Fastrax Hellfire 900 Leitfaden

Part No. HF18948.Rev.3.04 November 2018 Printed in Canada

ANSI Z83.7-2017 / CSA 2.14-2017

Gas Fired Unvented Construction Heaters (Unattended Type)

IMPORTANT INSTRUCTIONS - SAVE THESE INSTRUCTIONS

Read all instructions before installing or using the heater. Please adhere to instructions published in this manual.

Failure to do so may be dangerous and may void certain provisions of your warranty.

Fastrax®is a registered trademark of Thermon Heating Systems, Inc.

ISO 9001

2014

HELLFIRE 900

Gas Fired Railway Switch Heater

Installation, Operation, & Maintenance Instructions

TABLE OF CONTENTS

A. Important Notices And Warning Symbols 4

B. Identification 6

B.1 Heater Labels ........................................................6

B.2 Model and Serial Number Tag...............................6

B.3 Components Diagram...........................................6

B.4 Control Panel Diagram - 240V Single Phase

Example Shown ....................................................7

B.5 Gas Manifold Diagram...........................................7

C. Pre-Operation Inspection 8

C.1 Important Notices..................................................9

C.2 Prior to Heater Start-Up ........................................9

D. Operation 11

D.1 Introduction......................................................... 11

D.2 Modes................................................................. 11

D.3 Start-Up Sequence (All Modes)........................... 11

D.4 Occurrences During Normal Operation ............... 11

D.5 Heat Output Adjustment ..................................... 11

E. Controls & Indications 13

E.1 AAR Signal Wiring - For non SCADA installations 13

E.2 Controller.............................................................13

E.3 Controls...............................................................14

E.4 Indications ...........................................................14

E.5 Terminal Blocks ...................................................15

E.6 Data Communications.........................................16

E.7 Controller EEPROM Memory ...............................16

E.8 Activating a COMMUNICATION Parameter..........16

E.9 Mode Parameters ................................................16

E.10 Activating MODE Parameter................................. 17

E.11 Fan Mode.............................................................17

E.12 Local EMS Mode.................................................. 17

E.13 RAIL THERMOSTAT Mode, Normal...................... 17

E.14 RAIL THERMOSTAT Mode, Reverse ....................17

E.15 Failure Shutdowns and Alarm Indications.............17

E.16 Fault Conditions ................................................... 17

E.17 Aggressive Retry Feature .....................................18

E.18 R e s et ...................................................................18

E.19 Energy Management System (EMS).....................19

E.20 Terminal Blocks ...................................................20

E.21 Inputs and Outputs..............................................20

F. Troubleshooting 21

G. Installation 25

G .1 O v e r v i e w .............................................................25

G.2 Recommended Tools..........................................25

G.3 Site Preparation - Typical Clearances .................25

G.4 Site Preparation ..................................................28

G.5 Heater Installation ...............................................28

G.6 Gas Supply Piping and Minimum Pressure Drop 28

G.7 Electrical Power Connections .............................28

G.8 Power Connections ............................................29

G.9 Thermostat Installation........................................31

G.10 Energy Management System (EMS) Options .....31

G.11 Inspection and Commissioning............................34

H. Heater Specifications 35

H .1 P e r f o r m a n c e........................................................35

H.2 Gas Firing............................................................35

H.3 Gas Conversion ..................................................35

H.4 Electrical .............................................................35

H.5 Controls ..............................................................35

H.6 Wiring Terminations.............................................35

H.7 Safety Features ...................................................35

H.8 Controller Terminal Identification .........................36

H.9 SchematicsMaintenance.....................................37

I. Maintenance 43

I.1 Thermostat Removal .............................................43

I.2 Motor/Impeller/Base Removal...............................43

I.3 Impeller Removal ..................................................43

I.4 Flame Rod and Spark Igniter Removal..................44

I.5 Burner Removal....................................................44

I.6 Burner Defroster Removal.....................................44

J. Service 45

J.1 Recommended Service Schedule........................45

J.2 Gas Supply Pressure ...........................................46

J.3 Gas Supply Leak Test ..........................................46

J.4 Manifold Leak Test...............................................46

J.5 Main And Safety Gas Solenoid Valves Leak Test .47

J.6 Dirt Trap And Strainer ..........................................47

J.7 Motor ...................................................................47

J.8 Vibration Specifications and Measurement..........47

J.9 Lubrication...........................................................47

J.10 Flame Safety Relay (FSR)......................................47

J.11 Flame Signal.......................................................48

J.12 Air Switch .............................................................48

J.13 Air Switch Calibration .........................................48

J.14 High Temperature Limit ........................................48

J.15 AAR Terminals, Signals, and Communications.....49

J.16 Burner ..................................................................49

J .17 D e f r oste r ..............................................................49

K. Parts 50

K.1 Parts - Heater Body.............................................50

K.2 Parts - Control Panel, 240V Single Phase............ 51

K.3 Parts - Control Panel, 208V Three Phase ............51

K.4 Parts - Control Panel, 460V/575V

ThreePhasewith120V Duplex Receptacle .........52

Important Notices and Warning Symbols

A. IMPORTANT NOTICES AND WARNING SYMBOLS

Keep this manual with the machine at all times. The purpose of

this manual is to provide owners, operators, and installers with

the precautions and procedures essential for the safe and proper

operation for its intended purpose.

