PANDROL HFP 36V User manual

Preheater
HFP36V
OPERATION AND MAINTENANCE
MANUAL
ENGLISH
S0000473
January 2022 rev6
Instruction video

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Revision
Revision
Date
Writer
Comments
V1
20/04/2021
ND
Creation
V2
06/12/2021
ND
Updated 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.

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Content
1. EXPLANATION OF SYMBOLS 4
2. GENERAL SAFETY INSTRUCTIONS 5
3. DESCRIPTION 8
4. INSTRUCTION FOR USE 10
4.1 Storage 10
4.2 Personal Protective Equipment 10
4.3 Safety checks before welding commences 10
4.4 Handling the HFP 11
4.4.1 Handling the HFP box 11
4.4.2 Handling the HFP unit 12
4.4.3 Positioning the preheater 12
4.4.4 Batteries 13
4.4.5 Installation 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 GUIDE 26
8. IDENTIFICATION 27
9. TECHNICAL CHARACTERISTICS 28
9.1 Dismantling and disposal 28
10. CONFIGURATIONS OF THE HFP 29
11. LIST OF SPARE PARTS AVAILABLE FOR MAINTENANCE 31
12. DECLARATION OF CONFORMITY 37

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1. EXPLANATION OF SYMBOLS
Read 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.

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2. GENERAL SAFETY INSTRUCTIONS
The HFP is only intended to be used for the preheating of rail ends in the moulds prior to
welding with our Aluminothermic Welding Process.
• In the event of use other than that recommended, PANDROL declines all responsibility.
• Never use the HFP without first reading and understanding its instructions for use.
• The user must always work with material in good order.
• Never use the machine if you are tired or if you are taking substances, such as drugs, alcohol, which could impair
vision, dexterity or the ability to judge.
• The HFP user must comply with the regulations, procedures and site safety instructions in force.
• The HFP is a dangerous machine 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 cables, flammable substances,
etc.)
• The user should not make any changes to the design or configuration of the machine without consulting
PANDROL.
• The operator must have a stable position before starting to work.
• Ensure correct positioning of the HFP on its support when in use.
• Ensure that the propane cylinder is properly supported during use, keep it vertical, never lay the cylinder down
during use.
• Replace the protective cap of the propane cylinder valve before any handling, never handle the cylinder by its
valve directly.

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• Use of gas cylinders must be in a well-ventilated area at all times.
• Transport and store the HFP in its protective case.
• Secure the propane cylinder on a support linked to the vehicle during transportation.
• Position the flexible hoses straight with no kinks and away from sharp objects.
• Always use this HFP under supervision; never let the HFP run alone.
• Use lighting or install temporary lighting when carrying out work at night or in dark places.
• During maintenance operations, 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 gases and any unburned
gases.
• It is strictly forbidden to intervene on or in the HFP during operation and bring your hands or other parts of the
body in contact with the flame.
• It is forbidden to operate the device outside of its possibilities and capacities predetermined by the factory settings
and stated in this document.

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•Wearing Personal Protective Equipment is necessary for the use of this HFP Preheater. This list is a prerequisite;
it is liable to be modified with regard to the constraints specific to each particular environment that each site
constitutes, which remains the choice and decisions of the user.
Suitable flame retardant 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 at the cylinder and use an extinguisher to extinguish the fires. CO2
extinguishers are preferred.
•In the event of an accident, refer to the worksite safety instruction.

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3. DESCRIPTION
This HFP preheater is a device for heating the rails as part of the realization of a weld of rails by the thermite welding
process.
This manual is written in conjunction with the instructions for installing the welds. These documents should be referred
to for the welding and 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.
The equipped box weighs 18 kg without battery and 19 kg with batteries.
Its overall dimensions are (L x W x H): 750 x 340 x 295 mm approximately.

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• A preheating torch attached to the HFP.
• 2 batteries 18V Metabo 8Ah
• A gas supply line comprising:
- a HARRIS Model 25 GX brand pressure regulator adjustable from 0 to 4 bars to be screwed onto
a conventional 13 kg propane gas cylinder,
- a flame arrestor valve,
- a gas pipe standard EN 559 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 overall dimensions are (L x W x H): 1000 x 500 x 400 mm approximately.
Purge hose
2 batteries
Preheater HFP
Support
Charge
Gas supply line

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4. INSTRUCTION FOR USE
4.1 Storage
•Do not expose the machine to rain, this could cause a malfunction.
•Pack the HFP in its suitcase.
Be careful, do not store it immediately after preheating, let the nozzle cool down.
for about 15 minutes.
4.2 Personal Protective Equipment
It is necessary to wear Personal Protective Equipment when using the HFP Preheater. You must have :
–Suitable flame retardent clothing covering the arms and legs.
–Welders boots with heat resistant soles or high top safety shoes with heat resistant soles and gaiters.
–A pair of handling gloves adapted for the risk of burns Category 3.
–Pair of fireproof gloves.
–A pair of safety glasses 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 gas cylinder is sufficiently filled to carry out the preheating correctly, which takes about
eight minutes (variable depending on the nature of the weld) under a gas pressure of 1 bar, i.e. a minimum quantity
of gas of 1 kg to maintain correct propane vaporization and therefore correct preheating.
The use of scales or equivalent can be used to find out the amount of gas remaining in the cylinder.
With the HFP and its connection hose in its transport and storage case, carefully remove the HFP.

