BAIEKUR COILS HOT COILS 400 User manual

HOT COILS®
MODEL 400/1200
USER MANUAL
(is a registered trademark of)
BAIEKUR COILS Ltd.
Sept. 2012

1
INDEX
SECTION PAGE
1. Introduction 2
2. Limited Warranty 4
3. Quick Reference 5
4. Important Safety Rules 6
5. Operation 9
6. Service 12
7. Replacement Parts 12
8. Specications 13

2
1. Introduction
Thank you for your purchase of a Hot Coils®
Heater. We know you will nd the Hot Coils®
Heater a valuable addition to your tool kit and
you will benet from the efciency, safety and
enviromental advantages that are to be found
over traditional pipe pre-heating methods.
The coil heater is designed to preheat new
piping to specied temperature prior to the
welding sequence (this is usuallyspecied by the
owner/welding procedure/ or the boilers branch,
or any other authority that has jurisdiction).
Also all insitu piping in a H2S service requires a
hydrocarbon bake out prior to cutting or welding
(specied by authority in place). The heater coil
in this case expels the H2S molecules at 550º
F (286ºC) so that cutting and or welding can
commence without fractures to the parent metal.
Hot Coils®offer SAFTY ADVANTAGES over
traditional pre-heat techniques.
Hot Coils®can be installed quickly and easily.
The coil provides even heat throughout the weld
joint and provides better weld platform as heat is
localized.
Hot Coils®offers different models and may not
be exactly as shown in Figures 1 and 2 below.
Thermostat
Plug Receptical
Pin
Figure 1 Figure 2

3
1. Introduction (con’t.)
Getting Quality Service:
Hot Coils provide a process for dealing with your questions or problems to ensure that product
quality continues with your Hot Coils®dealer support.
Follow these steps to get responses to questions regarding your product:
1. Refer to Hot Coils®User Guide
2. Contact your Hot Coils®dealer with unanswered questions
3. Contact the Hot Coils®customer service department at 1 866 942 6457
Hot Coils®
is a registered trademark of
Baiekur Coils Ltd.
Box 264
5312-52 A Street
Wabamum, Alberta
Canada
T0E 2K0
Telephone: 1 866 94 COILS
(1 866 942 8657)
Email: [email protected]
Web: www.hotcoils.com

4
2. Limited Warranty
Hot Coils®warrants to the original purchaser
that each new Hot Coils®is free from defects in
material and workmanship and agrees to repair
or replace, under this warranty, any defective
heater coil for 90 days from the original date of
purchase as the exclusive remedy. The essential
purpose of this warranty is to provide the
purchaser with a properly functioning coil. Any
action for breach of any terms of this product
shall be commenced within one year from the
date of breach. This warranty is not transferable.
SECURING WARRANTY
To secure warranty service the purchaser must
(1) report the Equipment defect to an authorized
dealer and request warranty service within the
applicable 90 Day Warranty Period (2) present
evidence of the warranty start date with valid
proof of purchase and (3) make heater coil
available to authorized dealer to repair or replace
for a reasonable amount of time.
DISCLAIMER OF ALL IMPLIED WARRANTIES
Hot Coils®makes no implied warranties or
statutory condition or warranties of
merchantability or tness for particular purpose
whether pursuant to the Sale Goods Act, the
Uniform Commercial Code, the commercial code
of any Province, state or territory, or any other
statute of any Province, state or territory.
No Representation or Condition.
To the extent permitted by law, Hot Coils®nor
any company afliated with it makes any
warranty, representation, condition, or promise,
expressed or implied, verbal or otherwise, as to
the quality, performance or freedom from defect
of the coil.
No Warranty Of Title
Hot Coils®does not warrant that the purchaser
has any right to convey the title of purchased
coils.
EXCLUSION OF REMEDIES
In no event will an authorized dealer,
Hot Coils®, or any company afliated with
Hot Coils®, be liable for any consequential
damages or injuries, including but not limited to,
loss of prots, rental or substitute equipment,
other commercial or personal loss, personal
injuries or property damages arising from a result
of a fundamental breach, breach of a
fundamental term, or any use, any handling, or
any maintenance of the Hot Coils®.
No Dealer Or Agent Warranty
The seller has no authority to make any
representation or promise on behalf of
Hot Coils®or to modify the terms of
limitations of this warranty in any way.
Oct. 2010

5
3. Quick References
IMPORTANT
DANGER
WARNING
CAUTION
This symbol alerts you to potential hazards
that can kill or injure either you or others.
Indicates a danger concerning operations
that if not performed properly will lead to
death or injury to persons. In order to use
the equipment safetly always pay attention
to these dangers.
Indicates a warning concerning operations
that if not performed correctly could lead to
death or injury to persons. In order to use
the equipment safetly always pay attention
to these warnings.
Indicates a caution concerning operations that
if not performed correctly could lead to
moderate to minor injuries or property
damage. In order to use the equipment
safetly always pay attention to these cautions.