WARNING

CAUTION. This symbol indicates a potentially

hazardous situation, which, if not avoided, may result in

personal injury or damage to the equipment.

WARNING

WARNING. This symbol indicates an imminently

hazardous situation, which, if not avoided, can result

in serious injury or damage to the equipment.

WARNING

WARNING. Read and adhere to the following. FAILURE

TO DO SO MAY RESULT IN SEVERE OR FATAL

INJURY. Warranty will be void.

NOTE: “NOTE:” indicates information or a company policy that

relates directly or indirectly to the safety of personnel or

protection of property.

Table 1 – Operation Warning/Avertissements (Intended for Signal Maintainers)

Symbol Description

English French

Risk of electrical shock or electrocution.

Disconnect electrical power prior to servicing.

Risque de choc électrique ou d’électrocution.

Couper le courant avant d’entreprendre l’entretien.

The heater is designed and approved for use as a

commercial heater (gas) – railway switch, class 2902 05

in accordance with ANSI Z83.7 / CSA 2.14. Check with

local authority, if you have questions about applications.

Cet appareil a été conçu et approuvé pour être utilisé comme

radiateur commercial (gaz) - aiguillage de voie ferrée de

classe 2902 05, conformément à la norme ANSI Z83.7 / CSA

2.14. Communiquez avec les autorités locales pour plus de

renseignements sur le lieu d’utilisation de cet appareil.

General hazard warning failure to comply with the

precautions and instructions provided with this heater,

can result in death, serious bodily injury and property

loss or damage from hazards of re, explosion, burn,

asphyxiation, carbon monoxide poisoning, and / or

electrical shock.

Only persons who can understand and follow the

instructions should use or service this heater. If you

need assistance or heater information such as an

instructions manual label, etc. Contact the manufacturer.

Mises en garde générales le non·respect des mises en garde

et des instructions fournies avec ce radiateur peut entraîner

la mort, des graves blessures et des pertes matérielles ou

des dommages à la propriété résultant d’un incendie, d’une

explosion, de brûlures, d’asphyxie, d’empoisonnement au

monoxyde de carbone et/ou d’un choc électrique.

Seules les personnes aptes à comprendre et à suivre les

instructions devraient se servir de ce radiateur ou le réparer.

Si vous avez besoin d’aide ou d’informations concernant ce

radiateur, soit une notice d’instructions, une étiquette, etc.,

Prière de communiquer avec le fabricant.

Fire, burn, inhalation, andexplosion hazard. Keep solid

combustibles, such as building materials, paper, or

cardboard, a safe distance away from the heater as

recommended by the instructions. Never use the heater

in spaces which do or may contain volatile or airborne

combustibles, or products such as gasoline, solvents,

paint thinner, dust particles or unknown chemicals.

Risque d’incendie, de brûlures, d’inhalation et d’explosion.

Garder les combustibles solides, tels les matériaux de

construction, le papier et le carton, à bonne distance de ce

radiateur, comme il est recommandé dans les instructions.

Ne jamais utiliser cet appareil dans des endroits qui

contiennent ou pourraient contenir des combustibles volatiles

ou en suspension dans l’air tels l’essence, les solvants, les

diluants pour peinture, les particules de poussières ou des

produits chimiques inconnus.

Not for home or recreational vehicle use. Ne pas utiliser dans une maison ou un véhicule de camping.

All persons employed in handling propane or natural

gas shall be trained in proper handling and operating

procedures, as required by local authorities having

jurisdiction.

Toute personne qui manipule le propane ou le gaz naturel

doit avoir suivi une formation sur les bonnes procédures de

manipulation et d’utilisation qui est conforme aux exigences

des autorités locales compétentes.

Important Notices & Warning Symbols

Symbol Description

English French

If you smell gas; immediately extinguish all sources of

ignition and turn off gas source. Call qualied service

technician to repair leak.

S’il y a une odeur de gaz : fermer immédiatement toute

source d’allumage et de gaz. Faire réparer la fuite par un

technicien qualié.

Do not attempt to manually light burner.

Heater equipped with an automatic electronic ignition

system.

