Fastrax Hellfire 900 Installation, Operation & Maintenance Instructions Manual

IMPORTANT INSTRUCTIONS - SAVE THESE INSTRUCTIONS

ISO 9001

Read all instructions before installing or using the heater. Please adhere to instructions published in this manual.
Failure to do so may be dangerous and may void certain provisions of your warranty.

Gas Fired Railway Switch Heater

HELLFIRE 900

2014

Installation, Operation, & Maintenance Instructions

ANSI Z83.7-2017 / CSA 2.14-2017
Gas Fired Unvented Construction Heaters (Unattended Type)

Fastrax® is a registered trademark of Thermon Heating Systems, Inc.
Copyright© 2018. All rights reserved.

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

TABLE OF CONTENTS

A. Important Notices And Warning Symbols 4

B. Identification 6

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

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

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

B.4 Control Panel Diagram - 240V Single Phase

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

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

C. Pre-Operation Inspection 8

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

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

D. Operation 11

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

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

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

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

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

E. Controls & Indications 13

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

F. Troubleshooting 21

G. Installation 25

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

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

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

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

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

G.6 Gas Supply Piping and Minimum Pressure Drop 28

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

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

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

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

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

H. Heater Specifications 35

H.1 Pe r f o rm a nc e ........................................................35

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

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

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

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

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

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

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

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

I. Maintenance 43

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

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

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

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

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

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

J. Service 45

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

J.17 D ef r o s t e r ..............................................................49

K. Parts 50

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

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

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

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

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

A. IMPORTANT NOTICES AND WARNING SYMBOLS

Keep this manual with the machine at all times. The purpose of
this manual is to provide owners, operators, and installers with
the precautions and procedures essential for the safe and proper
operation for its intended purpose.

CAUTION. This symbol indicates a potentially
hazardous situation, which, if not avoided, may result in

WARNIN G

personal injury or damage to the equipment.

.

WARNING. Read and adhere to the following. FAILURE
TO DO SO MAY RESULT IN SEVERE OR FATAL

WARNIN G

INJURY. Warranty will be void.

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

relates directly or indirectly to the safety of personnel or
protection of property.

WARNING. This symbol indicates an imminently

hazardous situation, which, if not avoided, can result

WARNIN G

in serious injury or damage to the equipment.

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

Symbol

English French

Risk of electrical shock or electrocution.

Disconnect electrical power prior to servicing.

Description

Risque de choc électrique ou d’électrocution.

Couper le courant avant d’entreprendre l’entretien.

The heater is designed and approved for use as a

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

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

local authority, if you have questions about applications.

General hazard warning failure to comply with the

precautions and instructions provided with this heater,

can result in death, serious bodily injury and property

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

asphyxiation, carbon monoxide poisoning, and / or

electrical shock.

Only persons who can understand and follow the

instructions should use or service this heater. If you

need assistance or heater information such as an

instructions manual label, etc. Contact the manufacturer.

Fire, burn, inhalation, andexplosion hazard. Keep solid

combustibles, such as building materials, paper, or

cardboard, a safe distance away from the heater as

recommended by the instructions. Never use the heater

in spaces which do or may contain volatile or airborne
combustibles, or products such as gasoline, solvents,

paint thinner, dust particles or unknown chemicals.

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

All persons employed in handling propane or natural

gas shall be trained in proper handling and operating

procedures, as required by local authorities having

jurisdiction.

Cet appareil a été conçu et approuvé pour être utilisé comme

radiateur commercial (gaz) - aiguillage de voie ferrée de

classe 2902 05, conformément à la norme

2.14. Communiquez avec les autorités locales pour plus de
renseignements sur le lieu d’utilisation de cet appareil.

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

et des instructions fournies avec ce radiateur peut entraîner

la mort, des graves blessures et des per tes matérielles ou

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

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

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

Seules les personnes aptes à comprendre et à suivre les

instructions devraient se servir de ce radiateur ou le réparer.

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

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

Prière de communiquer avec le fabricant.

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

Garder les combustibles solides, tels les matériaux de

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

radiateur, comme il est recommandé dans les instructions.

Ne jamais utiliser cet appareil dans des endroits qui

contiennent ou pourraient contenir des combustibles volatiles

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

diluants pour peinture, les par ticules de poussières ou des

produits chimiques inconnus.

Toute personne qui manipule le propane ou le gaz naturel
doit avoir suivi une formation sur les bonnes procédures de
manipulation et d’utilisation qui est conforme aux exigences

des autorités locales compétentes.

ANSI Z83.7 / CSA

Important Notices and Warning Symbols

4

4

Symbol

Description

English French

If you smell gas; immediately extinguish all sources of

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

technician to repair leak.

Do not attempt to manually light burner.

Heater equipped with an automatic electronic ignition

system.

Risk of cutting ngers or hand.

Disconnect fan power prior to removing combustion

chamber access panel or air intake.

Heater can start automatically.

Exercise caution when in close proximity.

Burn hazard / hot surfaces.

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

duct connected downstream of heater during operation.

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

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

technicien qualié.

Ne pas allumer le brûleur manuellement.

Radiateur équipé d’un système d’allumage électronique.

Risque d’amputation des doigts ou de la main.

Couper le courant au ventilateur avant d’enlever le panneau

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

Attention : le radiateur peut démarrer automatiquement.

Faire preuve de prudence près du radiateur.

Surface chaude; risque de brûlure.

Ne pas toucher les conduits latéraux à la voie ferrée, les
buses ni aucun conduit non isolé branchés en aval d’un

radiateur en marche.

Sheet metal edges can be sharp.

Wear protective clothing when handling track duct,

insulted ducts and any other sheet metal components.

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

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

Risque de coupure.

Les rebords de la tôle sont coupants. Porter des vêtements

protecteurs lors de la manipulation des conduits isolés et tout

autre composant en tôle.

Important Notices & Warning Symbols

5

B. IDENTIFICATION

B.1 Heater Labels

1. Each heater has a ratings label, a logo label, a model and
serial number tag and a voltage label.

2. The ratings label contains all identication and safety
information. It is fastened by a lanyard and stored in the
manual pocket inside the control enclosure next to the gas
manifold. The electrical specications are indicated with a
punch mark.

Installation & Instruction
Manual Location

Voltage Label

3. The logo, located on the side of the air intake hood
identies the series as HELLFIRE, and the size, either 400

or 900.

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

The model number is applied to an adhesive backed label

bonded to the tag, and the serial number is engraved. The
serial number is a sequential 6-digit number.

