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Fastrax G Series

CCI Thermal Technologies Fastrax G Series Installation & Operation Manual

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Installation & Operations Manual
G Series - Control Panel Package
Contents
Equipment Inspection
System Layout
Single Stand Alone Switch With Frog ..................................................................................................................... 8
Crossover No. 20/24 Switches With Frogs ............................................................................................................. 9
No. 14, 15 Or 16 Standard Switch Size - All Tie Styles ........................................................................................ 11
Control Panel Installation
Assembling Fastrax® FCSA Panel Support Structure ........................................................................................... 14
Installing Fastrax® FCSA Panel ............................................................................................................................15
Installing Fastrax® Aerial Snow Sensor & Support Mast ....................................................................................... 16
Junction Box Installation
SwitchBlade® Heater Installation
SwitchBlade® Heaters (Field Side Running Rail) Switches Up To No. 16 ............................................................19
SwitchBlade® Heaters (Field Side Running Rail) Switches No. 20 - 24 ................................................................ 21
SwitchBlade® Heater(s) For Gauge Side Of The Moving Rail .............................................................................. 23
SwitchBlade® Heater(s) For Spring Frog (Spring Frog Channel Style) ................................................................. 24
SwitchBlade® Heater(s) For Spring Frog (Retrot Style) ...................................................................................... 25
Crib Heater Installation
System Wiring
Control Panel SwitchBlade® Heater Wiring - Stand Alone/Extension Panels Only ............................................... 29
2
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System Wiring Diagrams
Master Control Panel Wiring Diagram Up To (4) Fastrax® Extension Panels ....................................................... 36
Master Control Panel Wiring Diagram Up To (8) Fastrax® Extension Panels ....................................................... 38
Junction Box Connections .................................................................................................................................... 44
Junction Box Heater Connections ........................................................................................................................ 45
Control Panel General Equipment Procedures
Options Available For The Master/Extension Control Panel ................................................................................ 58
®
SwitchBlade
Procedures
Heating ........................................................................................................................................... 59
CCI Thermal Technologies Inc.
3
A. EQUIPMENT INSPECTION
A.1 REVIEW EQUIPMENT PAPERWORK
1. Identify the switch and frog sizes to be heated on your
project.
2. Ensure that the Pick Ticket (list of Fastrax® heating
equipment and accessories) provided with the shipment, matches the items listed on the complete Bill of Material for your project.
3. Notify your supervisor, purchasing department or
Fastrax® of any missing or damaged parts.
A.2 BILL OF MATERIAL
Table A.2-1 provides the scope of Bill of Materials available for standard switch and frog layouts and parts packages. A custom Bill of Material for special layouts is also available. A copy of the Bill of Material can be acquired by contacting your supervisor or CCI Thermal Fastrax®.
Table A.2-2 details a sample Bill of Material listing, refer to your company Bill of Material for exact system parts.
Table A.2-1 - Bill of Material by Standard Application
SWITCH TYPE
No. 9 No. 10 No. 11
- -
- -
No. 14 No. 15 No. 16
No. 20 No. 24
No. 30
Power Operated Turnout with Power Operated Movable Point Frog
Scanner and Dragging Equipment Detection Heating Package
- Power Operated Turnout
- Power Operated Turnout with Spring Rail Frog
Power Operated Turnout with Power Operated Movable
Automatic Gas Snow Control Package
BILL OF MATERIAL - APPLICATION
Spring Rail Frog
Power Operated Turnout
Power Operated Turnout with Spring Rail Frog
Power Operated Turnout
Power Operated Turnout with Spring Rail Frog
Spring Rail Frog
Power Operated Turnout
Power Operated Turnout with Spring Rail Frog
Spring Rail Frog
Point Frog
Platform Heating Package
(2) No. 20 / 24 Power Operated Turnout with (2) Power Operated Movable Point Frog
Quantity
Required
Fastrax
®
Part No. Description
1 FCM4
2 GDSM1-12148200
3 FCSA3630U
8 FSR32420
4 FSE32408
12 FCH152409
4 FSM32412
8 FSM42403
5 FJA200SU Fastrax
1 FJAM200SUP Fastrax
1 FA2032
Table A.2-2 - Bill of Material Example
Master Control with Extension Panels
®
Fastrax
Master Control Panel - Controls maximum of 4 Extension panels. Minimum 10 AMP, 120V, 1-phase
required. Enclosure size: 36” H X 30” W X 10” D.
®
Fastrax
Extension Combination Switch & Movable Point Frog Control Panel - Controls heaters for (1) No. 20 switch with crib and moving rail heaters and (1) No. 20 movable point frog. 48 kW maximum capacity, 200 Amps, 240V, 1-phase disconnect. Enclosure size: 36” H X 30” W X 10” D.
®
Fastrax
Control Panel Support Assembly - 36” H X 30” W overall panel size. 4” square vertical support risers. Includes (2) 4” PVC raceways.
®
Fastrax
SwitchBlade® Rail Heater - 5,800W total, 240V. 300W per foot of active heater length. 20 ft overall length. (11) FRB600 Spring tension clamp kits included. No drilling required.
®
Fastrax
SwitchBlade® Rail Heater - 2,200W total, 240V. 300W per foot of active heater length. 8 ft overall length. (5) XTC-0193 Anchor spring tension clamp kits included. No drilling required.
®
Fastrax
Crib Heater Assembly - 1,350W total, 240V. 150W per foot of platform length. 8 ft L X 8” W X 2-1/2” H. Includes (4) jack-bolt clamps.
®
Fastrax
SwitchBlade® Heater for Movable Point Frog - 3,400W total, 240V. 300W per foot of active heater length. 12 ft overall length.
®
Fastrax
SwitchBlade® Heater for Movable Point Frog - 750W total, 240V. 400W per foot of active heater length. 2 ft 9” overall length.
®
Junction Box Assembly
®
Junction Box with Snow Sensor Assembly
®
Fastrax
Installation Kit - Includes entrance glands, insulated connector blocks, liquid tight extra exible protective conduit, exible conduit connectors, stainless steel hose clamps, wire markers, test and tool accessories.
Hollow Metal Ties
4
Fastrax
TM
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A.3 PICK TICKET EXAMPLE
A
_
The Pick Ticket is included with the Fastrax® product shipment. The following sample Pick Ticket details the list of Fastrax® products in a shipment. Please compare the Pick Ticket with the items listed on the Bill of Material to be sure you have all required parts for your project.
Note: The Pick Ticket may not be available if the shipment was warehoused prior to project site delivery.
Pick Ticket# 003378
1500 W. Campus Drive Littleton, CO 80120 Phone: (303) 979-7339 Fax: (303) 979-7350
Bill To: Ship To:
00001063
123456
Class 1 Railroad Company Class 1 Railroad Company
Anywhere, USA, Anywhere,
09/21/2005
Ship Via
BEST WAY
#20/24 Crossover w/ MPF and HST
09/30/2005 003378
Item#
FOB
FASTRAX
UOM
Bin Location
EACH NONE Fastrax Master Control Panel.
EACH NONE Fastrax Extension Control Panel.
EACH NONE Fastrax® control panel support structure assembly
Required
1 Master Control Panel - Maximum 4 SlavesFCM4
2 Extension Panel-Combo. Switch & MP FrogGDSM1-12148200
3 Fastrax® Panel Support StructureFCSA3630U
Special Instructions
Call for more information
From Our Order#Date Required
Shipped
Control maximum of 4 Extension panels of any size. Minimum 10 Amp 120 Volt 1-phase required. Enclosure size: 36"H X 30"W X10"D. Panel Serial #:__________________
Combination Switch and Moveable Point Frog Heater Control Panel. 1 Switch and 1 Moveable Point Frog. 48KW maximum capacity. 200 Amp 240 Volt 1-phase disconnect Control 2 switch heaters, 1 movable point frog heater, 4 FCH152409 crib heaters. Enclosure size: 36"H X 30"W X10"D.
36 Inch high X 30 inch wide overall panel size 4 inch square vertical support risers. Includes (2) 4" PVC protective raceway assemblies.
erial Sensor Serial:_____________
ContactCustomer ID
TelephoneCustomer PO
Special Order Drop Ship
Salesperson
John Doe
Description
Facsimilie
TermsOrder Date Comments
NET 30
EACH NONE Fastrax® SwitchBlade® Rail Heater -
Packed By Total Weight# of CartonsChecked ByPulled By
8 Fastrax® SwitchBlade® Rail HeaterFSR32420
5,800W total, 240V. 300W per foot of active heater length. 20 ft overall length. (11) FRB600 Spring tension clamp kits included. No drilling required.
1
1 of 3Page #09/21/2005Date Printed
CCI Thermal Technologies Inc.
5
A.4 EQUIPMENT CHECK
Note: Notify your supervisor, purchasing department or
Fastrax® of any missing or damaged parts.
1.0 Control Panel:
1. Using a Phillips screwdriver or Phillips driver head
and power drill, remove top and sides of panel crate.
Note: Inside each stand alone or master control panel crate there is one FAS1A Aerial Snow Sensor located in a box. Keep the sensor in a safe place until the panel support and panel installation are complete.
2.0 Control Panel Support:
1. Using a Phillips screwdriver, remove top and sides of
panel support assembly crate.
2. Ensure that each panel support size matches the
corresponding panel size.
3.0 Heating Equipment:
2. Using a socket wrench, remove lag bolts from the
crate.
3. Open the panel and check that the nameplate
information matches the Bill of Material list.
Figure A.4.1 - Typical Packaging
1. Unpack each heater at the project site, prior to
installation.
2. Ensure the correct voltage is marked on each heater
for your project.
3. Ensure the part number on each heater matches the
Bill of Material for your project (refer to page 4 - A.2-1 Bill of Material and Figure A.2.2).
6
Fastrax
TM
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Figure A.4.2 - Heater part number and voltage
4. Test each heater using the 500 Volt DC scale on a
standard meg ohm meter.
a) Connect one lead of the meg ohm meter to the
metal jacket of the heater and the insulation resistance should read at least 20 meg ohms from conductor to outer meter jacket (refer to Figure A.4.3). Do not come into contact with heater while performing the meg ohm test.
c) Record the ohm readings for each heater on the
“System Checkout” sheet located at the back of the manual.
4.0 Junction Box Assembly:
Ensure that each junction box has a corresponding
support pedestal.
5.0 Installation Accessories:
Unpack the installation accessory kit and check that the
contents matches the description on the Pick Ticket.
B. SYSTEM LAYOUT
B.1 LAYOUT GUIDELINES
1. Prior to installation of any of Fastrax® equipment, mark
or tag the location for product installation.
2. Locate equipment for each switch or frog.
3. Place the equipment near the location but out of the way
of cable or conduit trenching and general construction.
Figure A.4.3 - Meg Ohms Reading
Note: If any heater does not reach 20 meg ohms, contact Fastrax® and do not install the heater.
b) Using a standard ohm meter, connect each lead
from the ohm meter to each heater lead (see Figure A.4.4).
Figure A.4.4 - Standard Ohms Reading
Note: For systems that are not standard sizes or grouping of equipment as covered in this manual or in Bill of Material, please contact Fastrax® or your company system standards for assistance.
Note: Typical layouts are not to scale and are to be used for general positioning of equipment only. Review your company standards for exact equipment layout.
CCI Thermal Technologies Inc.
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B.2 SINGLE STAND ALONE SWITCH WITH FROG
TYPICAL OVERALL LAYOUT FOR SINGLE SWITCH WITH FROG
No. 9 - No. 11 Switch and Frog
No. 14 - No. 16 Switch and Frog
8
No. 20/24 Switch and Frog
12C. No.14
®
®
Fastrax
TM
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B.3 CROSSOVER NO. 20/24 SWITCHES WITH FROGS
Single Crossover No. 20 or No. 24 Switches with Frogs
Double Crossover No. 20 or No. 24 Switches with Frogs
12C. No.14
®
®
CCI Thermal Technologies Inc.