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Examine the condition of each element of the HFP for:
- the pressure gauge must be in good condition, the windows not broken and the boxes not distorted,
- the gas hose must not be split, cracked or cut,
- the connections at both ends of the hose must be in good condition and correctly tightened.
- the body of the HFP must be clean, not show any signs of damage,
- the outlet nozzle of the HFP preheater must not be scaled or damaged by oxidation,
If any of these conditions 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 equipment such has hoist whenever it is possible. In that case, web sling must be put
around the handles.
b. Use the wheels to transport the box whenever it is possible.
3. If the HFP case must be transported by hand, 2 persons are required; The HFP case must be put down
every 10m to allow the users to have a rest.

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4.4.2 Handling the HFP unit
The HFP weight 19kg. An ergonomic handle has fixed on the top of the unit to facilitate the handling. It is
preferable to keep the HFP in its transport box on the railborne trolley at site and to take it out when needed.
If the HFP has to be carried on long distance, the user must put down the HFP every 10m to have a rest or when
not possible switch hand to avoid reduce upper limb stresses.
4.4.3 Positioning the preheater
- Position the HFP support and tighten the fixing 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, loosen the support in order to position the HFP correctly.
- Ensure the good stability of the HFP unit and support.
- In case of strong wind, set up the HFP back to the wind so the flames are now blown on the HFP when it
runs at low speed during the first seconds of preheating.
- The user's workstation area is represented by a white perimeter and 4 arrows.

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4.4.4 Batteries
The HFP36v works with two 18v batteries in series. It is necessary to have 2 batteries to make it work.
Before use, check the charge level of the batteries by pressing the test button. If a battery shows only one light,
remove 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 HFP with 2 full batteries is 8 preheating cycles of 8
minutes.
Checking the charge level

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4.4.5 Installation of the gas line
Position the propane cylinder near the HFP on the side of the track.
Make sure the cylinder is stable before removing the protective cap from the valve.
Do not produce sparks, do not present a flame and do not smoke during this phase!
Take the regulator and gas line hose assembly.
Examine the condition of each item thoroughly for:
- the regulator must not have any trace of shock or damage,
- the pressure gauge must be 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 to the propane cylinder. The cylinder must remain vertical at all times during the welding
operation. Tighten the screwed connection of the regulator on the propane cylinder very moderately (not to the left).
Open the cylinder valve a quarter turn and listen and / or feel for any leaks at the connection.

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If a gas leak is discovered, immediately close the gas cylinder valve and remedy the fault before continuing with the
work.
The adjustment of the propane gas outlet pressure must be established at the pressure defined in the welding
instructions.
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.
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.
The gas pressure reading on the manometer when stopped, will be slightly higher than the reading during the
preheating operation.

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The gas pressure reading on the manometer when stopped, will be slightly higher than the reading during
the preheating operation.
Never search for a gas leak 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
wheel

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Adjust the preheating time on the timer of the HFP Preheater. The up and down 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.

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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.

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4.4.8 Keyboard and display
LED« RUN »
LED« ERROR »
TIME
LED « LOW BATTERY »
Time +30s
Time +30s
Cooling
START
4.4.9 HFP preheater operating cycle
Two operating phases are carried out by the HFP preheater:
1. The start-up for a duration fixed at about 35 seconds, phase in which the blower turns, gradually
accelerates to reach 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, first close the gas cylinder valve, then position the handle of the general switch on O.
Let the HFP preheater operate for the entire time delay preselected on the timer.

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4.4.10 HFP Operation
Monitor the HFP for the time required during preheating, you can also use this time to prepare the crucible and the
portion. The noise of the turbine and the HFP provides information on its operating state; monitoring this operating
parameter requires staying in the immediate vicinity.
If the HFP does not start or does not create a flame, refer to the malfunctions table.
In the event that the problem arises from a fault in the high voltage generator generating the spark, the HFP can be
ignited with a bell igniter.
Start the cycle, position yourself with your back to the wind, reach out and activate the igniter over a pipe. Do not
position yourself above the moulds, this will avoid any risk of burns when the flame emerges. This operation must
be carried out during the first 20 seconds of 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.
Wearing personal protection against the risk of burns and the use of handling tools are required.
Carefully remove the HFP, along with the gas hose and the electric cable from its support, taking care not to
damage the internal walls of the moulds.
Carefully place the HFP in a safe area away from the casting operation, taking care not to touch the torch nose, or
to place it near or against anything flammable. Take care not to bang the nose as this can result in damage to it.
Loosen the thumbscrew on the rail of the HFP support and remove it.
Resume the aluminothermic welding procedure, by the casting operation, which must very quickly follow the
preheating phase.