Rating Label

B.2 Model and Serial Number Tag

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

2. This is true for all congurations including heaters supplied
with the bungalow option.

3. Congurations are identied on the tag as model “HF 900”
followed by a 5-digit number, an optional 2-digit dash
number and a revision letter. For example,
HF900 12345-01A (HF900 BUNG XXXX X-XXX - for
bungalow enclosed heaters).

4. The operating voltage label is found on the electrical
access panel. Have this information available when
requesting parts or service.

B.3 Components Diagram

5. The following component names are referred to in this
manual. See Section L - Parts for par t numbers and

ordering.

Identification Tag with Model and Serial Number

Stand-Alone & Bungalow Enclosed Configurations

Identication

6

6

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

No. Label

1 Track duct

2 Track duct elb ow

3 Rail mounting spring clip and pad

4 Ballast retainer

5 Thermostat box

6 Precipitation detector

7 Burner

8 Regulator vents

9 Conde nsation vent

10 Gas manifold

11 Control cabinet lid

12 Air int ake hood

13 Ambient air temperature sensor

14 Air in take exte nsion

15 Identication tag

16 Mode selector switch

17 Electrical control access panel

No. Label

18 Air intake plenum

19 Leveling leg

20 Control panel

21 Motor/Impeller/Base

22 Combustion chamber access panel

23 Transition duct

24 Sensor duct

25 Square to ro und adapter

26 Flex duct

27 Track duct deector

28 Tie duct

29 Rail thermostat

30 Point nozzle

31 Track duct mounting bracket

B.5 Gas Manifold Diagram

No. Label

1 Ignition transformer

2 Burner control / Flame Safety Relay

3 Purge tim er card

4 Reset module

5 Controller

6 Programming key

7 EMS module

8 Control circuit breaker

9 Motor circu it brea ker

10 120V receptacle

11 Contactor

12 Control transformer

13 Power term inal blo ck

14 Mode selector switch

15 Hour meter

16 Receptacle circuit breaker

17 Tank va lve circu it breaker

18 Control and indication terminal block

19 Resettable fuse, burner defroster

20 Manifold terminal block

21 Rail thermostat receptacle

22 Precipitation detector receptacle

23 Flame signal amplier

Identication

77

C. PRE-OPERATION INSPECTION

No. Label

1 Regulator vent

2 Regulator vent pipe

3 Pilot gas solenoid valve

4 Pilot gas pressure regulator

5 Pilot manual shutoff valve

6 Gas supply inlet

7 Gas supply pressure gage

8 Main gas pressure regulator

9 Main and safety gas

solenoid valves

No. Label

10 Manifold gas pressure gage

11 Main manual shutoff valve

12 Union

13 Burner mounting bracket

14 Burner defroster

15 Igniter

16 Flame rod

17 Burner

Identication

8

8

C.1 Important Notices

To ensure trouble free operation during the winter months, inspect
the system annually at the start of the season.

WARNING. All persons employed in handling propane
or natural gas shall be trained in proper handling and

WARNIN G

operating procedures, as required by local authorities
having jurisdiction.

Gas leaks shall be repaired immediately or, gas supply
valve closed until repairs can be made.

All work performed on railway property must be
carried out in accordance with local railway authorities

NOTE: Perform inspection and operations in accordance with

the instructions provided in the ser vice section of this
manual.

NOTE: This inspection guide assumes that all applicable ser vice

bulletins have been implemented on the heater being
inspected.

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

expected indicates further service is required.

instructions.

CAUTION. Do not operate this machine until it has
been installed and commissioned according to

CAUTION

requirements specied in the installation section of this
manual.

C.2 Prior to Heater Start-Up

Table 2 – Heater Inspection List

Inspect Action

Condition of all ducting, particularly any
ex ducts

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

Track duct vents

Track duct mounting

Flame rod and spark igniter

Flame rod and ignition wires

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

Cycling and high limit thermostat
installation

Service surge protection Verify electric service has functioning surge protection.

Air switch port and vent Remove any obstruction.

Gas regulator vents Remove any obstruction.

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

Gas source

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

Flame Safety Relay Burner Control fault
histories

Repair or replace damaged ductwork.

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

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

Verify track ducts do not interfere with normal movement of the switch points and do not interfere
with the signal system.

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

cracked ceramic.

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

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

Inspect boot for degradation, cracks and poor seals. Replace if necessary.

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

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

Replace any with damaged wire insulation.

Verify thermostat enclosure is sealed and dry inside.

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

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

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

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

H1 Co de Hour Cycle

H2 Code Hour Cycle

H3 Code Hour Cycle

H4 Code Hour Cycle

H5 Code Hour Cycle

H6 Code Hour Cycle

Pre-Operation Inspection

99

Inspect Action

Electrical supply

Gas supply

Flame signal strength

Burner operation

Air switch calibration

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

Energy Management System (EMS)

Aggressive retry

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

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

Verify supply and manifold gas pressures are within nameplate limits when heater and all
connected loads are operating.

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

If signal strength is low:

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

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

or replaced.

Note current manifold pressure.

Set manifold pressure to maximum nameplate setting, measure point nozzle temperature, if
point nozzle temperature is 140°F or less above ambient air temperature have burner serviced or
replaced.

Return manifold pressure back to desired setting.

Block air intake 80%. Verif y heater still operates.

Then block 90% and verify FSR alarms.

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

If heater is operated automatically by an Energy Management System:

– Verify EMS module is installed and connected with POWER LED lit.
– Verify controller is in AUTO mode.
– Verify precipitation detector and ambient temperature sensor installed and connected.
– Verify rail thermostat is mounted on rail and connected to surge isolator.
– Verify its operation.

Verify operation.

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

Verify three attempts made followed by lockout.

Return heater to desired operating mode.

Open gas supply.

Reset controller.

Pre-Operation Inspection

10

10

D. OPERATION

D.1 Introduction

The switch heater is a gas red, hot air heating system that

keeps a turnout clear of ice and snow during winter storms
by blowing hot air, between the stock rail and moving
points, at the tie plates on which the points slide, and at the

gage rods.

D.2 Modes

The heater can be operated in the following modes:

1. MANUAL - by toggling the mode selector switch
to “MANUAL”, the heater will turn on and operate

continuously. If installed, the rail thermostat will cycle

the burner on and off as required to maintain the rail
temperature.