9
Control Panel
Stand Alone or Extension
®
Fastrax
Heaters
®
SwitchBlade
®
Fastrax
Crib Heaters
®
Fastrax
10
Junction Box
FJA or FJAM
®
Fastrax
B.4 NO. 9, 10 OR 11 STANDARD SWITCH SIZE - ALL TIE STYLES
Typical layouts are not to scale and are to be used for general positioning of equipment only. Review your company standards for exact equipment layout.
Fastrax
TM
1.855.244.3128 Fax: 1.303.979.7350 sales@fastraxind.com www.fastraxind.com
at each Switch or
Ground Snow Sensor
®
Switch Heated Frog Location
Fastrax
Control Panel
Stand Alone or Extension
®
Fastrax
Heaters
®
SwitchBlade
®
Fastrax
Crib Heaters
®
Fastrax
Junction Box
FJA or FJAM
®
Fastrax
B.5 NO. 14, 15 OR 16 STANDARD SWITCH SIZE - ALL TIE STYLES
Typical layouts are not to scale and are to be used for general positioning of equipment only. Review your company standards for exact equipment layout.
at each Switch or
Ground Snow Sensor
®
Switch Heated Frog Location
Fastrax
CCI Thermal Technologies Inc.
11
®
Fastrax
®
FJA or FJAM
Junction Box
Fastrax
®
FJA Junction Box
Fastrax
®
Stand Alone
Control Panel
Fastrax
®
Ground Snow Sensor
at each Switch
Fastrax
®
Crib Heaters
Fastrax
®
SwitchBlade
®
Heaters
Fastrax
®
SwitchBlade
®
Heaters
12
B.6 NO. 20 / 24 STANDARD SWITCH SIZE - ALL TIE STYLES
Typical layouts are not to scale and are to be used for general positioning of equipment only. Review your company standards for exact equipment
layout.
Fastrax
TM
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B.7 SPRING FROG AND MOVABLE POINT FROG HEATING LAYOUT
Typical Moveable Point Frog Layout - Equipment Detail
No. 20 / 24 Standard Size - All Tie Styles
Typical layouts are not to scale and are to be used for general positioning of equipment only. Review your company standards for exact equipment layout.
Spring Rail Frog Heating Layout
®
To Fastrax
Toe of Frog
Control Panel
Fastrax
®
Junction Box
To Fastrax
®
Control Panel
®
Junction Box
Fastrax with Ground Snow Sensor
®
SwitchBlade® Heater
Fastrax
Inserted in milled slot or clamped
to D-Bar of the Spring Rail Frog
Movable Point Frog Heating Layout
®
Fastrax
SwitchBlade® Heaters on Frog Wing Rails
Heel of Frog
Fastrax
®
Crib Heaters
Fastrax® SwitchBlade® Heaters on Frog Point Plates
CCI Thermal Technologies Inc.
13
C. CONTROL PANEL INSTALLATION
C.1 ASSEMBLING FASTRAX® FCSA PANEL
SUPPORT STRUCTURE
SUPPORT STRUCTURE COMPONENTS:
• 2 - 4” X 4” X 10’ Bronze Powder-coated Support Posts
• 1 - Upper Support Channel
• 1 - Lower Support Channel
• 2 - 4” Raceways
• Channel Nut Bolt Assembly - (9) 3/8” Channel Nuts, (9) 3/8” X 1 1/2” Bolts, (9) Split Washers, (18) Stanless Steel Flat Washers
1. Place the support posts where the control panel will be
installed with the unistrut channel facing up.
3. Slide one of the 3/8” channel nuts above and below
the four control panel mounting holes. Use one 3/8” x 1 1/2” bolt and place one split washer and two stainless
steel at washers onto the bolt and fasten through
each of the four control panel mounting holes and into the spring channel nuts and tighten.
Figure C.1.3 - Nut and bolt positioning
4. Mount the upper support channel (this piece has a
1/2” conduit clamp attached to the back) at the 2” mark from the top of the post with the channel nut and bolt assembly.
Figure C.1.1 - Unistrut channel position
2. Place the control panel on top of the unistrut channels
at the 11” mark.
Figure C.1.2 - Control panel positioning
Figure C.1.4 - Upper support channel positioning
5. a) Measure 20” below the base of the control panel.
b) Mount the lower support channel with the channel nut and bolt assembly.
Figure C.1.5 - (a) Figure C.1.6 - (b)
14
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TM
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C.2 INSTALLING FASTRAX® FCSA PANEL
Note: For system operation and maintenance, see
Reference Material pages 31 - 48.
1. Mark where the two, 10 ft support posts will be placed
in the ground.
2. Install two, 12” sonotubes.
3. Set panel support posts in the sonotubes and adjust
so that the channel support is 6 ft above ground level.
Note: For panels 4 ft or higher, place the top channel 7 ft above ground level.
4. Using temporary supports, level the panel support
structure.
5. Pour concrete around the panel support posts, lling
the sonotubes to ground level.
6. Allow concrete to cure completely.
7. Remove temporary supports.
C.3 INSTALLING WIRE CONDUIT RACEWAY TO
PANEL
1.0 If Panel is Pre-punched for Conduit:
1. Trench below each punched hole to bury the conduit
2 ft below nished grade. Temporarily support the
panel if necessary.
Note: Be careful not to weaken the panel support when trenching and installing conduit/underground cables.
If PVC Conduit is provided:
2.0
1. Two, 4” conduits are provided. One conduit is for
the direct burial conductors coming from the switch and frog junction boxes. The other conduit is for the panel feeder wires coming from the service fused disconnect switch.
2. Install 4” PVC conduits for protecting direct burial
wiring where the wire leaves the ground and enters the panel.
3.0 If PVC Conduit is Directly Connected From
the Control Panel to the Junction Box or Service Equipment:
1. Only use materials approved by UL, CSA or FM third
party test agencies. Install a minimum of 2” trade size conduit to each junction box or service equipment.
2. Locate and mark the holes needed for the conduit by
holding a piece of the conduit vertically level with the panel support and against the bottom conduit support channel. Cut proper size conduit openings in the bottom of the control panel.
3. Only install the conduits at the bottom of the control
panel. Use proper ttings with locknuts and plastic or
metal bushings to protect conductors.
4. Clamp conduit to the lower support channel with the
provided clamp.
CCI Thermal Technologies Inc.
15
C.4 INSTALLING FASTRAX® AERIAL SNOW SENSOR
& SUPPORT MAST
Note: If constructing your own support mast, please
contact Fastrax®.
1. The aerial snow sensor support mast comes pre-
assembled and packaged with the control panel support structure.
2. Loosely hold the mast in position with the one-hole
strap pre-installed on the back of the panel support channel.
3. Locate, mark and cut the preferred location for the 1/2”
tting to enter the bottom of the control panel.
4. Using the 1/2” opening in the panel bottom, install the
tting, if provided.
5. Thread the wire attached to the FAS1A snow sensor
through the 1/2” conduit support mast, through each elbow and into the panel.
6. Without twisting the snow sensor wire pull the wire
snug so the 1/2” union provided with the snow sensor mates with the 1/2” conduit mast.
7. Tighten the 1/2” union with snow sensor in place.
8. Leave excess wire inside the panel until system is
wired.
16
Fastrax
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D. JUNCTION BOX INSTALLATION
D.1 JUNCTION BOX PLACEMENT
1. Loosely assemble each junction box to the support
pedestal.
2. Place each junction box assembly near the area of
installation. Refer to the System Layout section of this manual, to ensure each junction box is placed in the correct location.
Note: There are various types of junction boxes, refer to Figures D.1.1 - D.1.4, for product description.
Figure D.1.4 - Direct Burial Cable Junction Box
Note: Always place the junction box in an area that provides good drainage. Excess water can enter the box causing ground fault tripping.
Figure D.1.1 - FJA200SUP Junction Box
Note: Follow Railroad guidelines and specifications for trenching to prevent damage to existing buried lines. Always locate and mark existing cables before digging.
3. For the placement of the junction box support pedestal,
dig a trench a minimum of 1 ft in diameter and 2 ft below grade.
4. Adjust the depth of the hole to position the junction
box above the nished grade. We recommend that
the bottom of the junction box extend a minimum of 2”
above the nished grade.
D.2 DIRECT BURIAL CABLE AND CONDUIT
TRENCHING
Note: Follow Railroad guidelines and specifications for
trenching to prevent damage to existing buried lines. Always locate existing cables before digging.
1. For direct burial cable or conduit raceways, dig a trench
a minimum of 2 ft below grade.
Figure D.1.2 - FJAM200SUP Junction Box with FGSP1A Ground Snow
Sensor
Figure D.1.3 - Conduit Junction Box
Figure D.1.5 - Trenching
2. Bury direct burial cables or conduit a minimum of 2 ft
below grade unless otherwise outlined by Railroad or National Electrical Code standards.
CCI Thermal Technologies Inc.
17
D.3 DIRECT BURIAL CABLE , CONDUIT AND
JUNCTION BOX INSTALLATION
1. Unscrew the four support ange bolts attached to the
junction box from the support pedestal.
Figure D.1.6 - Support Flange Bolts
Note: For customer provided conduit, prepare and terminate the conduit into the junction box with approved fittings such as terminal adaptors.
3. After the cables or conduits are in the junction box,
replace the four support ange bolts and fasten the
box in place.
4. Fill in trench, leaving an area around the junction box
clear for easier heater lead installation.
2. Install direct burial cable or conduit from the junction
box to the control panel and position it for the nished
location and height of the junction box.
Figure D.1.7 - Direct Burial Cable Junction Box
Note: For direct burial cables, use the glands provided in the accessory kit to properly terminate the cable for entry into the junction box.
Figure D.1.8 - Junction Box Installed
18
Fastrax
TM
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E. SWITCHBLADE® HEATER INSTALLATION
E.1 SWITCHBLADE® HEATERS (FIELD SIDE
RUNNING RAIL) SWITCHES UP TO NO. 16
1. Locate the SwitchBlade® heater(s) for the running rail.
Check that the proper voltage and length heater is placed near the installation location.
2. Uncoil the heaters, being careful not to bend or kink
the heaters.
3. Place one heater on the eld side of the rail and
through the openings in the rail braces on one rail only.
1. Position the heater end where the lead wire enters
the round metal area approximately 2 ft in front of the switch point. (Up to 4 ft in front of the switch point is acceptable if necessary).
2. Position the heater so a spring base style rail clamp
can be installed about 10” from where the lead wire
enters the heater, just beyond the heater o󰀨set.
3. Position the heater so a clamp can be placed at the
‘dead end’ of the heater.
7. Important: The spring clamp body female thread
is left handed. Turn swivel screw to the left or counter-clockwise to reinstall the spring body. When completely on, the spring clamp will travel freely on the swivel screw head so it can align with the heater position.
8. When tightening the spring clamp on to the heater
apply gentle pressure on the spring clamp body toward the swivel head screw so the left handed treads do not catch or bind.
Note: The spring base rail clamp should be installed and removed by hand. Do not use a sledge hammer or other tools to install the clamp. The clamp body can be removed by backing the screw out all the way and
pushing rmly on the top of the clamp body towards
the rail.
Figure E.1.1 - Heater Installed with FRB600 spring rail clamp
Note: Allow proper clearance for heater to move freely.
4. Mark the rail where clamps are to be installed. Heaters
should be clamped about every 2 ft. A common rule of thumb is to clamp each heater in every crib space. It is acceptable to space the clamps a bit further apart when necessary to avoid obstructions.
5. After marking the rail for clamps, mark the other
running rail in the same locations.
6. Locate Model FRB600 spring rail clamps (Step 7.6 on
opposite page) and install on the rail by hand.
CCI Thermal Technologies Inc.
19
9. Leave swivel screw and spring clip backed away from rail and slide heater in place.
1. Place clamp on eld side of rail
base with swivel screw backed completely out.