Ne pas allumer le brûleur manuellement.

Radiateur équipé d’un système d’allumage électronique.

Risk of cutting ngers or hand.

Disconnect fan power prior to removing combustion

chamber access panel or air intake.

Risque d’amputation des doigts ou de la main.

Couper le courant au ventilateur avant d’enlever le panneau

d’accès à la chambre de combustion ou l’entrée d’air.

Heater can start automatically.

Exercise caution when in close proximity.

Attention : le radiateur peut démarrer automatiquement.

Faire preuve de prudence près du radiateur.

Burn hazard / hot surfaces.

Do not touch track ducts, nozzles or any non-insulated

duct connected downstream of heater during operation.

Surface chaude; risque de brûlure.

Ne pas toucher les conduits latéraux à la voie ferrée, les

buses ni aucun conduit non isolé branchés en aval d’un

radiateur en marche.

Sheet metal edges can be sharp.

Wear protective clothing when handling track duct,

insulted ducts and any other sheet metal components.

Risque de coupure.

Les rebords de la tôle sont coupants. Porter des vêtements

protecteurs lors de la manipulation des conduits isolés et tout

autre composant en tôle.

For use with ductwork only. Pour utilisation avec réseau de gaines seulment.

Retain manual for future reference. Conserver le manuel pour consultation ultérieure.

B. IDENTIFICATION

B.1 Heater Labels

1. Each heater has a ratings label, a logo label, a model and

serial number tag and a voltage label.

2. The ratings label contains all identication and safety

information. It is fastened by a lanyard and stored in the

manual pocket inside the control enclosure next to the gas

manifold. The electrical specications are indicated with a

punch mark.

3. The logo, located on the side of the air intake hood

identies the series as HELLFIRE, and the size, either 400

or 900.

4. The model / serial number tag is a blue aluminum plate.

The model number is applied to an adhesive backed label

bonded to the tag, and the serial number is engraved. The

serial number is a sequential 6-digit number.

Installation & Instruction

Manual Location

Voltage Label

Rating Label

B.2 Model and Serial Number Tag

1. The tag is located on the front and above the selector

switch.

2. This is true for all congurations including heaters supplied

with the bungalow option.

3. Congurations are identied on the tag as model “HF 900”

followed by a 5-digit number, an optional 2-digit dash

number and a revision letter. For example,

HF900 12345-01A (HF900 BUNG XXXXX-XXX - for

bungalow enclosed heaters).

4. The operating voltage label is found on the electrical

access panel. Have this information available when

requesting parts or service.

B.3 Components Diagram

5. The following component names are referred to in this

manual. See Section L - Parts for part numbers and

ordering.

Stand-Alone & Bungalow Enclosed Configurations

Identification Tag with Model and Serial Number

Identication

B.4 Control Panel Diagram - 240V Single Phase Example Shown

B.5 Gas Manifold Diagram

No. Label

1Track duct

2 Track duct elbow

3Rail mounting spring clip and pad

4Ballast retainer

5Thermostat box

6Precipitation detector

7Burner

8Regulator vents

9Condensation vent

10 Gas manifold

11 Control cabinet lid

12 Air intake hood

13 Ambient air temperature sensor

14 Air intake extension

15 Identication tag

16 Mode selector switch

17 Electrical control access panel

No. Label

18 Air intake plenum

19 Leveling leg

20 Control panel

21 Motor/Impeller/Base

22 Combustion chamber access panel

23 Transition duct

24 Sensor duct

25 Square to round adapter

26 Flex duct

27 Track duct deector

28 Tie duct

29 Rail thermostat

30 Point nozzle

31 Track duct mounting bracket

No. Label

1Ignition transformer

2Burner control / Flame Safety Relay

3 Purge timer card

4Reset module

5Controller

6Programming key

7EMS module

8Control circuit breaker

9 Motor circuit breaker

10 120V receptacle

11 Contactor

12 Control transformer

13 Power terminal block

14 Mode selector switch

15 Hour meter

16 Receptacle circuit breaker

17 Tank valve circuit breaker

18 Control and indication terminal block

19 Resettable fuse, burner defroster

20 Manifold terminal block

21 Rail thermostat receptacle

22 Precipitation detector receptacle

23 Flame signal amplier

C. PRE-OPERATION INSPECTION

Identication

No. Label

1Regulator vent

2Regulator vent pipe

3 Pilot gas solenoid valve

4Pilot gas pressure regulator

5Pilot manual shutoff valve

6Gas supply inlet

7Gas supply pressure gage

8Main gas pressure regulator

9 Main and safety gas

solenoid valves

No. Label

10 Manifold gas pressure gage

11 Main manual shutoff valve

12 Union

13 Burner mounting bracket

14 Burner defroster

15 Igniter

16 Flame rod

17 Burner

Pre-Operation Inspection

C.1 Important Notices

To ensure trouble free operation during the winter months, inspect

the system annually at the start of the season.