2. AUTO – With the controller congured for LOCAL AUTO
MODE, toggling the mode selector switch to “AUTO/
REMOTE”, and with an EMS module, precipitation and
ambient temperature sensor installed, the heater will turn

on or off as required based on the weather conditions. If

installed, the rail thermostat will cycle the burner on and

off as required to regulate the rail temperature.

3. REMOTE RTC- by toggling the mode selector switch
to “AUTO/REMOTE” and with a Rail Trafc Control, RTC
(dispatcher) operated control relay contact wired to
terminals A1 and A2 of the control and indication terminal
block. With RTC timer disabled, the heater will operate

continuously while the RTC contact is closed, if the RTC

timer is enabled, the heater will run for the duration of
the RTC timer then stop. RTC can restart the heater for
additional run time by resetting the request. If installed, the
rail thermostat will cycle the burner on and off as required
to maintain the rail temperature.

4. REMOTE SCADA - With the controller congured for
REMOTE SCADA MODE, toggling the mode selector
switch to “AUTO/REMOTE” with the heater connected
to a Supervisory Control and Data Acquisition, SCADA,
network via the controllers’ RS-485 communications port,
and congured with a Remote Control and Monitoring
System (RCMS), software, the heater will operate
automatically.

If installed, the EMS module, precipitation detector,
ambient temperature sensor and rail thermostat provides
inputs to the RCMS software.

5. OFF – to disable the heater, toggle selector switch to

“O F F ”.

D.3 Start-Up Sequence (All Modes)

Once a start request is received the control sequence begins.

NOTE: If the controller is in ‘REMOTE RTC’ mode then it waits

for the ‘DELAY START’ time before initiating.

Table 3 – All Modes

Conditions/Sequence Status LED

Heater is in an operational mode not OFF. ENABLE

Cycling thermostat is cold or closed. CYCLING

Motor contactor closed, fan starts. MOTOR

Air pressure develops, air switch closes. AIR SW

FSR requested, trial for ignition, burner lit. HE AT

Main gas valve opens. FSR CHECK

Run indication contact closed. RUN

To conrm the heater operation, the burner remains lit and the rail

thermostat status is ignored for the rst 2 minutes.

Normal operation Heater runs as long as requested.

D.4 Occurrences During Normal Operation

NOTE: The rail thermostat closes when the rail temperature is

above 9°C (49°F) and opens when below 3°C (37°F).

6. As long as the rail is cold and the thermostat is open, the
burner remains lit. Once the rail warms and the thermostat
closes, the burner is extinguished. This cycle repeats as
required while the heater operates. If the rail temperature
remains warm for more than the post purge time then the
fan is turned off. The run indication is maintained during
this time.

7. If the heater is in ‘REMOTE SCADA’ mode and the
‘Fastrax® RCMS’ software is requesting performance

operation, the burner will remain lit regardless of rail
thermostat status.

NOTE: The cycling thermostat limits the heated air temperature

to a maximum of 193°C (380°F). Under normal
circumstances the air temperature remains below this
limit.

8. If the heated air temperature becomes excessively hot,
the cycling thermostat limit opens, and the burner is
extinguished immediately. Once the air cools and the
thermostat closes the burner is lit and heating resumes.
Run indication is maintained during this time.

D.5 Heat Output Adjustment

1. Depending on the length of switch points, its’ priority,
local climate conditions, and experience, the operator
can increase or decrease the heat output accordingly.

The recommended heat output is in the range of 10,000

to 22,000 BTU/hr per foot of turnout length.

Operation

1111

2. The factory default setting is 550,000 BTU/hr when
operated on LPG, or 390,000 BTU/hr on NG.

3. The heat output can be adjusted as follows:

3.1 With the heater running, unscrew and remove the

main regulator (8) cap.

3.2 Use a at blade screwdriver to turn the internal nut

clockwise to raise (shown) or counterclockwise
to lower pressure as indicated on the manifold
pressure gage (10).

3.3 Screw cap closed.

3.4 As a starting point, with the heater operating,

adjust the manifold gas pressure to attain an air
temperature of 121°C (250°F) above ambient as
measured at the near point nozzle.

WARNING. Do not operate above maximum manifold
pressure as this can produce carbon monoxide in

WARNIN G

excess of maximum allowable of 0.08 AFCO.

WARNING. Do not operate above or below the rated
manifold pressure limits. Operating outside limits will

WARNIN G

result in weak ame signal and unreliable operation.

WARNING. Install cap once regulator adjustment is
complete. In the event of pressure relief, the cap must

WARNIN G

be closed to vent gas to the exterior.

3.5 The heat output can be estimated from the manifold
pressure and the following formulas:

204,000 + ((Manifold pressure –2.5)/6.5)*696,000 for LPG or
230,000 + ((Manifold pressure –3.5)/12.5)*670,000 for NG

Pressure is in inches of water column.

NOTE: These formulas are simplied, assume the equipment is

in good condition, and are strictly for estimation only.

Operation

12

12

E. CONTROLS & INDICATIONS

E.1 AAR Signal Wiring - For non SCADA installations

Table 4 – AAR Signal Wiring

Terminals Label Description

A1 - A2 REMOTE START A contact closure across these terminals starts the heater when the heater is in REMOTE RTC mode.

A3 - A4 RUN Dry contact closes to provide a run indication.

A5 - A6 ALARM Dry contact closes to provide alarm indication.

A7 - A8 FORCE OFF Default is closed. If FORCE OFF function is desired, remove shorting link and replace with customer

supplied relay contact. Open contact disables heater.

A9 - A10 TANK VALVE These terminals are intended to operate a 120V AC gas supply solenoid shut off valve. They energize

when the motor contact closes.

A11 RS-485 (+) Communications, RS-485 positive terminal (for RCMS operation only)

A12 RS-485 (-) Communications, RS-485 negative terminal (for RCMS operation only)

E.2 Controller

1. The controller manages the operation of the heater and
allows it to either operate on its own or be part of a
network of heaters.

2. The controller monitors various inputs, controls the heater
functions, communicates status and provides indication
LEDs.

3. The controller is DIN rail mounted and all wiring

connections are made with plug connectors to allow quick

replacement in the event of a failure.

4. With the addition of the EMS package, a stand alone
heater can operate automatically based on weather

5. Its’ RS-485 serial communications port allows the heater

NOTE: Controllers are not interchangeable between HELLFIRE

conditions, or when connected to a network, act as a

weather station providing input to a SCADA system.

to interface with SCADA systems, and be operated and
managed by a Remote Control and Monitoring System,
such as the Fastrax® RCMS.