4. Tighten each clamp by turning the
swivel screw with an Allen wrench until the spring clamp U shaped edges surround the heater and are snug against the rail.
2. Push the bottom of the clamp
body rmly until it clicks into place
on the base of the rail. (Note: pushing on the top of the clamp will prevent it from seating on the rail).
5. Tighten the keps nut.
3. The end of the clamp body will
wrap around the gage side of the rail when seated properly.
6. Tie o󰀨 the tow hook at the heater
‘dead end’ with the stainless steel wire tie provided with the spring base clamp kits.
20
Fastrax
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E.2 SWITCHBLADE® HEATERS (FIELD SIDE RUNNING RAIL) SWITCHES NO. 20 - 24
Size No. 20 and 24 switches have one extra heater on each running or stock rail as shown in the layout section (refer to page 12).
Please follow the previous rail heater instructions (page 19) for the front rail heaters on a No. 20 or 24 switch. Use the following instructions for the rear heaters:
1. When laying uncoiled heaters in place as in step 3 of
the SwitchBlade® heater installation, lay the rear heater in place while feeding the ‘dead end’ in from the heel block location. Bring the ‘dead end’ to about 2” from the ‘dead end’ of the front heater.
2. If necessary, adjust both heaters to allow for proper
clamp clearance and to have the 2” gap between heater ‘dead ends’ between rail braces.
Install clamps on rear heater every 2”. Install the second heater from the rear of the switch
3. Follow the marking, clamping and heater installation as
on the front heater.
4. Install one stainless steel wire tie between the two
‘dead ends’ as shown below.
so that the point of the rear heater meets the point of the front heater.
Tie the heater dead ends together with a stainless steel wire tie.
CCI Thermal Technologies Inc.
21
E.3 HEATER POWER WIRE TO JUNCTION BOX
1. Heater power wires are standard 26 ft from the factory.
Uncoil the power wire on each heater and lay it in the general path it will be installed to the junction box. Place wires from each heater to the correct junction box as shown in the Layout Section of this manual.
Figure E.3.1 - Lead Wire & Conduit
2. Using the FAO375 orange protective exible conduit
provided in the accessory kit, cut one section to cover each lead wire from the metal connection on the heater to the junction. Be sure to allow enough extra lead wire and orange conduit to loop below and into the bottom of the box.
3. From the accessory kit, locate one FHC125 stainless
steel hose clamp for each piece of orange conduit.
4. Thread one FHC125 clamp over the heater wire and
up to the round metal sheath where the wire enters the heater.
5. Thread the heater wire through the orange conduit with
a sh tape if necessary.
6. The heaters generally will have a piece of cold shrink
strain relief rubber over the area where the wire enters the heater. Slip the orange conduit as far as it will go over the rubber cold shrink and clamp in place with the FHC125 hose clamp.
7. Scratch a shallow channel in the ballast or dirt to bury
the orange conduit with the heater wire inside. Route to the junction box .
8. Remove one plastic 3/4” NPT plug for each heater lead
in the bottom of the junction box.
Figure E.3.3 - Remove 3/4” NPT plug
9. Using one FA375PC black conduit connector for each
wire, thread the connector into any 3/4” NPT opening provided in the bottom of the box. Loosen the outer nut on the connector and thread the wire through the connector into the box. Push the orange conduit into the connector and tighten the outer nut to hold the orange conduit tight.
22
Figure E.3.2 - Orange Conduit Clamping
Fastrax
TM
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Figure E.3.4 - Install Orange Conduit to Junction Box
10. Leave wires long inside the box until nal connections
are made.
11. Cover the orange conduit with the wire in it with ballast
to prevent a tripping hazard.
Note: When heater shields are used, leave heater wire outside the end of the shield.
E.4 SWITCHBLADE® HEATER(S) FOR GAUGE SIDE OF THE MOVING RAIL
The following instructions are for new switch designs and made by only certain track system manufacturers. When applying SwitchBlade® heaters to your switch, please check to see if the clearance is on the gauge side of the switching rail you will need for installation as shown in these instructions.
Note: If your switch is of a different design or clearance is not there, please contact Fastrax® for instructions on how to install the SwitchBlade® heaters on the moving rail.
Figure E.4.3 - Track Switch Construction
HEATER INSTALLATION COMPONENTS:
®
• (1) FSE32408 Fastrax
Switchblade® Heater
(See Figure 1).
®
• (5) XTC0193 Fastrax
Spring Clamp (See Figure 1).
2. Marking clamp locations:
a) Place heater next to the rail where it is to be
installed.
b) Mark clamp bolt locations.
• (1) Stainless steel tie strap (See Figure 2).
Figure E.4.1 - SwitchBlade® Heater and Spring Clamps
Figure E.4.2 - Stainless Steel Tie Strap
1. Inspect track switch construction to conrm that the
installed track switch appears as shown in Figure 3.
Note: Proper heater clearance must exist above the reinforcement bolts to allow for an unobstructed path for heater element to extend at least 8 ft from the switch point toward the switch heel.
Figure E.4.4 - SwitchBlade® Heater Clamp Locations
Note: The switch clip adds approximately 1” thickness to the rail from the switch point to approximately 2 ft back (see Figure E.4.4). The heater will mount as shown over
the switch clip and will gradually o󰀨set to follow the D-bar
reinforcement as shown toward the switch heel.
Locating clamp bolts:
c) Mark the rst and last bolt for clamps on the
switch clip.
d) Mark the second bolt past the switch clip for clamp
past the heater o󰀨set.
e) Mark the third and fourth bolts approximately 24”
apart from other clamps. Locate the last clamp approximately 10 to 14” from heater termination end.
CCI Thermal Technologies Inc.
23
3. Installing clamps:
Field Side Gauge Side
Base Plate
Switchblade
®
heater inserted in milled slot in the base of the spring rail frog
a) Install clamps one at a time.
b) Remove cotter key and loosen the rst hex nut
leaving space to slide clamp body between the
lock washer and the rail structure. (If a 1/8” at
washer exists under the lock washer, remove it and replace the lock washer and hex nut.)
c) Tighten clamp and lock washer with hex nut to
original tension and replace cotter key. Make sure the heater clamp is installed straight so the spring portion is directly in line with the heater direction.
d) Repeat this step for installing the remaining four
clamps.
4. Installing Heater:
a) Slide heater in place under clamps as shown
in Figure 3. Be sure the connection wire end is located toward the heel end of the switch. The eye hook end of heater should dead end at the switch
point under the rst clamp as shown in Figure 5.
b) Bend the heater gradually to mount under clamps
on the switch clip as shown in Figure 4.
c) Using the stainless steel tie strap provided, insert
the strap through the heater eye hook and the slot in the XTC0193 Clamp as shown in Figure 5.
Figure E.4.5 - SwitchBlade® Heater End Tie-off
5. Route the lead wire to the proper junction box as
instructed under E.3 - Heater Power Wire to Junction Box. Moving rail heaters connect to the front (point) heater junction box.
E.5 SWITCHBLADE® HEATER(S) FOR SPRING FROG
(SPRING FROG CHANNEL STYLE)
Many new style spring frogs have a rectangular channel manufactured into the base of the frog casting. The channel is designed to extend from the frog heel to the toe and is open on each end.
Inspect your spring frog to see if it has a channel in the base. On the heel end of the frog the channel is not always
enclosed under the rst few ties until it rests on top of the
gauge plate. Please remove enough ballast to feel under the frog body and see if a channel exists. If there is no channel see E.6 SwitchBlade® Heater(s) for Spring Frog (Retrot Style).
Figure E.5.1 - SwitchBlade® heater installation location
1. Locate and check the heater length to be sure it is
the correct size for the frog. The heater will insert completely into the heel end of the frog channel up to
the o󰀨set. The heater will come within 12” to 18” of the
toe end of the channel but should not extend outside the channel toe end (refer to Figure E.5.2 and E.5.3).
2. Lay the heater close to its installed position and follow
the ‘Heater power wire to junction box instructions’ in this manual to establish wire and orange conduit length. Pre-install the orange conduit on to the heater end with the FHC125 clamp before inserting in the frog channel.
3. Using a sh tape, make sure the channel is clear all the
way through. Clear any dirt and debris blockage before installing the heater.
4. Push the heater into the channel being careful not
to sharply bend or kink the heater. Guide heater into
channel under rst frog body until reaching the gauge
plate.
5. Install the heater wire under the ballast.
24
Figure E.4.6 - Option used when clearance is limited
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Figure E.5.2 - SwitchBlade® heater installation location
Toe of Frog
Heel of Frog
Fastrax
®
SwitchBlade® Heater Inserted in milled slot or
clamped to D-Bar of the Spring Rail Frog
Figure E.5.3 - SwitchBlade® heater installation location
Field Side Gauge Side
3/8” x 1” Self Tapping Bolt
7/8” of flat clearance for heater retrofit,
Fastrax
®
XTC clamp assembly (with intregal spacer)
SwitchBlade
®
Heater
Base Plate
Toe of Frog
Heel of Frog
Fastrax
®
SwitchBlade® Heater Inserted in milled slot or
clamped to D-Bar of the Spring Rail Frog
E.6 SWITCHBLADE® HEATER(S) FOR SPRING FROG
(RETROFIT STYLE)
Older style spring frogs do not have a channel built in for a heater. Most however will have clearance under the horn bolt plates for the SwitchBlade® heater.
2. Lay the heater where it will be installed next to the
D-bar. Using a clamp as a template. mark the bolt locations on the D-bar.
3. Mark the 1st clamp right where the D-bar reinforcement
starts. Mark the rest of the clamps at 24” intervals and
place one nal clamp at the end of the heater.
Note: If proper clearance does not exist below the horn bolt spacers do not install heater and contact Fastrax® for instructions.
Remove heater from the frog.
4. Drill blind holes 5/8” deep into the D-bar reinforcement
with 11/32” or letter S diameter drill.
5. Using the 3/8” X 1” self tapping bolts provided, install
each XTC-0173SPACER clamp with the built-in spacer to the D-bar reinforcement. Be sure clamps are straight along with the heater direction so the heater does not bind when sliding in the clamps.
6. Slide heater into position under clamps. Heater must lie
at and straight on the D-bar reinforcement. Flat area
of heater must make full contact with the D-bar surface.
If heater does not lie at, remove heater and manually straighten. The o󰀨set of the heater can face in toward the
frog rail or casting to keep the lead wire out of harms way.
7. Tie o󰀨 the tow hook on the end of the heater to the end
clamp with the stainless steel wire tie provided.
Figure E.6.1 - SwitchBlade® heater installation location
1. Locate and check the heater length to be sure it is the
correct size for the frog. The proper size heater will have
the o󰀨set lead wire end of the heater start between 2”
to 10” before the D-bar reinforcement starts at the toe end of the frog. The heater then extends down the D-bar and ends about 12” to 18” before the D-bar ends.
Figure E.6.2 - SwitchBlade® heater end clamp
Figure E.6.3 - SwitchBlade® heater clamp installed
*Look for proper clearance
Figure E.6.4 - SwitchBlade® heater retrofit installation location
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25
E.7 MOVABLE POINT FROG - SWITCHES NO. 20 - 24
Fastrax® SwitchBlade® Heaters on Frog Point Plates
Fastrax
®
SwitchBlade® Heaters
on Frog Wing Rails
Many new style movable point frogs (MPF) have the following design features to allow easy access for the SwitchBlade® heaters. Please inspect the MPF for the following:
a) Slots in the wing rail braces to allow the
SwitchBlade® heater to slide on to the top of the base of each wing rail. (Refer to Figure E.7.1).
Figure E.7.1 - SwitchBlade® heater installed on frog wing rails
b) 4 channels welded on to the bottom of the base plate
just below the point area. (Refer to Figure E.7.2).
