sales service The HFP can be ignited wit...

Page 27: ... S0000473 January 2022 rev6 Pandrol 2022 27 sur 38 8 IDENTIFICATION The HFP benefits from a traceability code shown on this name plate COMPANY PLATE S0000473 ...

Page 28: ...46kg Fuel commercial propane gas packaged in 13 kg cylinders Nozzle Special refractory steel nozzle Operating temperature 5 to 40 C Protection index IP42 Noise emissions in operation 90 dB A at the workstation 1 m from the torch Vibration None Acoustic power 103 dB Lwa Sound pressure 92 dB Lpa 9 1 Dismantling and disposal The disposal of this HFP does not present any difficulties its dismantling w...

Page 29: ...DIN9 The presence of a charge The HFP is delivered with a standard 230V 50hz charge If the HFP is to be used in a country with another current standard it is necessary to purchase a case without charger and to buy the charger separately S000A473 HFP36V complete rectangular nozzle without charger type E A0 S000B473 HFP36V complete rectangular nozzle without charge type E B0 S001C473 HFP36V complete...

Page 30: ... S0000473 January 2022 rev6 Pandrol 2022 30 sur 38 Picture of the 2 regulators connectors available Square nozzle Round nozzle ...

Page 31: ...RE PARTS AVAILABLE FOR MAINTENANCE Preheater N N Description Quantity 1 35210008 or HFP Complete rectangular nozzle for HFP or 1 35210009 HFP Complete round nozzle for HFP 2 31260007 Torch seal 2 3 40908001 Nut nylstop M8 4 4 48402027 Battery METABO 18v 8Ah 2 2 1 3 4 ...

Page 32: ...R Rep No Designation QTY 50 48102016 Harris 25 propane pressure regulator type E 1 51 48302028 Gas regulator flame arrestor 1 52 S0000176 Propane hose 10 17 NF EN 559 5m 53 48301073 Clamp CL1020 2 54 48301008 RBE 06 splined sleeve coupler 1 51 5 2 Z C C 54 53 52 5 2 Z C C C V 5 2 Z C C C V 50 ...

Page 33: ...ystem Type DIN9 Rep No Designation QTY 50 2 S0000213 Harris 25 propane pressure regulator Type DIN9 1 51 48302028 Gas regulator flame arrestor 1 52 S0000176 Propane hose 10 17 NF EN 559 5m 53 48301073 Clamp CL1020 2 54 48301008 RBE 06 splined sleeve coupler 1 50 2 51 52 54 53 ...

Page 34: ... S0000473 January 2022 rev6 Pandrol 2022 34 sur 38 21245008 HFP support H90mm for vignole rail A Yellow N N Description Quantity 55 35910533 Support foot 1 56 47403007 M16x60 screw with Ø25 pad 1 ...

Page 35: ... S0000473 January 2022 rev6 Pandrol 2022 35 sur 38 21245016 HFP support H90mm for groove rail B Grey N N Description Quantity 55 35910535 Support foot 1 56 xx xx 1 ...

Page 36: ... S0000473 January 2022 rev6 Pandrol 2022 36 sur 38 21245017 HFP support H70mm for vignole rail C Blue N N Description Quantity 55 35910537 Support foot 1 56 47403007 M16x60 screw with Ø25 pad 1 ...

Page 37: ...uirements of article R4313 20 self certification procedure The relevant provisions of the following standards have also been used Standard NF EN 746 2 2010 Industrial thermal equipment Part 2 Safety requirements concerning combustion and handling of fuels Standard EN 60204 1 2006 Safety of machines Electrical equipment of machines PART 1 General rules Raismes 04 2021 Mr Thibaut DESCAMPS is the hol...

Page 38: ... S0000473 January 2022 rev6 Pandrol 2022 38 sur 38 More on pandrol com Raismes Z I du Bas Pré B P 9 59590 RAISMES FRANCE 33 0 3 27 22 26 26 infos pandrol pandrol com Pandrol ...

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