400 (24VAC) and HELLFIRE 900 (120VAC).

Controls & Indications

1313

E.3 Controls

1. Power: This switch turns the power supply to the board
‘ON’ or ‘OFF’.

WARNING. 120VAC inputs to controller can remain
energized.

WARNIN G

2. Reset: This push button is used to reset the controller in
case of a lockout.

3. Delay Start: This dial sets the length of the delay, 0 to 60
seconds, before starting the heater. It is intended to allow
the stagger start of multiple heaters connected to one
power service thereby reducing the maximum current
draw. This setting is true for REMOTE RTC mode only.
Under MANUAL, AUTO and REMOTE SCADA modes
there is no delay.

NOTE: This setting is overridden when operated in REMOTE

SCADA mode by the corresponding Fastrax® RCMS
software parameter.

4. Post Purge: This dial sets the length of the delay, 5
seconds to 4 minutes, once the heater is no longer
requested, before stopping the fan. It is intended to purge
the remaining heat and moisture from the combustion and
duct system. This setting is true for all modes.

5. RTC Time: (RTC stands for Rail Trafc Control dispatch)
This dial limits the run time between 20 minutes to 4 hours,

when requested by RTC dispatcher, and with the RTC
SW switch ON, and the heater is in REMOTE RTC mode.
When the RTC request exceeds the time limit, the heater

turns off, and the run indication is maintained as long as
the heater is requested.

Timer is reset once the RTC request is removed. RTC can

then request the heater for another cycle.

It is intended to save fuel by avoiding unnecessary heater

operation by the dispatcher. This setting is true for RTC

MODE only. Under MANUAL, AUTO, and REMOTE SCADA
modes there is no limit.

6. RTC SW: This switch enables the RTC TIME function when
in the ON position. When switched OFF, RTC TIME is

disabled and the heater runs as long as requested.

7. JUMPER, JP1: Used to congure controller parameters.

E.4 Indications

1. On the controller are a number of status LEDs intended
to aid the user’s understanding of the heater state of

operation. See Table 6 - Controller LED Descriptions for

full description.

NOTE: With the exception of the communications TD, RD, and

TX LED’s. Solid green, solid green with a red pulse, or

yellow LED’s indicates normal status. Solid red and
alternating LED’s indicate a failure. This is true for the

controller only, not the EMS module.

2. Refer to Section F - Troubleshooting for explanation of
problem condition LED codes.

3. The LEDs listed can be found on the controller from top
left to bottom right on the board.

Table 5 – Controller LED Descriptions

LED Name Description State Indication

TD, RD on and pulsing
TX off and pulsing

TD, RD, TX

Status Processor status

ENABLE Heater enable

FSR CHECK

RES FSR Reset On Controller clears FSR alarm.

RS-485
communications

Flame Safety
Relay check

TX off
TD and RD on

TD, TX off and pulsing

RD on

Solid green with a red
pulse

Alternating red and
green

Solid red

Solid green or off Processor has stopped functioning.

On

Off Mode selector switch is in OFF position. Heater is in OFF mode and will not start.

On Gas valve energised. Used to conrm correct operation of FSR.

Alternating The FSR did not energized the main gas solenoid valves when expected.

Heater in REMOTE SCADA mode.

Heater in LOCAL AUTO mode.

8N1 COM communications mode.

Normal operation.

FSR failure alarm. Aggressive retry mode in process.

Failure alarm.

Note any alternating LEDs and refer to Section F - Troubleshooting.

Controller must be reset.

Mode selector switch is either in MANUAL or REMOTE/AUTO position.

Heater can be started in AUTO REMOTE RTC or REMOTE SCADA modes.

Controls & Indications

14

14

LED Name Description State Indication

EMS REQ EMS request On

POWER Power supply On Controller energized.

MOTOR Motor On Contactor closed, motor turned on.

HE AT

RUN IND

ALARM

FSR ALARM

AIR SW

CYCLING

HIGH LIM

MANUAL Manual operation On Selector switch in “MANUAL” position. Heater in MANUAL mode.

RAIL TH Rail thermostat On Thermostat open. Rail temperature is BELOW set point.

RTC

Controller
request for heat

Heater run
indication

Heater alarm
indication

Flame safety
relay alarm

Air pressure
switch

Cycling
thermostat

High limit
thermostat

Rail trafc control
mode

On FSR requested. Ignition sequence started or burner operating.

On Indication contact closed. Turns on after 60 seconds of normal operation.

On

On FSR in ALARM, or controller is preventing its operation.

Alternating FSR is in ALARM. Heater failed 4 times in 5 minutes.

On Contact closed. Sufcient air ow to allow burner operation.

Alternating

Off with pulse on Continuous fan mode with selector switch in OFF position.

On with pulse off

On Thermostat closed. Heated air temperature is BELOW set point.

Alternating Cycling thermostat open for more than 10 minutes.

On Thermostat closed. Heated air temperature ABOVE set point.

Alternating

On

Off with pulse on

On with pulse off

EMS module request for heater to run.

Heater only acts on this request if in AUTO mode.

Alarm indication contact closed. Heater off and locked out. Controller must be
reset manually.

Air switch did not operate as intended. Air switch either did not close with fan ON
or did not open with fan OFF.

Continuous fan mode with selector switch in MANUAL or REMOTE/AUTO
position.

High limit thermostat closed momentarily indicating air temperature exceeded
set point.

Indicates selector switch is in “REMOTE/AUTO” position and AAR terminals 1
and 2 are closed.

Indicates selector switch is in “REMOTE/AUTO” position and requested by
RCMS.

Indicates selector switch is in “REMOTE/AUTO” position and requested by
RCMS and A AR terminals 1 and 2 are closed.

E.5 Terminal Blocks

1. The controller interconnects with the control panel by means of 8 board level headers, TB1 to TB8, which accept the various
wire harness plug connectors. The controller and EMS module connect via a ribbon cable that plugs into the 10-pin header
found on each.

Table 6 – Terminal Block Description

Name Description

JP1 Jumper. Used to congure EEPROM settings

TB1 120V power, transformer primary and motor contactor coil output

TB2 Transformer secondary 24V power and FSR request output

TB3 RTC run and alarm indication contacts outputs

TB4 Rail thermostat, RTC request, Manual, and Enable inputs

TB5 Air switch, FSR/DSI alarm, gas valve inputs

TB6 Cycling and high limit thermostats inputs

TB7 Communication port, RS-485

TB8 FSR reset and current transformer inputs

10-pin header* EMS module power and signal connection

*Located in the upper right corner next to TB8.