4. Slide each plate SwitchBlade
®
heater into the channel provided under the base plate beneath the point area. Two of these channels will generally be located in each hollow steel tie or between concrete ties where the switch rods are located.
5. Support lead wires inside orange conduits above the
crib heater platforms, if possible so they are protected from the platform heat.
6. Install the heater lead wires under the ballast to the
junction box as previously described in this manual.
Figure E.7. 2 - SwitchBlade® heater installed on frog point plates
Note: If the features noted in a) and b) are not present please contact Fastrax® for alternate instruction methods. Please note that all frogs and heaters are not compatible.
1. Locate the heating equipment for MPF including two
wing rail SwitchBlade® heaters, approximately 12 ft long, 4 plate SwitchBlade® heaters, approximately 3 ft long and 2 crib heaters, 8 ft 8” long. Lay out equipment near MPF.
2. Install crib heaters (refer to Section F - Crib Heater
Installation).
3. Beginning at the point end of the MPF, slide each wing
rail SwitchBlade® heater along the base of each wing rail through the slots provided in the braces. Any non­toxic lubricant may be used and it will evaporate once the heaters are turned on. Allow the heater to follow the contour of the rail as it is inserted toward the heel of the MPF.
Figure E.7.3 - Refer to Section B - System Layout for an exploded view of the layout.
2 Clamps Per Heater
NOTE: To apply retrofit heaters to obsolete plate style movable point frog, contact Fastrax
Figure E.7.4 - To apply retrot heaters to obsolete plate style movable point frog, contact Fastrax
®
.
®
.
Note: Frog heaters have a ground wire and may shunt track circuits in some cases. If signal problems are present after installing heaters, disconnect the heater ground wire.
26
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F. CRIB HEATER INSTALLATION
F.1 ALL SWITCH AND FROG SYSTEMS
Fastrax® crib heaters have a unique low profile design to fit all switch and frog designs including conventional wood, composite, rubber, concrete or hollow steel ties.
We recommend using the 8 ft 8” units for all applications unless access space for installation prohibits using this length. If other lengths are required contact CCI Thermal Fastrax®.
2. Locate the crib heaters for your project and place
them near the area they will be installed. Check the heater nameplate for proper voltage.
3. Between conventional ties, remove the ballast to
allow 2” of clearance below the switch rods.
4. For heating cribs with switch rods connecting to a
switch machine, place the heater under the rod all the way up to the switch machine. For other cribs, center the heater under the gauge of the rail.
5. For conventional ties, use the jack-bolt clamps
provided. Turn the bolts counter-clockwise to allow the bolts to sit into each tie until secure.
6. Replace the ballast around the heater up to the top of
the heater platform.
7. For hollow steel ties, remove the four gold plated jack
bolts. It may be necessary to also remove the four 3/4” x 1” bolts at the same time. After sliding the crib heater on the bottom of the hollow steel tie, tighten the 4 smaller bolts into the side of the hollow steel tie until snug.
8. Route the heater lead wires as covered in this manual
to the point area junction box.
Figure F.1.1 - Jack Bolt Mount
Figure F.1.2 - Hollow Steel Tie Mount
1. Review Section B - Heater Layout for the crib heater
placement. In extremely severe weather areas crib heaters may be applied under any moving rod on the switch or frog.
Figure F.1.3 - Crib Heater Installation
CCI Thermal Technologies Inc.
27
G. SYSTEM WIRING
Section B - System Layout shows generally used minimum wire sizes and number of conductors to be installed between panels and connection points for 240V and 480V systems.
Note: Always size conductors and electrical equipment
to carry actual load conditions. Use Railroad and National Electrical Code standards for guidelines. Use
only copper conductors.
Note: Pay close attention to the routing and number
of cables required between connection points. Multiple conductors are required between master and Extension panels for control operations. Multiple conductors are also required between the control house and each master or stand alone panel to provide for dispatch control and annunciation.
IMPORTANT NOTE
Surge Protection Recommendations
This switch heater utilizes a number of processor-based control systems, all of which are susceptible to damage from lightning and other electrical surges. While every effort has been made to ensure that the control systems have been adequately ‘hardened’, CCI Thermal’s surge mitigation efforts can only be effective if ALL external remote circuits connecting to the switch heater have been protected by primary surge protection devices in accordance with the following generally accepted requirements for surge protection of wayside signal equipment:
• Provide primary surge protection devices (standard signal air gap arresters) on all external switch heater control I/O circuits. These arresters should be located “upstream” of the switch heater housing (within the signal housing, which interfaces to the switch heater). It is essential to protect ALL circuits entering or leaving the signal housing.
• Provide a primary surge protection device (commercial high capacity MOV type) on the external switch heater ac power feed. This surge protection device should be located “upstream” of the switch heater in conjunction with the electrical service entrance panel and main disconnect. Observe primary surge protector manufacturer’s instructions for installation and circuit breaker protection (if required).
• Grounding of the switch heater metal housing as well as the ground terminals of the primary arresters is essential for personnel protection as well as surge protection. Grounding rods and conductors must be installed in accordance with the AREMA Signal Manual of Recommended Practice.
• Primary surge protection must be installed in accordance with the AREMA Signal Manual of Recommended Practice.
For system designs not covered in this manual or questions please contact Fastrax specification guide for more information on our systems.
®
or consult your Railroad
1. Ensure all direct burial cable or conduit with wire is in place.
2. Terminate the wires at the control panel and at the
junction boxes. If the wiring is not installed in the raceways, please do so now and size the conductors as shown in Section B - System Layout or consult the National Electrical Code for sizing guidelines. Use only
copper conductors.
Note: Neatness and attention to detail count when
wiring the system. Please pay close attention to number markings on the wires and keep the wiring area neat and clean.
G.1 CONTROL PANEL WIRING
For your convenience, all field wiring connection terminals are located in the bottom section of the control panel only. Wiring and conduits enter the control cabinet through the bottom to protect the panel from water entering.
G.2 CONTROL PANEL DISCONNECT FEEDER
WIRING - STAND ALONE AND SLAVE PANELS
1. Find the amperage rating on the nameplate of each
panel. Install feeder service sized to supply the panel amperage rating.
Note: Most panels rated at 100 amperes may be supplied with No. 2 copper wire. Most panels rated at 200 amperes may be supplied with No. 2/0 or 3/0 copper wire.
Note: Consult the National Electrical Code or your engineering department for final wire sizing and type of wire insulation required.
2. Determine how many conductors are needed to
supply your panel. We recommend installing 3 full size conductors with an additional green or bare grounding wire for any single-phase panel and 4 full size conductors with an additional green or bare grounding wire for any three-phase panel. The grounding conductor can be full size or reduced size as shown in Article 250 of the National Electrical Code.
3. Install the feeder conductors from the service disconnect
to the panel leaving enough slack in the wire to connect to the disconnect lugs.
28
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4. Identify each feeder conductor with a phase color tape
on each end. Black, red, and blue are commonly used
to identify the individual phases. White or grey identies
the neutral conductor, but we do not require a neutral conductor for power to our panels. If a neutral conductor
is installed please tape it o󰀨 and leave disconnected
at the Fastrax
®
heater control panel. Green color or
bare wire always identies the equipment grounding
conductor.
5. Strip the ends of each feeder conductor.
6. Install one conductor under each disconnect lug.
7. Connect the green or bare grounding conductor to
the lug on the back panel marked with the grounding symbol.
8. Using the proper Allen wrench, socket or screw driver,
tighten to the proper torque as shown below. Leave power off until start-up.
Table G.2-1 Torque Values
Description Torque (in/lb)
175 - 200 Amp Disconnect 200
80 - 100 Amp Disconnect 50
400 Amp Disconnect 375
G.3 CONTROL PANEL SWITCHBLADE
®
HEATER WIRING - STAND ALONE & EXTENSION PANELS ONLY
1. Locate the wiring diagram on the following pages for
your control panel style. A basic wiring diagram is also
permanently a󰀩xed to the inside of the dead front panel
for reference.
2. As shown in the Layout Section, stand alone panels need
(12) No. 14 American Wire Gauge (AWG) conductors from the stand alone panel to the signal control house. Identify and mark the panel end and the signal control house end of each conductor.
3. As shown in the Layout Section, Extension panels need
(12) No. 14 AWG conductors from the extension panel to the master panel. Identify and mark the extension panel end and the master panel end of each conductor.
4. Using the wiring diagram for guidance, bend wires close
to their connection point. Strip the wire insulation and connect each wire as shown tight to the torque value shown in Table G.3-1. Terminals marked SP are for spare conductors.
Before testing tightness of any electrical connection disconnect electrical feeder to control
CAUTION
panel to ensure entire panel is de-energized.
Table G.3-1 Electrical Equipment
Clamp/Screw Torque Values
Part Type Description
Torque
(in/lb)
Terminals Control Circuits 9
Terminals Crib Heater Circuits 10
Terminals Heater Load Circuits 16
Terminals Ground Block Terminals 12
Disconnect Up To 100 Amperes 50
Disconnect 100 To 200 Amperes 200
Disconnect 400 Amperes 375
Contactors Pressure Plate Lugs 15 - 20
Contactors Box Lugs 40 - 45
Pwr. Dist. Block Primary 120
Pwr. Dist. Block Secondary 45
Circuit Breakers Heater And Control Loads 17.7
G.4 MASTER CONTROL WIRING
1.
Locate the wiring diagram on the following pages for your master control panel style. A basic wiring diagram
is also permanently a󰀩xed to the inside of the dead
front panel for reference.
2. As shown in the Layout Section, master panels need (12)
No. 14 AWG conductors connecting to each extension panel and (12) No. 14 AWG conductors connecting to the signal control house. Identify and mark the master panel end, the extension panel end, and the signal control house end of each conductor.
3. Using the wiring diagram, bend wires close to their
connection point. Strip the wire insulation and connect each wire as shown tight to the torque value shown in Table G.3-1. Terminals marked SP are for spare conductors.
4. Connect the extension panel conductors.
Before testing tightness of any electrical connection disconnect electrical feeder to control
CAUTION
panel to ensure entire panel is de-energized.
CCI Thermal Technologies Inc.
29
Figure G.4.1 - Typical Extension Control
Panel
G.5 FAS1A AERIAL SNOW SENSOR WIRING
1. Mount and install FAS1A sensor and wire as instructed
in the Control Panel section of this manual.
2. Locate the wiring diagram for your panel style in this
section. FAS1A sensors are only connected to master or stand alone panels.
3. Leaving extra slack in the panel cut the sensor wire to
comfortably reach their designated terminals. Strip the insulation from each conductor leaving about 5/8” bare wire. Connect the wire colors as per Table G.5-1.
Table G.5-1 Wire Descriptions
Wire Color Description
Black Common 60
White Signal 61
Red Supply 62
Green Supply 62
Terminal
Number
Figure G.4.2 - Typical Master Control Panel
Figure G.5.1 - FAS1A Aerial Snow Sensor
Figure G.5.2 - Terminal Connections
30
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G.6 FGSP1A GROUND LEVEL SENSOR WIRING AT
PANEL
1. Mount and install FGSP1A ground snow sensor style
junction box (FJAM200SUP) and eld wires to junction
box as described in this manual.
2. Locate and identify each end of three of the seven 14
AWG wires installed from the panel to the junction box. It is helpful to identify with the numbers 63, 64 and 65 where possible.
3. Locate the wiring diagram for your panel type in Section
H - System Wiring Diagrams. FGSP1A ground snow sensors are connected to extension or stand alone panels.
4. Leaving extra slack in the panel, cut the sensor wire to
comfortably reach their designated terminals. Strip the insulation from each conductor leaving about 5/8” bare wire. Connect the wire colors as per Table G.6-1.
Table G.6-1 Wire Descriptions
Wire Color Description
Black Common 63
White* Signal 64
Red Supply 65
White* Supply 65
Terminal
Number
*White wires are interchangeable.