WARNING

WARNING. All persons employed in handling propane

or natural gas shall be trained in proper handling and

operating procedures, as required by local authorities

having jurisdiction.

Gas leaks shall be repaired immediately or, gas supply

valve closed until repairs can be made.

All work performed on railway property must be

carried out in accordance with local railway authorities

instructions.

CAUTION

CAUTION. Do not operate this machine until it has

been installed and commissioned according to

requirements specied in the installation section of this

manual.

NOTE: Perform inspection and operations in accordance with

the instructions provided in the service section of this

manual.

NOTE: This inspection guide assumes that all applicable service

bulletins have been implemented on the heater being

inspected.

NOTE: The outcome of any inspection items that differ from that

expected indicates further service is required.

C.2 Prior to Heater Start-Up

Table 2 – Heater Inspection List

Inspect Action

Condition of all ducting, particularly any

ex ducts Repair or replace damaged ductwork.

Inside of all tie duct and cross ducts Remove any blockages, such as debris and mud.

Track duct vents Close vents that do not direct air at tie plates or rods.

Set vent openings to 1/8” - 1/4” maximum.

Track duct mounting Verify track ducts do not interfere with normal movement of the switch points and do not interfere

with the signal system.

Flame rod and spark igniter

Remove and visually inspect for cracks in the ceramic, and evidence of soot. Replace any with

cracked ceramic.

If evidence of soot is found, clean rod and investigate condition of burner, gas manifold, and

inspect tie duct, cross ducts and air intake for blockage.

Flame rod and ignition wires Inspect boot for degradation, cracks and poor seals. Replace if necessary.

Inspect connectors for signs of corrosion. Clean connections, or replace wire if necessary.

Combustion chamber Verify it is clear of any obstructions or debris, ie. animal nests.

Cycling and high limit thermostat

installation

Verify thermostats are fastened and are in full contact with duct surface.

Replace any with damaged wire insulation.

Verify thermostat enclosure is sealed and dry inside.

Service surge protection Verify electric service has functioning surge protection.

Air switch port and vent Remove any obstruction.

Gas regulator vents Remove any obstruction.

Flame Safety Relay Verify it is installed and is in standby mode with ‘POWER’ LED blinking, and ‘ALARM’ LED off.

Gas source Verify propane tank is lled, or natural gas service is open and has pressure.

Open all manual gas shut off valves and inspect all gas lines for leaks.

Electrical service Verify electric service power is on. Close supply circuit breakers.

Flame Safety Relay Burner Control fault

histories

Using Honeywell display module S7800A1001 (Part number 9040-0021). Review and record the

last 6 stored fault history error codes. See Honeywell manual for description of faults.

H1 Code Hour Cycle

H2 Code Hour Cycle

H3 Code Hour Cycle

H4 Code Hour Cycle

H5 Code Hour Cycle

H6 Code Hour Cycle

Pre-Operation Inspection

Inspect Action

Electrical supply Verify correct line voltages at each heater. Must be within +/- 5% of nominal voltage.

Verify current draw is less than or equal to nameplate rating.

Gas supply Verify supply and manifold gas pressures are within nameplate limits when heater and all

connected loads are operating.

Flame signal strength

Verify ame signal strength is stable (+/- 0.5) and between 3.0 and 5.0 Vdc.

If signal strength is low:

– Clean or replace ame rod.

– Clean ame rod wire connections, or replace wire.

If cleaning or replacement of ame rod and wire does not increase strength, have burner serviced

or replaced.

Burner operation

Note current manifold pressure.

Set manifold pressure to maximum nameplate setting, measure point nozzle temperature, if

point nozzle temperature is 140°F or less above ambient air temperature have burner serviced or

replaced.

Return manifold pressure back to desired setting.

Air switch calibration

Block air intake 80%. Verify heater still operates.

Then block 90% and verify FSR alarms.

If heater fails with 80% or less blockage, recalibrate air switch.

Control and indication wiring Verify the correct control and indication wiring between the heater and the signal bungalow.

Energy Management System (EMS)

If heater is operated automatically by an Energy Management System:

– Verify EMS module is installed and connected with POWER LED lit.

– Verify controller is in AUTO mode.

– Verify precipitation detector and ambient temperature sensor installed and connected.

– Verify rail thermostat is mounted on rail and connected to surge isolator.

– Verify its operation.

Aggressive retry

Verify operation.

Turn gas supply off, toggle heater to “Manual”.

Verify three attempts made followed by lockout.

Return heater to desired operating mode.

Open gas supply.

Reset controller.

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