Controls & Indications

1515

E.6 Data Communications

1. The RS-485 serial communications port, and an
EEPROM, allows the heater to be part of a Supervisor y
Control and Data Acquisition (SCADA) network and
Remote Control and Monitoring System (RCMS) software.

2. The RS-485 port runs at 9600 baud and allows
communication over long distances of up to 1000’ and

possibly longer.

NOTE: Cable construction: Cat5 24 AWG twisted pair is a very

common cable type used for RS-485 systems. Adding
shielding to the cable enhances noise immunity, and
thereby allows greater distance. If used, connect one
end only of shield to ground.

3. The 8-bit memory address allows a maximum of 254

heaters to connect to the same communications bus.

E.7 Controller EEPROM Memory

1. EEPROM memor y chip stores parameters and an address.

2. EEPROMs can be switched between controllers. In the
event a controller needs to be replaced the EEPROM can

be removed from the old and put in the replacement. The
parameters and address remain with the heater and no
RCMS software modications are required.

WARNING. Electrostatic discharge can damage ICs.
Have qualied personnel remove and install EEPROM IC.

WARNIN G

E.8 Activating a COMMUNICATION Parameter

NOTE: Read and understand the following procedure before

starting. COMMUNICATION parameters require a
hardware programming key to make changes, MODE
parameters do not.

1. Toggle mode selector switch to “OFF”. If installed,
disconnect EMS cable from controller. Plug programming

key into the mating EMS 10-pin connector. Then the red
LED on the key lights.

2. Press the RESET button, and shor t jumper JP1.

3. Release the RESET button. The RTC, MANUAL, CYCLING,
and AIR SWITCH LEDs will each pulse, one after the other
for one sequence. Then the RUN indication LED pulses
and the green LED on the programming key alternates on
and off.

4. After ve RUN indication pulses, the red ALARM LED lights
for 3 seconds. This cycle continues as long as the jumper,

JP1, is shorted.

5. Count the number of times the red ALARM LED lights.

6. Once the count equals the parameter number, remove
the jumper before the ALARM LED turns off. For example,
when the AL ARM LED lights for the second time
removing the jumper will activate REMOTE SCADA MODE,
parameter #2.

7. Function performed.

8. Parameter or new address is stored on the EEPROM.

9. Repeat sequence as required to activate other parameters.

3. Parameters activated locally or remotely by the RCMS
software are stored on the EEPROM.

NOTE: There are two parameter types, ‘COMMUNICATION’ and

‘MODE’.

Table 7 – Communication Parameters (Activated Locally)

Name Setting1Function

Disables communications and
enables local EMS control.

Enables RS-485 MODBUS
communication.

2

Disables local EMS control.

Enables weather station mode.

Enables 8N1 communication.

Enables local EMS control.

7 Disables local EMS control.

When enabled, the fan runs
continuously.

When disabled, the fan runs only
when heating is requested.

16

16

LOCAL AUTO MODE 1

REMOTE SCADA

MODE

DEFAULT ADDRESS 3 Writes 254 to processor address.

ADDRESS SET 4 Writes new address to EEPROM

8N1 C OM 5

LOCAL EMS, enabled 6 Enables local EMS control.

LOCAL EMS,
disabled

FAN MODE ----

1

Setting number equals alarm LED/relay count.

2

One time functions.

3

The 8N1 conguration allows the heater to send status information only

Controls & Indications

and is intended to aid service technicians. This conguration does not allow
the heater to be part of a network.

4

See CONTINUOUS FAN MODE section for instructions.

E.9 Mode Parameters

Table 8 – Mode Parameters

Name Parameter1Function

FAN MODE
ENABLE

FAN MODE
DISABLE

LOCAL EMS
MODE

ENABLE

LOCAL EMS
MODE

2

DISABLE

2

3

RAIL

TH E RMOS TAT

MODE NORMAL

RAIL

TH E RMOS TAT

MODE

VERSED

4

RE

1

Parameter number equals alarm LED/relay count.

Turns the motor on and keeps it

1

2

running continuously.

Motor runs only when heater is
requested.

3 Local EMS controls the heater.

The local EMS will not turn the

4

heater on.

Congures operation to new

5

thermostat, open when cold,

closes on temperature rise (COR).

Congures operation to older rail

6

thermostats that are closed when

cold, open on temperature rise

(OOR).

E.10 Activating MODE Parameter

NOTE: Read and understand the following procedure before

starting.

1. The controller must be powered on for a minimum of 60
seconds, the mode selector switch toggled OFF, and
terminals A1 A2 open (i.e. no RTC request).

2. Short jumper JP1. The RUN indication relay and LED
pulses on and off. After ve RUN indication pulses, the red

ALARM LED lights for 3 seconds. This cycle continues as

long as the jumper, JP1, is shorted.

3. Count the number of times the red ALARM LED lights.

4. Once the count equals the parameter number, remove
the jumper before the ALARM LED turns off. For example,
when the AL ARM LED lights for the second time removing
the jumper will activate FAN MODE DISABLE, parameter

#2.

5. Function performed.

6. Parameter or new address is stored on the EEPROM.

7. Repeat sequence as required to activate other parameters.

E.11 Fan Mode

1. When enabled for continuous operation, this mode can
be benecial for locations with difcult to detect drifting
snow conditions that cause snow accumulation in the
turnout and or in the duct system.

2. When enabled, and with the mode selector switch in either
the MANUAL or REMOTE/AUTO position, the fan will run

continuously, with heating requested or not.

NOTE: The fan will stop when the mode selector switch is in the

OFF position.

3. This parameter can be set, either, locally, or remotely by
the RCMS software.

4. Refer to RCMS documentation for remote activation.

E.14 RAIL THERMOSTAT Mode, Reverse

1. When enabled, the controller is congured to operate
with the previous, open on rise (OOR), thermostat.

E.15 Failure Shutdowns and Alarm Indications

1. In the event of a failure, the controller ceases the heater

operation and indicates alarm.

2. While the heater is shutdown and indicating alarm the
controller continues communications with the RCMS

software. All start requests, local or through the RCMS
software, are ignored until the problem is resolved.

3. The controller indicates the nature of the failure in three

ways. LED’s on the controller, an alarm contact closure,
and error codes communicated via the RS-485 serial port
when under RCMS control.