Figure G.6.1 - Snow Sensor Wiring
5. Once all conductors are terminated correctly at the
panel and the system is checked for proper operation, seal the wires in the conduit entries to prohibit water from entering the panel. Use electrically approved sealing cement, duct seal or other approved material.
Figure G.6.2 - Sealed Conduits
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H. SYSTEM WIRING DIAGRAMS
H.1 STAND ALONE CONTROL PANEL WIRING DIAGRAM (1) NO. 9, 10, OR 11 SWITCH & SPRING FROG
HEATING SYSTEM
32
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H.2 STAND ALONE CONTROL PANEL WIRING DIAGRAM (2) NO. 9, 10, OR 11 SWITCH & SPRING FROG
HEATING SYSTEM
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H.3 STAND ALONE CONTROL PANEL WIRING DIAGRAM (1) NO. 14, 15, OR 16 SWITCH & SPRING FROG
HEATING SYSTEM
34
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H.4 STAND ALONE CONTROL PANEL WIRING DIAGRAM (1) NO. 20 OR 24 SWITCH & SPRING FROG
HEATING SYSTEM
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H.5 STAND ALONE CONTROL PANEL WIRING DIAGRAM (1) NO. 20 OR 24 SWITCH & MOVABLE POINT
FROG HEATING SYSTEM
36
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H.6 MASTER CONTROL PANEL WIRING DIAGRAM UP TO (4) FASTRAX® EXTENSION PANELS
CCI Thermal Technologies Inc.
37
H.7 EXTENSION CONTROL PANEL WIRING DIAGRAM (1) NO. 20 OR 24 SWITCH & MOVABLE POINT FROG
HEATING SYSTEM
38
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H.8 MASTER CONTROL PANEL WIRING DIAGRAM UP TO (8) FASTRAX® EXTENSION PANELS
CCI Thermal Technologies Inc.
39
40
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H.9 EXTENSION CONTROL PANEL WIRING DIAGRAM (1) NO. 9, 10, OR 11 SWITCH & SPRING FROG
HEATING SYSTEM
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41
H.10 EXTENSION CONTROL PANEL WIRING DIAGRAM (2) NO. 9, 10, OR 11 SWITCH & SPRING FROG
HEATING SYSTEM
42
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H.11 EXTENSION CONTROL PANEL WIRING DIAGRAM (1) NO. 14, 15, OR 16 SWITCH & SPRING FROG
HEATING SYSTEM
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H.12 EXTENSION CONTROL PANEL WIRING DIAGRAM (1) NO. 20 OR 24 SWITCH & MOVABLE POINT FROG
HEATING SYSTEM
44
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H.13 JUNCTION BOX CONNECTIONS
Figure H.13.1 - Side View of a Typical Junction Box Installation
Figure H.13.2 - Fastrax® FC Insulated Connectors Used For Wire Connection In Junction Box
Table H.13-1 - Insulated Connector Torque & Strip Chart
Wire Size (AWG) Torque (in/lb) Strip Length (in)
#14 - #10 35 11/16
#8 40 11/16
#4 - #6 45 11/16
CCI Thermal Technologies Inc.
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H.14 JUNCTION BOX HEATER CONNECTIONS
Wire entrances are located as shown in Figure H.14.1.
Note: When using conduit, cable connectors or glands, please be sure there are no burrs or sharp edges that will damage wire insulation inside the junction box.
1” NPT For Fastrax® FG100 Entrance
Gland, Entry For 7C#14 Direct Burial
Cable, or 2” NPT For Conduit Installation
®
1 1/4” NPT For Fastrax Entry For 5C#6 Direct Burial Cable, or 2” NPT For Conduit Installation
Breather/Drain Installed
Junction Box Grounding Lug
3/4” NPT For Fastrax Entry For Rail, Crib, Spring Frog and/or Crib Heaters For Movable Point Frog
- Typical Of 9
FG125 Entrance Gland,
®
FA375 PC Connector,
Junction Box
Grounding Lug
®
Fastrax
FC2/414 Insulated
Multi-cable Connector Blocks
2C#10 Marine Cable From
Left Side FSE SwitchBlade
®
Heater
for Moving Rail
2C#10 U.G. Marine Cable From Left Side
SwitchBlade
®
Heater for Stock Rail
Figure H.14.1 - Top View of Junction Box, Cover Removed
5C#6 Cable From SwitchBlade® Heater Control Panel
2C#10 U.G. Marine Cable From Right Side SwitchBlade Stock Rail
2C#10 Marine Cable From Right Side FSE SwitchBlade
®
Heater for
Moving Rail
®
Heater for
Figure H.14.2 - Typical Junction Box Connections - Showing SwitchBlade® Heaters (2) for Moving Rails and (2) for Stock Rails
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46
Junction Box Grounding Lug
7C#14 U.G. Cable From Stand
Alone or Extension Panel
Fastrax
®
FC3/414 Insulated
Multi-Cable Connector Blocks
3C#12 Cable From Crib Heaters
Individually Tape Unused Conductors
Green Wire to be Terminated at
Junction Box Grounding Lug
®
Fastrax
FC2/414 Insulated
Multi-Cable Connector Blocks
5C#6 Cable From SwitchBlade® Heater Control Panel
2C#10 U.G. Marine Cable From
Left Rear SwitchBlade
Figure H.14.3 - Crib Heater Typical Connections - (4) Crib Heaters at Switch Point Junction Box
®
Heater
Figure H.14.3 - No. 20 or 24 SwitchBlade® Heater Running Rail Connections -
Left and Right SwitchBlade® Heaters At Rear Junction Box
Right Rear SwitchBlade
2C#10 U.G. Marine Cable From
®
Heater
CCI Thermal Technologies Inc.
47
Individually Tape
Unused Connectors
5C#6 Cable From Stand Alone or Extension Panel
Figure H.14.4 - SwitchBlade® Heater for Spring Frog Typical Connections
2C#10 Cable From (2)
®
SwitchBlade
Heaters for
Movable Point Frog Wing Rail
2C#10 Cable From SwitchBlade Heater for Spring Frog
5C#6 Cable From Stand Alone or Extension Panel
3C#12 Cable From (2) Crib Heaters (1350 Watts Each)
®
3C#12 Cable From SwitchBlade
Heaters
(750 Watts Each) for Movable Point Frog Plate
®
Figure H.14.5 - SwitchBlade® Heater and Crib Heater for Movable Point Frog Typical Connections
Typical Junction Box Cable Entries and Connections
Tape all unused conductors in junction boxes. Square cut, fold back 2” minimum and tape conductor end. Turn wire entry side of insulated connector toward bottom of box after completing connections to prevent moisture build-up.
Fastrax
TM
1.855.244.3128 Fax: 1.303.979.7350 sales@fastraxind.com www.fastraxind.com
48
H.15 FGSP1A GROUND SNOW SENSOR WIRING AT FJAM200SUP JUNCTION BOX
FGSP1A snow sensors are only found at various switch locations as shown in the System Layout section of this manual. If there is no sensor located in your junction box, square cut conductors, fold back a minimum of 2 inches and tape the conductor end.
1. Using (3) 14 AWG previously identied wires, strip
each wire 5/8 inch.
2. Pushing each wire into the spring connector provided with
the sensor, connect the wires as shown in Figure H.15.2.
Figure H.15.2 - FGSP1A Junction Box Wire Connections
Table H.15-1 Wire Descriptions
Wire Color Description
Black Common 63
White Signal 64
Red Supply 65
White Supply 65
Terminal
Number
Figure H.15.1 - FGSP1A Ground Snow Sensor
Fastrax® FGS1A Ground
Snow Sensor Assembly
Individually Tape Unused
Conductors
®
Fastrax
FG100 1” Cable
Entrance Gland
7C#14 Cable or Conduit From
Stand Alone or Extension Panel
Fastrax
®
FJAM200SU Weather
Proof Junction Box (1’ x 1’ x 6”)
Snow Sensor Wires
Spring Tension Connector Provided With Sensor
Figure H.15.3 - Junction Box Diagram
4949
1500 W. Campus Drive Littleton, Colorado 80120
PH: 855.244.3128 FAX: 303-979-7350
www.fastraxind.com
MASTER PANEL
or
STAND ALONE PANEL
DATE:
TECH:
Photocopy
this page
for reuse.
PROJECT:
LOCATION:
CONTACTS:
CONTACTS/DIRECTIONS:
SERIAL NUMBER: MODEL NUMBER:
SENSORS QUAN:
STRUCTURE
ENCLOSURE
DRAWING ATTACHED
WIRING - GENERAL
REMOTE COMMUNICATION WIRING
NOTES:
FAS1A FGS1A
INSTALLATION CHECKOUT
CUSTOMER:
CONTRACTOR:
ACTUAL INPUT
VOLTAGE:
CONDITIONS:
LOCK / SECURITY
INSTRUCTIONS
SENSOR CONDITION
FEED TO EXTENSIONS
FEED TO CONTROL HOUSE
PHONE
TRANS OUTPUT
°F SNOW RAIN CLEAR
CELL
VOLTAGE:
INSTRUCTIONS: (QUALIFIED PERSONNEL ONLY)
OPERATION CHECKOUT
1. FOR STAND ALONE PANELS, TURN ALL HEATER LOAD CIRCUIT BREAKERS TO OFF POSITION.
2. PUSH GREEN START - WAIT FOR PANEL TO ENERGIZE. CHECK FULL POWER ON PILOT. PUSH STOP.
3. PUSH BLACK OVERRIDE - WAIT FOR PANEL TO ENERGIZE. CHECK FULL POWER ON PILOT. PUSH
STOP.
4. ADJUST FDC-6/FDC-7 TIMER TO .01 HOURS (PLEASE SEE PAGE 55 FOR ADJUSTING THE FDC-6/FDC-7). PRESS GREEN START. WAIT FOR PANEL TO GO TO REDUCED POWER. CHECK REDUCED POWER PILOT.
PRESS STOP. RESET FDC-6/FDC-7 TIMER TO 5 HOURS.
5. USING FREEZE SPRAY AND WATER, TEST FAS1A AERIAL SENSOR.
6. TURN PANEL HEATER THERMOSTAT ABOVE AMBIENT TEMPERATURE. CHECK HEATER. RETURN THERMOSTAT TO 40˚F.
7. CHECK FDC-6/FDC-7 AND MANUAL TIMER SETTINGS AND RECORD.
8. TEST REMOTE DISPATCH CONTROL FUNCTION
9. PRESS RED STOP BUTTON. CLOSE PANEL. LEAVE DISCONNECT "ON". SECURE PANEL.
TIMER SETTINGS:
NOTES:
FULL POWER:
HOURS
REDUCED POWER :
HOURS HOURS
OVER-RIDE:
IMPORTANT: PLEASE COMPLETE FORMS AND RETURN / COPY TO FASTRAX
®
KEEP COPY WITH PANEL MAINTENANCE DOCUMENTS
Fastrax
TM
1.855.244.3128 Fax: 1.303.979.7350 sales@fastraxind.com www.fastraxind.com
50 50
AMPS:
KW:
FORM 000452
PAGE 2 - STAND ALONE PANEL
PH: 855.244.3128 FAX: 303-979-7350
www.fastraxind.com
Turn power “On” and initiate full power to heaters. Record load voltage and amperage for each heater
DATE:
1500 W. Campus Drive Littleton, Colorado 80120
TECH:
STAND ALONE PANEL
VOLTAGE: PH:
SERIAL NUMBER: MODEL NUMBER:
OPERATION CHECKOUT
INSTRUCTIONS: (QUALIFIED PERSONNEL ONLY)
Disconnect (lockout & tag) all power sources to control panel.
1.
Open dead-front panel and turn all heater load circuit breakers in panel to off position.
2.
Photocopy
this page
for reuse.
Measure and record the ohm resistance of each heater circuit. Record on form 0004ET.
3.
If values vary more than 20% from REF OHMS, check heaters individually.