6
4. Important Safety Rules
1. 4.
5.
2. Unit will become hot on the outside
(150º F/66º C) when in use. Always wear
proper PPE when handling heater coil.
3. Do not operate in gaseous or hazardous
conditions.
6. Do not operate in gaseous or hazardous
conditions.
IMPORTANT CAUTION
CAUTION
CAUTION
DANGER CAUTION
Read ALL instructions in the
user’s manual before using
the heater coil.
Do NOT use the Hot Coil®as a heating
element for anything other than the perscribed
purpose.
Do NOT immerse in water or any other liquid
or operate in wet conditions.
HOT SURFACE
Contact with skin may cause
burns.
DO NOT TOUCH
The coil is not electrically
explosion proof. In gaseous or
hazardous enviroments, use
of electrical equipment could
result in re or explosion.
Do NOT plug Hot Coil®in
when in wet conditions.
Burn
Hazard
Fire
Hazard
Shock
Risk

7
7.
8.
CAUTION
CAUTION
The Hot Coil® plug must be connected to
a properly grounded power cord. Ensure
that the power cord is in good condition.
When using a power cord ensure it is heavy
enough to carry the current the Hot Coil® will
draw. An undersized cord will cause a drop in
the line voltage.
The table below shows the correct size to be
used, depending on cord length and
amperage rating. If in doubt, use the next
heavier cord (wire larger in gauge).
See rgure 3.
Always disconnect from power source before
removing Hot Coil® or setting it in a new
location. Also, disconnect from the power
source prior to cleaning.
Volts Max. Gauge For Cord
Total Length In Feet
120 <50 51-100 101-150
Amps American Wire Gauge
6-10 18 16 14
10-12* 16 14 12
12-16 14 12 Not
Recommended
*Heater coil draws 15 amps Fig. 3

8
9.
10.
11. 13.
14.
12.
IMPORTANT
IMPORTANT
CAUTION
CAUTION
Hot Coils®are controlled by thermostat only.
There is no ON/OFF switch.
When transporting or storing keep unit dry
and safe from damage.
Make sure the power cord does not touch the
heater other than at the plug. Secure power
cord to something other than the Hot Coil®
or pipe to prevent burning of the cord. Make
sure the cord does not present a tripping
hazard.
Make sure unit is secured properly on pipe
priot to releasing it. Use care in handling
heater coil at elevation that you don’t drop unit
on someone or on equipment. Do not drop, hit
or abuse the Hot Coil®. Do not operate coil if
it is damaged or malfunctioning. This includes,
but is not limited to damage or dents to the
outer cover or inner diameter surface of the
ceramics. Report any damage to your safety
representative and/or supervisor for immediate
removal from service. Return the Hot Coil®
to an authorized dealer for inspection prior to
reusing.
WARNING
WARNING
Damage to internal diameter
ceramics may expose bare
wire and cause an electrical
short.
Replace all safety decals that are not in place
and/or damaged. Contact your authorized
dealer for replacement decals.
Shock
Risk

9
5. Operation
Start Up
1.
2. Inspect heater coil for damage before
using.
4. Open Hot Coil®by pulling the latch pin.
(see gure 4).
3. Inspect area for combustibles, gaseous
or hazardous materials, and ensure the
work area is dry.
5. Fit Hot Coil®over pipe. Place units as
shown in g. 5 with plugs at the 3 o’clock
position. (NOTE: use proper heater
coil for pipe diameter being worked on).
IMPORTANT
WARNING
DANGER
Read ALL instructions in the
user’s manual before using
the heater coil.
Damage to internal diameter
ceramics may expose bare
wire and cause an electrical
short.
The coil is not electrically
explosion proof. In gaseous or
hazardous enviroments, use
of electrical equipment could
result in re or explosion.
Shock
Risk
Fire
Hazard
Latch Pin
Pipe
Hot Coils®
Fig. 4
Fig. 5