NOTE: With the exception of the communications TD, RD, and

TX LED’s. Solid green, solid green with a red pulse, or

yellow LED’s indicates normal status. Solid red and
alternating LED’s indicate a failure. This is true for the

controller only, not the EMS module.

4. There are two types of failure alarms, minor and major.
Both cease the heater operation, however, minor alarms

clear when the condition that caused the failure recties

itself. Major alarms, which are more serious and require
inspection, must be manually reset.

E.16 Fault Conditions

1. A failure exists when the STATUS and the ALARM LED’s
are solid red.

2. In addition, an alternating LED of equal duration on and off,
or red and green indicates the failure condition.

3. Heaters connected via the RS-485 port to a network and

RCMS software will communicate fault codes.

E.12 Local EMS Mode

1. This parameter enables the locally installed EMS module
to control the heater according to the module set points.
If connected to a SCADA system, all weather data will be
transmitted to the system. No other functions are affected
by this mode.

2. The HEAT LED pulses to indicate that the local EMS
module can turn on the heater.

3. When disabled, the HEAT LED will not pulse. It will light up
when conditions are met, but it will not turn on the heater.

E.13 RAIL THERMOSTAT Mode, Normal

1. With the introduction of the 2014 model Hellre, the rail
thermostat operation was reversed. The thermostat now

opens when cold and closes when warm.

2. When enabled, the controller is congured to operate with
the new, close on rise (COR), thermostat.

Controls & Indications

1717

Table 10 – Fault Condition Codes and LED States

Alarm

Code

Type

1 Minor

2 Major

3 Major

10 Major

11 Major

12 Major

13 Major

14 NA FSR in alarm.

20 Minor

21 Major

30 Minor

31 Minor

Fault Condition LED State

Selector switch left in
OFF position for more
than 60 minutes.

Air switch does not
open after fan motor
turned off.

Air switch does not
close after fan motor
turned on.

Flame failure at start
up.

Loss of ame signal
while running.

4 FSR alarms within 2
minutes.

Gas valve does
not energize when
expected.

Cycling thermostat

failed to close after 10

minutes.

Maximum output air
temperature exceed.

High limit thermostat

closed momentarily.

Controller in
conguration mode.

JP1 jumper shorted.

EMS module TEST

switch on.

ENABLE Dark

AIR SW Alternating

AIR SW Alternating

FSR

ALARM

FSR

ALARM

FSR

ALARM

FSR
CHECK

FSR

ALARM

CYCLING Alternating

HIGH LIM Alternating

(none)

SENSOR
WET

Alternating

Alternating

Alternating

Alternating

Solid Red

Solid Red

E.18 Reset

1. Prior to performing a reset:

WARNING. If you smell gas; Immediately extinguish all
sources of ignition and turn off gas source.

WARNIN G

Call qualied service technician to repair leak.

1.1 Toggle the selector switch to OFF.

1.2 Gain access to the controller by removing the
electrical access panel.

NOTE: Note the status of the controller LEDs, contactor thermal

overload relay reset (three phase models only), control

panel circuit breaker, and motor circuit breaker. Connect
a display module to the FSR and note the current and
past fault histories.

1.3 Close any tripped or open breakers. Green means
safe and red means danger circuit energized.

1.4 In the case of three phase models, if found tripped,
reset the thermal overload relay located on the panel
and connected to the contactor.

WARNING. Risk of cutting ngers or hand.

Open motor circuit breaker before opening combustion

WARNIN G

chamber access panel. Keep clear of fan.

1.5 In the case of single phase models, OPEN THE
MOTOR CIRCUIT BREAKER. Remove the
combustion chamber access panel and, if tripped,
reset the thermal overload switch found on the
motors junction box. Close the combustion chamber
access panel and close the motor circuit breaker.

2. Press and release the controller reset.

E.17 Aggressive Retry Feature

1. The controller has an aggressive retry feature. It is
intended to avoid nuisance failure shutdowns and
alarm indications due to temporary conditions, such as

condensation on the igniter and or ame rod, which are

rectied with repeated attempts.

2. In the event of an FSR alarm, as indicated by the FSR
ALARM LED, occurring at start up or under normal
operation, this feature will reset the FSR and allow up to 4

trials for ignition attempts within 2 minutes.

3. Between attempts the STATUS LED alternates red and
green and after 20 seconds the FSR is reset, as indicated

by a pulse of the RES LED and the clearing of the FSR

ALARM LED.

4. After 4 failures within 2 minutes, the heater ceases
operation, the controller locks out, the STATUS LED turns

solid red, the run indications are removed and the alarm
indications applied with the ALARM FSR LED alternating

on and off.

Controls & Indications

18

18

E.19 Energy Management System (EMS)

Adding the EMS allows a heater to operate automatically,
or to act as a weather station when part of a network of

heaters controlled by the Fastrax® RCMS.

The system includes a module, a precipitation detector,

ambient temperature sensor, and rail thermostat. Once
installed, the controller recognizes the EMS module and
works in conjunction with it.

5. TEST:

6. SENSITIVITY:

4.2 When snow is no longer sensed the heater request
is held for the duration of the timer. If at any time
during the delay snow is sensed the timer is reset.

5.1 This switch simulates precipitation when ON. Used
to test the module operation.

6.1 This dial adjusts the precipitation detector sensitivity
between the least, 1, and most, 6. For example,
when set at 1 the detector has to be very wet to
indicate precipitation.

7. INDICATIONS:

7.1 On the module are a number of status LED’s
intended to aid the user’s understanding of the state
of operation. See table for full description.

Table 11 – Status LED’s

LED Name Description State Indication

Green with
a red pulse

STAT U S Processor status

POWER Power supply On Module energized.

Off

Solid green

Solid red

Controls:

NOTE: These settings are true for AUTO mode only, with the

COMM Communications Flashing

exception of the TEST switch.

These setting are overridden when operated in REMOTE

HE AT O N Heater request On

SCADA mode by the corresponding Fastrax® RCMS
software parameter.

1. SNOW-RAIN:

1.1 This dial adjusts the temperature set point between

LOW

TEMP

Low Temperature On

-12°C to +12°C.

1.2 Precipitation detected when the ambient
temperature is below this set point is considered
snow or above it is rain.

2. LOW TEMP:

2.1 This dial adjusts the temperature set point between

DE L AY

TIME

Delay Time

–55°C to +5°C.

2.2 The EMS will not request the heater to operate when
the ambient temperature is below this set point and
snow is detected.