Test megohm values of each heater circuit. If any heater circuit falls below 20 megohms,
4.
check heaters individually.
With dead-front open, turn disconnect to “on” position. Record input voltages below.
Turn on all heater load circuit breakers and turn panel on Full Power. Record main load voltages
5.
6.
and amperages below.
Ground Fault modules are factory set. No adjustments necessary. To view the trip set-point, open the
7.
plastic cover (hinges up). Push the “R” button twice, it should read 30 mA.
8.
To test the ground fault press and hold the “T” button until read-out changes. Release the button and in 1 - 3 seconds the module will go into fault. Check that the pilot light (on dead front panel) turned off. Wait 8 - 10 seconds, the GFI will reset.
9.
Record ground fault test data below.
10.
circuit on Form 0004ET.
11.
Check voltage and test GFCI 120 volt outlet in dead front when present.
Turn panel heater thermostat above ambient temperature. Check heater. Return to 40ºF.
12.
Test remote dispatch functions.
13. Press red
14.
INPUT VOLTS: AB
LOAD VOLTS: AB
LOAD AMPS: AB
GFI
mA
Stop button. Close panel. Leave disconnect "On". Secure panel.
VOLTS
VOLTS
AMPS
PILOT LIGHT
TEST GFI mA TEST
BC
BC
BC
NOTES NOTES
VOLTS
VOLTS
AMPS
PILOT LIGHT
AC
AC
AC
VOLTS
VOLTS
AMPS
NO. 1
NO. 2
NO. 3
NOTES:
NO. 4
NO. 5
NO. 6
51
AMPS:
KW:
CHECK EXTENSION PANELS AND RELATED EQUIPMENT
FORM 000452
PH: 855.244.3128 FAX: 303-979-7350
www.fastraxind.com
Turn power “On” and initiate full power to heaters. At master panel record load voltage and amperage
Open dead-front panel and turn all heater load circuit breakers in panel to off position.
Photocopy
this page
for reuse.
1500 W. Campus Drive Littleton, Colorado 80120
DATE:
TECH:
SLAVE PANEL ___ OF ___
EXTENSION POWER OPERATION
(EACH EXTENSION PANEL)
VOLTAGE: PH:
SERIAL NUMBER: MODEL NUMBER:
INSTALLATION CHECKOUT
STRUCTURE
ENCLOSURE
DRAWING ATTACHED
WIRING - GENERAL
SERVICE
INSTRUCTIONS: (QUALIFIED PERSONNEL ONLY)
Disconnect (lockout & tag) all power sources to control panel.
1.
OPERATION CHECKOUT
LOCK / SECURITY
INSTRUCTIONS
SENSORS
FEED TO MASTER
FEEDER
2.
Measure and record the ohm resistance of each heater circuit. Record on form 0004ET.
Test megohm values of each heater circuit. If any heater circuit falls below 20 megohms,
With dead-front open, turn disconnect to “on” position. Record input voltages below. Turn on all heater load circuit breakers and turn panel on Full Power. At master panel record main load
Ground fault modules are factory set. No adjustments necessary. To view trip set-point, open plastic cover (hinges up). Push “R” button twice, should read 30 mA.
3.
If values vary more than 20% from REF OHMS, check heaters individually.
4.
check heaters individually.
5.
6.
voltages and amperages below.
7.
8.
To test the ground fault press and hold the “T” button until read-out changes. Release the button and in 1 - 3 seconds the module will go into fault. Check that the pilot light (on dead front panel) turned off. Wait 8 - 10 seconds, the GFI will reset.
Record ground fault test data below.
9.
10.
for each heater circuit on Form 0004ET.
Check voltage and test GFCI 120 volt outlet in dead front when present.
11.
Turn panel heater thermostat above ambient temperature. Check heater. Return the thermostat to 40ºF.
12.
INPUT VOLTS: AB
LOAD VOLTS: AB
LOAD AMPS: AB
GFI
NO. 1
NO. 2
NO. 3
mA
VOLTS
VOLTS
PILOT LIGHT
52
BC
BC
AMPS
TEST GFI mA TEST
BC
NOTES NOTES
VOLTS
VOLTS
AMPS
PILOT LIGHT
NO. 4
NO. 5
NO. 6
AC
AC
AC
VOLTS
VOLTS
AMPS
1500 W. Campus Drive Littleton, Colorado 80120
PH: 855.244.3128 FAX: 303-979-7350
www.fastraxind.com
HEATER CIRCUIT READINGS
FORM 0004ET
Photocopy
this page
for reuse.
PROJECT:
LOCATION:
TERMINAL
NUMBERS
(*1)
LOCATION SWITCH FASTRAX (POSITION)
DESIGNATION MODEL NUMBER
PAGE:
DATE:
TECH:
®
(*2)
REF
OHMS
MEG OHM AMP VOLT NOTE
NOTES:
*1. Position: Facing switch point - left or right hand heater
*2. Complete “REF OHM” column immediately before installation
FORM 0004ET
53
1500 W. Campus Drive Littleton, Colorado 80120-4519
PH: 855.244.3128 FAX: 303-979-7350
www.fastraxind.com
Individual Heaters - Common Sizes
All Heaters At 300 Watts Per Foot Nominal
Individual Heaters - Common Sizes
All Heaters At 400 Watts Per Foot Nominal
Individual Crib Heaters - Common Sizes
Combination Of Heaters - Common Parallel Circuit Readings
Combination of Moveable Point Frog Heaters - Common Parallel Circuit Readings
(2) 3,400W 6,800 8.5 28.3 33.9 14.2 52.9 11.3
240 VOLT
120 VOLT
480 VOLT
600 VOLT
240 VOLT
480 VOLT
480 VOLT
600 VOLT
240 VOLT
600 VOLT
240 VOLT
480 VOLT
600 VOLT
240 VOLT
480 VOLT
600 VOLT
Calculated Circuit Nominal Test Readings
Ohm’s Law
2
E
R X I
R
2
E X I
√
R X I
P R
WATTS
AMPS
P E
VOLTS
E
P
I
R
OHMS
E
P
R
2
I
E P
P I
√
2
P X R
E I
HEATER WATTAGE
3 Ft. 750 76.8 3.1 307.2 1.6 480.0 1.3
8 Ft. 2,200 26.2 9.1 104.7 4.6 163.6 3.7 10 Ft. 2,800 20.6 11.7 82.3 5.8 128.6 4.7 12 Ft. 3,400 17.0 14.2 67.8 7.1 105.9 5.7 16 Ft. 4,600 12.5 19.2 50.1 9.9 78.3 7.7 20 Ft. 5,800 9.9 24.2 39.7 12.1 62.1 9.7 26 Ft. 7,600 7.6 31.7 30.3 15.8 47.4 12.7
HEATER WATTAGE
8 Ft. 3,000 19.2 12.5 76.8 603.0 120.0 5.0 10 Ft. 3,800 15.2 15.8 60.6 7.9 94.8 6.3 12 Ft. 4,600 12.5 19.2 50.1 9.6 78.3 7.7 16 Ft. 6,200 9.3 25.8 37.2 12.9 58.1 10.3 20 Ft. 7,800 7.4 32.5 29.5 16.3 46.2 13.3 26 Ft. 9,600 6.0 40.0 24.0 20.0 37.5 16.0
HEATER WATTAGE
CRIB 700 20.6 5.8 82.3 2.9 329.1 1.5 514.3 1.2 CRIB 1,350 10.7 11.3 42.7 5.6 170.1 2.8 266.7 2.3 CRIB 2,000 7.2 16.7 28.8 8.3 115.2 4.2 180.0 3.4
OHMS AMPS OHMS AMPS OHMS AMPS OHMS AMPS
OHMS AMPS OHMS AMPS OHMS AMPS
OHMS AMPS OHMS AMPS OHMS AMPS
HEATER COMBINATIONS WATTAGE
(1) 2,200W + (1) 4,600W 6,800 8.5 28.3 33.9 14.2 52.9 11.3 (1) 2,200W + (1) 5,800W 8,000 7.2 33.3 28.7 16.7 45.0 13.3 (1) 2,200W + (1) 7,600W 9,800 5.9 40.8 23.5 20.4 36.7 16.3 (1) 2,200W + (2) 5,800W 13,800 4.1 58.5 16.7 23.8 26.1 23.0 (1) 2,200W + (1) 6,200W 8,400 6.9 35.0 27.4 17.5 42.9 14.0 (1) 2,200W + (1) 7,800W 10,000 5.8 41.7 23.0 20.8 36.0 16.7
(1) 2,200W + (1) 10,200W 12,400 4.6 51.7 18.6 25.8 29.0 20.7
(1
) 2,200W + (2) 7,800W 17,800 3.2 74.0 12.9 37.1 20.2 29.7
(2) 1,350 W. CRIBS 2,700 21.3 11.3 85.7 5.6 133.3 4.5 (3) 1,350 W. CRIBS 4,050 14.3 16.8 57.1 8.4 88.9 6.8 (4) 1,350 W. CRIBS 5,400 10.7 22.4 42.9 11.2 66.7 9.0 (5) 1,350 W. CRIBS 6,750 8.5 28.1 34.1 14.1 53.3 11.3 (6) 1,350 W. CRIBS 8,100 7.1 33.8 28.4 16.7 44.4 13.5
HEATER COMBINATIONS WATTAGE
(4) 750W + (2) 1,350W 5,700 10.1 23.8 40.4 11.9 63.2 9.5
54
OHMS AMPS OHMS AMPS
OHMS AMPS OHMS AMPS OHMS AMPS
OHMS AMPS
I. CONTROL PANEL GENERAL EQUIPMENT PROCEDURES
I.1 MASTER & STAND ALONE PANEL FDC-6/FDC-7
ADJUSTMENT INSTRUCTIONS
FULL POWER TIME SETTING:
1. Push center button to the left. Full power screen
appears.
2. Push ALT, then push OK.
3. Move curser to the digit you wish to change by pushing
the center button left or right.
4. Use center button by pushing up or down to change
the digit.
5. When all the digits are changed, push OK to save.
6. Screen will return to normal screen 30 seconds after
starting.
REDUCED POWER TIME SETTING:
1. Push center button to the right. Reduced power screen
appears.
2. Push ALT, then push OK.
3. Move curser to the digit you wish to change by pushing
the center button left or right.
4. Use center button by pushing up or down to change
the digit.
5. When all the digits are changed, push OK to save.
6. Screen will return to normal screen 30 seconds after
starting.
TO START SYSTEM IN FULL POWER:
1. Push up on the center button while it is in the normal
screen. Hold until “Full Power” starts.
2. When the system is in full or reduced power, the normal
screen reads:
a) Full or reduced power (Depending on what cycle
the system is in).
b) Set point time for the condition showing.
c) Actual time accumulated for that cycle.
I.2 STAND ALONE CONTROL PANEL (AUTOMATIC
OPERATION)
WHEN AMBIENT TEMPERATURE FALLS BELOW 38°F:
1. Snow or blowing snow exists.
2. Fastrax® FDC-6/FDC-7 automatic snow sensing
integrated control and sensor system initiates to full power heater operation.
3. When full power is applied the green “Full Power On”
indicating light will be illuminated.
4. The integrated control and sensor system will continue
to monitor the environment until no further snowfall is detected or the ambient temperature rises above 38°F.
Note: On control panels heating 3 or more switch assemblies, the heaters are sequenced on in 4 steps with a 10 second delay between heaters coming on.
5. After snowfall stops a timer holds full power on for a
period of 1-99 hours (adjustable by customer or default adjustment of 5 hours). Two types of snow sensors are supplied as standard equipment.
a) FAS1A aerial snow sensor assembly (eld
installed above panel).
b) FGSP1A ground snow sensor assembly (factory
installed in FJAM200SUP junction box).
These snow sensors include a preset 38°F temperature control, a low voltage heater to melt falling snow, and a moisture/snow sensor.