10
5A. For models 800,1000,and 1200 orientate
coil so arrow located on outer shell by
handle points towards joint to be heated.
6. Secure unit in place by reattaching pin in
latch.
Efciency Note: Installing Hot Coils®on
several joints at one time will reduce waiting time
and maximize number of joints welded per day.
CAUTION
DO NOT leave units at elevation until latched,
due to potential of heater being jarred and
falling on someone or equipment. (g. 6)
The number of coils heating at one time is only
limited to standard 110 volt sources available.
(This compares very favorably to using high
voltage trucks or other current methods).
7. Set thermostat setting prior to plugging
in Hot Coils®. Dial on thermostat is for
guidance only as desired temperature
setting will vary with ambient temperature.
Adjust temperature by using a standard
insulated screw driver. Turn clockwise
to increase temperature, turn counter
clockwise to reduce temperature.
(see g. 7).
8. Install all monitoring devices such as data
loggers, chart recorders, or any other
devices that may be required before
plugging in power source.
9.
CAUTION
Use care when installing power
cord. Always install Hot Coil®
end connection rst ensuring
it is in the appropriate condi-
tion, the right size (see gure
3), does not present a tripping
hazard nor does it touch the
pipe being welded, and is not
in contact with the heater coil
other than at the plug.
Shock
Risk
Fig. 5A
Fig. 6
Reattach Pin
Thermostat
Reattach Pin
Fig. 7

11
10. When conditions are met and your safety
representative has reviewed all safety
requirements, plug in the power cord to a
properly grounded power source 110 volts,
15amp service (see g. 3 for proper cord
sizing).
11. After 15 minutes check the pipe
temperature with temperature sticks or
other devices mentioned in section 8.
Adjust thermostat up (clockwise) or down
(counter clockwise) to achieve desired
temperature using an insulated standard
at screw driver.
12. After desired temperature is achieved and
has been approved by Quality Assurance,
you can begin to weld. Hot Coils®can
easily be slid to give you the required
access room for welding.
Note - use anti splatter spray or paste on
outside shell of Hot Coils®to avoid splatter
sticking to stainless.
CAUTION
The heater is instantly on when plugged into a
power source, as there is no On/Off switch.
Maximum internal temperature is
550ºF/286ºC.
CAUTION
CAUTION
HOT SURFACE
Contact with skin may cause
burns.
DO NOT TOUCH
Use proper PPE when
handling the Hot Coils®.
When Required Work Is Complete
1. Unplug power cord from power source.
2. Allow a cool off period until it is safe to
remone the Hot Coil®.
3. Remove pin from the latch and open the
heater coil (g.8)
Burn
Hazard
Burn
Hazard
Fig. 8

12
4. Remove unit from pipe.
5. Carefully relocate heater coil to next
desired weld location and repeat the start
up procedure.
6. When nished with the unit store in a dry
protected location.
6. Servicing
Clean outside casing with dry cloth.
Note - use anti splatter spray or paste on
outside shell of Hot Coils®to avoid splatter
sticking to stainless
Clean inside surface with dry cloth.
Inspect for any damage before and after each
use. Report any damage to your safety
representative or supervisor for immediate
removal from service. Hot Coil®should be
returned to an authorized servicing dealer
7. Replacement Parts
Latch pins and decals are available from an
authorized Hot Coils®Dealer.
WARNING
Damage to internal diameter
ceramics may expose bare
wire and cause an electrical
short.
Shock
Risk

13
8. Specications
Std. Pipe Dia. 4 6 8 10 12
Model No. 400 600 800 1000 1200
Voltage (1) 110 / 120 110 / 120 110 / 120 110 / 120 110 / 120
Hertz 60 Cycle 60 Cycle 60 Cycle 60 Cycle 60 Cycle
Watts 1500 1500 1500 1500 1500
Amp. 15 15 15 15 15
Max. Inside Temp. (2) 550°F 550°F 550°F 550°F 550°F
(286°C) (286°C) (286°C) (286°C) (286°C)
Time to Max. Temp (2) 20 min. 20 min. 20 min. 20 min. 20 min.
Adjustable Thermostat Standard Standard Standard Standard Standard
Thermostat Accuracy +/- 2.5 F +/- 2.5 F +/- 2.5 F +/- 2.5 F +/- 2.5 F
Coil Wall Thickness 1.75’’ 1.75’’ 1.75’’ 1.75’’ 1.75’’
(45 mm) (45 mm) (45 mm) (45 mm) (45 mm)
Outside Dia. 7.5” 9.5’’ 11.5’’ 13.5’’ 15.5’’
(191 mm) (241 mm) (292 mm) (343 mm) (394 mm)
Width 6 in. 6 in. 6 in. 6 in. 6 in.
(150 mm) (150 mm) (150 mm) (150 mm) (150 mm)
Weight 6lbs 6.5lbs 7lbs 7.5lbs 8lbs
(2.7 kg) (2.9 kg) (3.2 kg) (3.4 kg) (3.6 kg)
(1) Also available in 220 volt on special order.
(2) Based on 4 inch schedule 40 pipe at an ambient temperature of 70° F (21° C)