3. D EL AY O N:

SENSOR
WET

Precipitation
sensor wet

On with a
pulse off

Off with a
pulse on

On

Processor
functioning normally.

Processor failed.

Indicates
communications
with controller.

EMS request to turn
on heater.

Ambient
temperature is
below set point.

Heater will turn off
or not turn on if
requested.

Delay active.

Delay on when
HEAT ON is off.

Delay off when
HEAT ON is on.

No delay.

Precipitation above
set point.

3.1 This dial sets the length of the delay, 0 to 30 minutes,
before making the heater request.

3.2 When snow is sensed continuously for the duration
of the delay on period the heater request is made. If

Controls & Indications

at any time during the delay snow is not sensed the
timer is reset.

4. DELAY OFF:

4.1 This dial sets the length of the delay, 0 to 60 minutes,
before removing the heater request.

1919

E.20 Terminal Blocks

1. The controller interconnects with the control panel by
means of 2 board level headers, TB-1 and TB-2, which
accept wire harness plug connectors.

2. The controller and EMS module connect via a ribbon cable
that plugs into the 10-pin header found on each. The
ambient temperature sensor connects via the RJ11 header.

Table 12 – Terminal Blocks

Name Description

TB-1

TB-2 Precipitation detector

JP1 Ambient air temperature sensor RJ11 header

10-Pin header* EMS power and signal connection

* Located in the upper left corner.

Precipitation detector 24

VAC power supply

E.21 Inputs and Outputs

1. PRECIPITATION DETECTOR: As its name implies, it
senses precipitation that can be in the form of rain or
snow.

Snow landing on the detectors heated cone and heated
sensing grid, melts to form water drops that can be sensed.

The head design draws blowing snow into the detector

where it can be sensed.

See the installation section for mounting instructions.

There are no adjustments on the detector itself. Sensitivity

adjustments are made on the controller.

2. AMBIENT TEMPERATURE SENSOR: The ambient
temperature sensor is mounted beneath the air intake
hood. The controller compares the measured temperature
to the SNOW-RAIN and the LOW TEMP set point.

3. R A I L THER M O STAT: The rail thermostat optimizes
fuel consumption and performance while the heater is
requested. It functions independently of the EMS module,

cycling the heater off when the rail temperatures rises

above 9°C (49°F) then back on again once the temperature

drops below 3°C (37°F).

Controls & Indications

20

20

F. TROUBLESHOOTING

* The resets made by aggressive retry function are not described in the

conditions.

Problem Conditions* Possible Cause Remedy**

No LEDs are on. No line power.

• Selector switch in

manual position.

• Controller and FSR

Heater not running

when expected.

NO alarm indications.

Fan running.

No heat. No alarm.

POWER LEDs are on.

• RUN LED on.

• Ambient temperature is

above 3°C (37°F).

• Selector switch in

REMOTE/AUTO.

• EMS module installed.

• Controller, EMS and

FSR POWER LEDs

areon.

• Controller in AUTO

mode.

• Snowing.

• Selector switch in

REMOTE/AUTO.

• EMS module installed.

• Controller, EMS and

FSR POWER LEDs

areon.

• Snowing.

• LOW TEMP LED on.

• Selector switch in

REMOTE/AUTO.

• Controller, EMS and

FSR POWER LEDs are

on.

• Controller LEDs

– POWER on.

– RUN on.

– HE AT on.

• FSR LEDs

– Power on.

– PILOT on.

– HE AT on.

– MAIN on.

Rail thermostat is closed.

EMS module SNOW-RAIN set
point below –1
ambient temperature sensor

disconnected.

SNOW-RAIN set point too low, i.e.

°C (10°F).

-12

Precipitation detector damaged. Replace detector head and/or cable.

Precipitation detector
disconnected.

Controller / EMS ribbon cable
disconnected.

SENSITIVITY set point too low, i.e.

°C (34°F).

1

Controller in AUTO mode and
LOW TEMP set point too high.

Controller in REMOTE SCADA
mode and RCMS has not
requested heater.

• Main ball valve closed.

• Pilot ball valve open.

Main and/or safety solenoid valve
not opening.

Cycling thermostat open.

(Heater will operate for 10 minutes
before controller indicates alarm).

**Reset controller only after observing the condition of all status indicators

then follow reset instructions.

• Verify panel and motor breakers are closed.

• Verify supply voltage at power terminal

block.

1. Wait for ambient temperature to drop and
the rail to cool.

2. To verify heater operation, toggle selector
switch OFF, then back to MANUAL.

The heater starts, disregarding the rail

thermostat status for the rst 2 minutes of

operation.

°C (30°F) and

Install ambient temperature sensor. Raise set
point above 0°C (32°F).

Raise set point, i.e. 3°C (37°F).

Verify connection to panel.

Verify presence of cable and connections.

Raise set point to increase sensitivity.

• Verify set point.

• For natural gas installations set to minimum,

-55°C (-67°F ).

• For LPG installations without tank heaters,

set to –30 (-22°F).

Contact RCMS software operator and verify

status.

Open main ball valve.

Verify operation of solenoid valves.

• Inspect cycling thermostat and wiring

connections.

• Replace failed thermostat.

• Repair any damaged wiring.

• Connect any disconnected terminals.

Troubleshooting

2121

Problem Conditions* Possible Cause Remedy**

Heater operating

but does not deliver

adequate heat.

No alarm.

Manifold pressure at
maximum for propane.

Manifold pressure at
maximum for appropriate
fuel.

Gas manifold and supply
pressure slowly drop while
operating.

• Fan does not start.

• Controller LEDs

– POWER on.

– ALARM red.

– AIR SW alternating.

Heater connected to natural gas.

Corrosion, dirt or other debris
restricts burner orii.

Duct system restricted.

Vapour withdrawal causes
refrigeration effect that lowers
LPG tank pressure.

Motor thermal overload
relay open.

Motor breaker open.

• Air switch closed when

expected open.

• Air switch jumped.

• Air switch frozen.

• Air switch out of calibration.

The as delivered heater is set for LPG operation.

Increase manifold pressure to within natural gas
limits.

• Service burner.

• Drill out each orice with #47 drill (0.0785"

diameter)

Inspect tie duct or cross ducts
for mud.

Remove snow accumulation on propane tanks.

1. 240V single-phase models:

Reset

overload located on motor junction box.

2. Three-phase models: Reset thermal
overload relay located on control panel
below contactor.

Close breaker.

Inspect air switch.

Remove jumper.

Clear any ice or debris from air switch ports.