The FDC-6/FDC-7 control system has the ability to accept as many sensors as desired wired to the master control. Any combination of the above sensors may be used. The worst­case location will then turn the system on.
6. After full power time has elapsed the green “Full Power
On” indicating light will go o󰀨.
7. After 5-7 seconds an energy saving heater circuit
energizes, the green “Reduced Power On” indicating light will illuminate, and maintains the rail heaters at 25% of full power to maintain heating of residual or blowing snow.
®
8. Crib heaters and SwitchBlade
frog and movable point frog maintain full power during this period.
heaters for the spring
Figure I.1.1 - FDC-6/FDC-7 Integrated Control & Sensor System
Note: At any point during the hold time operation (either full or 25% power maintenance cycle) if new snow falls and the ambient temperature falls below 38°F, the automatic control is re-initiated and full heating operation starts over.
CCI Thermal Technologies Inc.
55
I.3 STAND ALONE CONTROL PANEL (MANUAL
OPERATION)
I.4 ADDITIONAL FEATURES STAND ALONE
CONTROL PANEL
1. Manual start operation is a momentary push button
on the inner door that initiates the same timed heating cycles as explained in the preceding ‘Automatic Operation’ section. This push button simulates the snow sensor turning the system on which is a good system test and allows the system to be manually started.
a) The green “Manual Start” push button must be
held until the green “Full Power” indication light illuminates which generally takes 5-7 seconds.
Note: On panels heating 3 or more switch assemblies, the heaters are sequenced on in 4 steps with a 10 second delay between heaters coming on.
b) Automatic sensing is overridden for initial start up.
Automatic control will operate the system once the control cycle is started manually.
2. Manual stop is a momentary push button that shuts the
control system down if an operator inadvertently starts the system when it is not needed or if system testing
is nished.
a) Automatic control overrides this stop feature if
conditions exist that would initiate the system. In this case, the system shuts down for 5-10 seconds and then will restart in full power.
3. Manual over-ride is a momentary push button that
bypasses the automatic equipment and initiates full power to all heating elements.
4. Pressing the black “Manual Over-ride” push button
starts a 0-60 hour timer (adjustable by customer or default adjustment of 24 hours) and will illuminate the green “Full Power“ indicating light after 5-7 seconds.
Note: On panels heating 3 or more switch assemblies, the heaters are sequenced on in 2 steps with a 5 second delay between heaters coming on. Full power will remain on for the time period regardless of weather conditions. Once the time period is up the system will enter the energy saving cycle and then shut off. To interrupt the over-ride heat cycle, press the red “Manual Stop” push button.
REMOTE ANNUNCIATION:
• For single and multiple switch stand-alone panels, terminal 200 & 201 is an annunciation dry contact output for customer use to indicate if the system is on or off. Closed indicates the system is on with no faults, open indicates system is off or in fault.
REMOTE START/STOP:
• The customer can utilize remote start/stop with a maintained dry contact wired into terminals 50 & 70. When the contact closes the system will react the same as if the green “Manual Start” push button is pressed. When the contact opens the control system will shut down unless snow conditions activate the automatic control.
GROUND FAULT PROTECTION:
®
• Each SwitchBlade Fault Interrupter module (GFI) to protect the heating elements and wiring from ground faults. If a fault is detected the system will turn off the power to that switch or frog heating equipment and the amber indicator light will turn off to indicate which switch is in fault. One ground fault module protects all heaters in one complete switch assembly. A separate ground fault module protects all heaters in one complete frog assembly. The system will wait 5 minutes and automatically try to reset the GFI and if the fault has cleared the switch heater will resume in the sequence where it was interrupted. If a fault remains the switch or frog heater will remain off. The system will continue to try and reset every 5 minutes until it resets or an operator repairs the damaged switch heater or associated wiring. If the system is running multiple switches or frogs, only the switch or frog in fault will be disabled and the remaining switches or frogs will continue to function normally.
STROBE LIGHT CIRCUIT:
• Strobe light output (terminals 38 & 39) is a dry contact, which closes if the main disconnect switch, is off or the circuit breakers for the transformer are manually turned off or tripped off.
heater is protected with a Ground
5. If positive shut down of the system is desired turn the
disconnect switch mounted on the inner door to the
o󰀨 position. Automatic control will not operate again
until the disconnect is returned to the on position. For normal automatic control leave disconnect in the on position.
Fastrax
TM
1.855.244.3128 Fax: 1.303.979.7350 sales@fastraxind.com www.fastraxind.com
56
TIMER ADJUSTMENT:
• Timers can only be adjusted by turning the disconnect switch off and opening up the inner door. Only qualified personnel should perform this task.
I.5 MASTER/EXTENSION CONTROL PANELS
(AUTOMATIC OPERATION)
The Master control panel contains most of the control equipment and the extension panel(s) contain the power distribution apparatus.
Note: At any point during the hold time operation (either full or 25% power maintenance cycle) if new snow falls and the ambient temperature falls below 38°F, the automatic control is re-initiated and full heating operation starts over.
WHEN AMBIENT TEMPERATURE FALLS BELOW 38°F:
1. Snow or blowing snow exists.
2. The control will be activated. (Internal thermostat
controlled heater keeps panel components above freezing during the heating season).
3. Fastrax® FDC-7 automatic snow sensing integrated
control and sensor system initiate full power heater operation will continue to monitor the environment until no further snowfall is detected or the ambient temperature rises above 38°F.
4. When full power is applied the green “Full Power On”
indicating light will be illuminated.
Note: The extension panels are sequenced on in 4 steps with a 10 second delay between Extensions coming on.
5. After snowfall stops a timer holds full power on for a
period of 1-99 hours (adjustable by customer or default adjustment of 5 hours). Two types of snow sensors are supplied as standard equipment.
a) FAS1A aerial snow sensor assembly (eld
installed above panel).
b) FGSP1A ground snow sensor assembly (factory
installed in FJAM200SUP junction box).
These snow sensor assemblies include a preset 38°F temperature control, a low voltage heater to melt falling snow and a moisture/snow sensor.
The FDC-6/FDC-7 control system has the ability to accept as many sensors as desired wired to the master control. Any combination of the above sensors may be used. The worst-case location will then turn the system
on.
6. After full power time has elapsed the green “Full Power
On” indicating light will go o󰀨.
7. After 5-7 seconds an energy saving heater circuit
energizes, the green “Reduced Power On” indicating light will illuminate, and maintains the rail heaters at 25% of full power to maintain heating of residual or blowing snow.
8. Crib heaters and SwitchBlade® heaters for the spring
frog and movable point frog maintain full power during this period.
I.6 MASTER/EXTENSION CONTROL PANELS
(MANUAL OPERATION)
The manual controls and timers are located at the Master panel only. The extension panels have annunciation for ground faults only.
1. Manual start operation is a momentary push button
(located in the Master panel) on the inner door that initiates the same timed heating cycles as explained in the preceding ‘Automatic Operation’ section. This push button simulates the snow sensor turning the system on which is a good system test and allows the system to be manually started.
2. The green “Manual Start” push button must be held
until the green “Full Power” indication light illuminates which generally takes 5-7 seconds.
Note: The extension panels are sequenced on in 4 steps with a 10 second delay between extensions coming on. Automatic sensing is overridden for initial start up. Automatic control will operate the system once the control cycle is started manually.
3. Manual stop is a momentary push button (located in
the Master panel) that shuts the control system down if an operator inadvertently starts the system when it is
not needed or if system testing is nished.
a) Automatic control overrides this stop feature, if
conditions exist that would initiate the system. In this case, the system shuts down for 5-10 seconds and then will restart in full power.
4. Manual over-ride is a momentary push button (located
in the Master panel) that will bypass the automatic equipment and initiates full power to all heating elements.
a) Pressing the black “Manual Over-ride” push button
starts a 0-60 hour timer (adjustable by customer or default adjustment of 24 hours) and will illuminate the green “Full Power“ indicating light after 5-7 seconds.
b) The extension panels are sequenced on in 2 steps
with a 5 second delay between extensions coming on.
c) Full power will remain on for the time period
regardless of weather conditions. Once the time
period is up the system will then shut o󰀨.
d) To interrupt the over-ride heat cycle press the red
“Manual Stop” push button.
CCI Thermal Technologies Inc.
57
5. If positive shut down of the Master system is desired
turn the circuit breaker CB1 (located in the Master
panel) to the o󰀨 position.
a) Automatic control will not operate again until CB1
is returned to the on position.
b) For normal automatic control leave CB1 in the on
position.
c) For positive shut down of the extension panels,
turn the disconnect switch mounted on the inner
door of the extension panel to the o󰀨 position.
d) For normal automatic control leave disconnect in
the on position.
I.7 ADDITIONAL FEATURES MASTER/EXTENSION
CONTROL PANEL
REMOTE ANNUNCIATION:
• Terminal 201& 211, 202 & 212, 203 & 213, 204 & 214 (located in the Master panel) are annunciation dry contact outputs for customer use to indicate if the extension panels are on or off. Closed indicates the system is on with no faults, open indicates system is off or in fault.
REMOTE START/STOP:
• The customer can utilize remote start/stop with a maintained dry contact wired into terminals 50 & 70 of the Master panel. When the contact closes the system will react the same as if the green “Manual Start” push button is pressed. When the contact opens the control system will shut down.
GROUND FAULT PROTECTION:
®
• Each SwitchBlade
heater is protected with a Ground Fault Interrupter module (GFI) to protect the heating elements and wiring from ground faults. If a fault is detected the system will turn off the power to that switch or frog heating equipment and the amber indicator light will turn off to indicate which switch is in fault. One ground fault module protects all heaters in one complete switch assembly. A separate ground fault module protects all heaters in one complete frog assembly. The system will wait 5 minutes and automatically try to reset the GFI and if the fault has cleared the switch heater will resume in the sequence where it was interrupted. If a fault remains the switch or frog heater will remain off. The system will continue to try and reset every 5 minutes until it resets or an operator repairs the damaged switch heater or associated wiring. If the system is running multiple switches or frogs, only the switch or frog in fault will be disabled and the remaining switches or frogs will continue to function normally.
STROBE LIGHT CIRCUIT:
• Strobe light output (terminals 38 & 39 in the Master panel) is a dry contact, which closes if the circuit breakers for the transformer are manually turned off or tripped off.
TIMER ADJUSTMENT:
• Timers are located in the Master panel and should be adjusted only by qualified personnel.
I.8 OPTIONS AVAILABLE FOR THE MASTER/
EXTENSION CONTROL PANEL
®
(Contact engineering or Fastrax
)
• Painted steel enclosure for NEMA 12 installations indoors.
• Sequence individual or groups of heaters on start up for multiple heater installations.
• SCR power switching.
• Temperature sensor – rail mounted (thermocouple or RTD)
I.9 MAINTENANCE
Hazard of electric shock. Disconnect all power to panel before servicing. Only qualified personnel trained in electrical equipment service should
WARNING
perform maintenance on switch heating and control equipment.
1. Visually check the panel for external physical damage. Repair or replace as necessary.
2. Check all eld load terminations annually and tighten to torque specied on attached torque chart.
3. Visually inspect internal components for wear or deterioration. Replace as necessary. Consult Fastrax
®
for replacement parts.
4. Inspect sensor for dirt, grease or any conductive debris making contact with moisture sensing button. If
dirt or conductive lm is present clean unit with a mild
detergent.
5. Test the external FAS1A and FGSP1A snow sensors annually using the following procedure:
Tools Needed: Volt meter, Freeze spray and water.
6. Ensure that the control panels used with the snow
sensors are energized and performing correctly.
7. Ensure that the moisture-sensing grid on the FAS1A and the contact surfaces on the FGSP1A are clean and dry.
8. Connect the voltmeter across the black and red leads from the sensor (terminals 60 and 62 at the load terminal blocks. Normal reading is 24-28 volts AC.
58
Fastrax
TM
1.855.244.3128 Fax: 1.303.979.7350 sales@fastraxind.com www.fastraxind.com
9. Now connect the voltmeter across the black and white
sensor leads (terminals 60 and 61 at the panel terminal blocks). Normal reading of 0 volts AC should appear with a clean dry sensor at 38°F or greater.
10. Cool the temperature probe of FAS1A snow sensor with
the freeze spray and wet the grid with water. Normal voltmeter reading should be 24-28 volts AC across the black and white terminals (60 &61) within 1 minute.
11. Let the grid dry. (The internal sensor heater will
accomplish this given time.) The voltage reading should return to 0 volts AC.
12. Repeat steps 1-11 to test the FGSP1A snow sensor
(terminal blocks 63, 64 and 65).
13. If any of the above conditions are not met, the sensor
may be damaged. Consult Fastrax® for assistance.
14. Test ground fault circuit breaker by tripping internal test
button or lever.
Note: If panel does not function properly or does not operate as specified, disconnect power from the panel and contact Fastrax® for assistance.
FOR GENERAL OPERATION AND MAINTENANCE GUIDE SEE FASTRAX® SYSTEM INSPECTION REQUIREMENT DOCUMENT.
STANDARD EQUIPMENT SELECTION
I.10 SWITCHBLADE® HEATING
Contact Fastrax® or review the bill of material for proper heater selection.
1.0
If necessary, follow the steps below:
1. Determine switch and heater size. Use the following
guideline for selecting heater length:
• Measure from switch point to center line of heel block.
• Consult Bill of Material for standard heater sizes.
• Select heater overall length to cover switch length from standard sizes.
• Installation standard is on the field side of the rail. Two stock rail and two moving rail heaters are required for each standard switch up to a No. 15 in size. Two additional stock rail heaters are required for No. 20 size switches. See Layout Section in this manual.
2. Select crib heaters for each switch as required or if
drainage is not adequate during winter months. Select 8 ft 8”, 1,350 watt crib heaters standard or 7 ft, 1,350 watt crib heaters if space restricts the length of unit to be installed.
TORQUE SPECIFICATION
CAUTION: Before testing tightness of any electrical connection disconnect electrical feeder to control panel to ensure entire panel is deenergized
ELECTRICAL EQUIPMENT CLAMP / SCREW
TORQUE VALUES
Part Type Description Torque (in/lb)
Terminals Control Circuits 9
Terminals Crib Heater Circuits 10
Terminals Heater Load Circuits 16
Terminals Ground Block Terminals 12
Disconnect Up To 100 Amperes 50
Disconnect 100 To 200 Amperes 200
Disconnect 400 Amperes 375
Contactors Pressure Plate Lugs 15 - 20
Contactors Box Lugs 40 - 45
Pwr. Dist. Block Primary 120
Pwr. Dist. Block Secondary 45
Circuit Breakers
Heater And Control
Loads
17.7
I.11 SPRING FROG HEATING
Follow the steps below:
1.0
1. Determine spring frog type:
• Retrofit type has continuous clearance below horn bolts and does not have milled channel in the frog base.
• New style has milled channel in the frog base.
2. Determine heater size:
• Verify length of retrofit spring frog by measuring clear length of D-bar. D-bar should be of sufficient length to provide surface contact for entire heater length.
• Verify length of new spring frog with milled channel by inserting fish tape in channel and measuring channel length. Frog heater length must not exceed channel length.
• Select appropriate frog heater from bill of material.
Note: If frog does not have proper heater clearance or is not a size listed contact engineering or Fastrax® for optional installation methods.
CCI Thermal Technologies Inc.
59
I.12 MOVABLE POINT FROG HEATING
J.2 INSTALLATION PROCEDURE
Contact Fastrax or review the bill of material for proper mov­able point frog heater selection.
J. PROCEDURES
J.1 GENERAL OPERATION
GENERAL OPERATION
1. Fastrax® Switchblade® style track switch, crib
heaters, spring frog rail heaters and movable point frog heaters are engineered for state of the art heat transference and are ruggedly designed and constructed for endurance.
2. When properly installed, operated and maintained,
they will provide long life and dependable, trouble­free service. The flattened stainless steel heater style is extremely efficient and durable.
3. When energized at the rated voltage, each heater
will operate at the nameplate wattage and transfer heat to the rail or crib area it is attached to.
4. Flat heaters are attached to the rail or crib platform
with XTC spring style clamp assemblies that will expand and contract while maintaining excellent contact with the metal and readily transfer heat bringing the rail or platform above freezing temperatures.
5. Once above freezing, the heat from the rail or platform
will radiate warmth to melt existing or accumulating snow and ice in the track switch, spring frog wing, movable point frog rail, or crib area.
6. When controlled with a Fastrax® control panel
system the switch heaters will operate in an energy saving mode but only after snow has stopped falling.
7. The energy saving mode will continue to operate
the spring frog, movable point frog and crib heaters at full nameplate rated wattage while the switch heaters will function at 25% of their rated wattage for an adjustable time period.
8. If snow begins to fall again all heaters automatically
return to full output.
Note: Do not operate heaters at voltages in excess of that stamped on the heater. Excess voltage will shorten heater life.
1.0
SWITCHBLADE® AND CRIB HEATERS
1. Switch Heaters:
• After equipment selection is made and installation side of rail is determined, reference the System Layout and Rail Heater sections (page 9) of this manual. When installing heaters, they should be located on the rail web extending from a point approximately 2 ft ahead of the switch toward the heel block.
®
2. SwitchBlade
• Layout the proper clamp locations for the heaters. Be certain that clamp locations are placed approximately 24” on center following the Rail Heater section of this manual
• Avoid locating clamps where braces, signal wires, or other apparatus is blocking access to the rail web.
• If existing braces are not of the notched style as shown in drawings
• Replace braces with the notched style or contact engineering or Fastrax Industries for optional installation methods.
3. SwitchBlade
• Type FRB600 spring base style rail clamps should be used to allow the heater to maintain close contact with the rail while permitting normal expansion and contraction. Install clamps by hand and assemble on heater as described in the Rail Heater section of this manual.
4. Crib Heaters:
• Clear ballast from between the ties below the switch rods. Allow for a minimum of 4” from the base of the rail to the top of the FCH Crib Heater platform. Always mount top of Crib Heater platform to allow proper clearance for free operation of switch rods. Place heater platform in the desired position to maintain a snow and ice-free area below the operating switch rods. Install as outlined in the Crib Heater section of this manual. Replace ballast in area around crib heater.
5. SwitchBlade
Heater Clamp Positioning:
®
Heater Clamping:
®
Heaters for Frog:
60
Fastrax
TM
• Install all frog heaters as covered in this manual.
1.855.244.3128 Fax: 1.303.979.7350 sales@fastraxind.com www.fastraxind.com
2.0 ALL HEATER POWER LEADS
Reference details shown in this manual for direct burial of heater power conductor. Fasten as shown. Direct power leads below ballast to prohibit tripping hazard. Route leads to proper junction box as covered in System Wiring section of this manual.
1. Wiring and Connections:
Hazard of electrical shock. When electric heaters are applied to track switches where track circuits are used in conjunction with signal or switch operation and it is necessary that power system
WARNING
be maintained free from grounds, suitable ground fault detection and interrupting systems must be in use at all times to reduce shock hazard and protect signal system.
• Electric wiring to heating elements must be installed in accordance with National Electrical Code (NFPA 70) and any applicable third party standards.
• Use approved wiring accessories as listed on bill of materials.
• Leads between heater and junction boxes should be located so as to minimize possible damage.
• Electrical lead terminations shall be located in approved style FJA junction boxes rated for the area of service. Torque wire connections as specified.
• Install minimum AWG heater conductor size to control panel terminals. Connect as shown on reference drawings.
• It is recommended that switch heaters be tested annually for proper insulation resistance. Turn off the breakers feeding the heaters and test insulation resistance at the incoming terminal blocks with a 500 Volt DC Meg Ohm Meter. A minimum value of 20 Meg Ohms should be obtained between heater metal sheath and electrical conductors. If this insulation level is not achieved, leave heaters disconnected and contact Fastrax
®
.
• Periodically check heater-mounting hardware for loose or missing clamps - tighten or replace as needed. It is important that heating element surface maintains close contact with rail to insure long life and maximum efficiency.
• Inspect heater and ensure that heater is secured and flat on the rail web.
• Visually check heaters regularly to keep debris, combustible materials, and other objects from lying against or lodging between the heater and the rail.
• Visually check heaters regularly for signs of physical damage from abnormal circumstances. If physical damage is apparent, disconnect and perform insulation test immediately before placing the heater back in service.
DO NOT attempt to disassemble any component
CAUTION
of this heater.
J.3 MAINTENANCE PROCEDURE
Hazard of severe shock. Disconnect all power to heaters before servicing or replacing heaters.
Only qualied personnel trained in electrical
WARNING
equipment service should perform maintenance on switch heating and control equipment.
• Periodically (minimum annual) check connection of the electrical terminals and tighten if necessary to torque specification guides.
CCI Thermal Technologies Inc.
61
NOTES
62
As a leader in advanced heating and filtration solutions with facilities across North America, CCI Thermal Te chnologies Inc. manufactures
six of the top brands in industrial heating in addition to a comprehensive line of engineered industrial filtration products including:
Cata-Dyne™ is the industry standard in infrared gas catalytic heaters, enclosures, pipeline systems and accessories. Customers across a wide range of industries rely on Cata-Dyne™ to supply them with safe, reliable, efficient and versatile infrared catalytic heating equipment for a variety of applications in both hazardous and non-hazardous environments.
Ruffneck™ is renowned for its rugged, reliable and versatile heavy-duty explosion-proof heaters, heating systems and heating accessories. Ruffneck™ has a long and proud history of supplying quality heating products for the harshest industrial environments to a worldwide customer base for over 30 years. Ruffneck™ is well-known in the industry for its "ship the heat in a week" policy, where 95% of all standard orders are shipped within one week of order placement.
Caloritech™ electric heaters, heating elements and heating accessories are well-known in the industry for their quality, reliability, performance and versatility. In addition to standard "off the shelf" industrial heaters and heating systems components, Caloritech™ also offers engineered heating solutions custom designed, manufactured and tested to satisfy customer specifications. No matter what your application or environment, Caloritech™ has a solution to fit your heating needs.
3L Filters™ has satisfied the most demanding industrial filtration requirements for over 40 years. A broad range of standard and custom products includes liquid filters, strainers, separators, pressure vessels, and engineered products and systems. 3L Filters™ has special expertise for nuclear, petrochemical, water treatment and environmental applications.
Norseman™ is the most technologically advanced line of explosion-proof electric air heaters and heating accessories, including both forced air heaters and natural convection heaters, as well as unit heaters, panel heaters and thermostats. Norseman™ offers innovative, low maintenance solutions for a wide range of applications in a variety of industrial and commercial environments. Custom engineered heaters or heating systems are available for specialized applications.
®
Fastrax
has manufactured railroad track and switch heating since 1995. Fastrax® engineers complete heating packages for the rail industry. Fastrax® track and switch heaters are designed to provide the most efficient heat transfer on rail equipment and components for the coldest environments. In addition to heaters, Fastrax fully automatic energy saving controls to complete the rail heating system.
®
manufactures
DriQuik™ provides components for infrared drying ovens. DriQuik™ utilizes a pioneered radiant oven technology established in the 1930s providing the industry standard in infrared radiant heating components.
VISIT WWW.CCITHERMAL.COM FOR DETAILED PRODUCT INFORMATION.
Edmonton, AB
Head Office
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F 905-829-4430
Orillia, ON
1-877-325-3473
(705) 325-3473
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Houston, TX
1-855-219-2101
(281) 506-2310
F 281-506-2316
Denver, CO
1-855-244-3128
(303) 979-7339
F 303-979-7350
M80000.Rev.2.02
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