Calibrate air switch.

Heater fails to start.

Alarm indicated.

• Fan does not start.

• Controller LEDs

– POWER on.

– ALARM red.

– AIR SW alternating.

• High limit exceeded.

Cycling thermostat loose inside
sensor duct and high limit
thermostat limit reached.

Cycling thermostat leads shorted
and high limit thermostat limit
reached.

High limit thermostat leads
shor ted.

Fasten thermostats in place.

1. Remove any test jumper shorting
thermostat leads.

2. Verify leads are not shorted together
between sensor box and control panel.

3. Inspect wire insulation for damage and
verify no shorts to ground.

4. Verify manifold pressure is within
nameplate limits.

1. Remove any test jumper shorting

thermostat leads.

2. Verify leads are not shorted together
between sensor box and control panel.

3. Inspect wire insulation for damage and
verify no shorts to ground.

4. Verify interior of sensor box is dr y.

5. Seal or replace any damaged or missing
gasket. Close lid.

Troubleshooting

22

22

Problem Conditions* Possible Cause Remedy**

Heater fails to start.

Alarm indicated.

(con t’d)

Heater starts, runs

for 10 minutes with no

heat, stops and then

alarm indicated.

• Fan starts, runs briey

then stops.

• Controller LEDs

– POWER on.

– ALARM red.

– AIR SW alternating.

• Fan starts.

• Controller LEDs

– POWER on.

– MOTOR on.

– HE AT on.

• FSR LEDs sequence:

1. POWER on.

2. PILOT on.

3. PILOT off.

4. ALARM on.

• Controller LEDs

– POWER on.

– ALARM red.

– FSR ALARM

alternating.

• Fan runs for post purge

duration then stops.

• Controller LEDs

– POWER on.

– ALARM red.

– FSR CHECK

alternating.

• Controller LEDs

– POWER on.

– ALARM red.

– CYCLING alternating.

• FSR LED.

– Power on.

Heater NOT connected to duct
system.

Air intake severely blocked.

Air switch fails to close when fan
operating.

Inadequate gas pressure.

Air in line. Purge air from gas supply line.

No spark.

Inadequate ame signal.

FSR missing. Install missing FSR in sub base.

FSR failed. Unable to energize
solenoids.

Open circuit between FSR 9-pin
and main and safety solenoid.

Complete heater installation.

Clear intake screen of blockage,
i.e. ice, snow, paper.

Calibrate air switch.

See manual for instructions.

• Verify supply pressure is within

nameplaterating.

• Verify pilot solenoid valve operation.

• Verify manual pilot valve is open. Handle in

line with body.

• Inspect igniter and ignition wire.

• Replace any damaged items, fouled igniter,

corroded wire or cracked boot.

Inspect ame rod and wiring.

Replace any damaged items, fouled rod,

corroded wire or cracked boot.

Replace FSR.

Trace wiring. Repair damaged wires. Tighten
any loose connections.

Replace thermostat.

Cycling thermostat failed open.

NOTE: If thermostat closes the alarm is

cleared and the heater resumes
normal operation.

• Connect thermostat.

Cycling thermostat disconnected.

• Inspect for damaged wiring between

control panel and thermostat box.

Troubleshooting

2323

Problem Conditions* Possible Cause Remedy**

Heater cycles

excessively. (Less than

30 second cycle time).

No alarm.

Heater starts and runs

normally for a period

of time then stops

unexpectedly.

Alarm indicated.

• Fan starts.

• Controller LEDs

– POWER on.

– MOTOR on.

– HE AT on.

– RUN IND on.

• FSR LEDs sequence

1. PILOT on.

2. HE AT o n.

3. MAIN on.

4. H E AT of f .

5. MAIN of f.

6. PILOT of f.

• FSR sequence repeats

indenitely.

• Controller LEDs

– POWER on.

– ALARM red.

– FSR ALARM

alternating.

• FSR LEDs

– POWER green.

– ALARM red.

Marginal ame signal.

PILOT signal above and MAIN
signal below 1.2 micro amps.

Manifold gas pressure set toohigh.

Air intake blocked. Clear intake screen.

Duct system blocked.

Insufcient number of track duct
vents open.

• Marginal ame signal.

• PILOT signal and MAIN signal

occasionally dropping below

1.2 micro amps.

Manifold gas pressure set too high.

FSR reset module disconnected

No retries possible.

FSR detected fault.

• Inspect ame rod and wiring.

• Replace any damaged items, fouled rod,

corroded wire or cracked boot.

Reduce gas pressure to within nameplate
setting.

Remove any blockage such as mud, ice, or
debris from:

1. Cross duct.

2. Tie duct.

3. Nozzles.

4. Rodent screens.

Open vents as per “Switch Heater Track Duct
Field Modications Manual” 11237.

• Measure ame signal.

• Inspect ame rod and wiring.

• Replace any damaged items, fouled rod,

corroded wire, or cracked boot.

Reduce gas pressure to within nameplate
rating.

Verify reset module is correctly plugged
intoFSR.

• Leave heater in ALARM.

• Install FSR display module. Review

fault history and refer to Honeywell
documentation for further explanation.

24

24

Troubleshooting

Heater runs

continuously.

NO alarm.

Gas manifold and supply
pressure slowly drop while
operating.

Unable to stop the heater
re motel y.

Mode selector switch in
manual position.

• Mode selector switch in

REMOTE/AUTO position.

• Controller LEDs

– Power on.

– MOTOR on.

– HE AT on.

– RUN on.

– RTC on.

Vapour withdrawal causes
refrigeration effect to lower LPG
tank pressure.

Heater accidentally left on. Toggle selector switch to REMOTE/AUTO.

RTC has heater requested. Notify RTC dispatcher.

Remove snow accumulation on propane tanks.

G. INSTALLATION

WARNING. Install and use Heater in accordance with

owners manual and local codes.

WARNIN G

In the absence of local codes, installation must comply
with CAN/CSA-B149 Installation code and National Fuel
Gas Code ANSI Z223.1 / NFPA 54, or Standard for the
Storage and Handling of Liqueed Petroleum Gases,
ANSI / NFPA 58.

For outdoor use only.

For use with ductwork only. Only duct work supplied
by Thermon Heating Systems shall be used with the
heater. Minimum clearance from combustibles: 2
inches.

Failure to comply with warnings may lead to serious
personal injury or death.

To be installed in accordance with railroad and all
applicable local governing regulations by persons
approved by the railroad having authority.

Lift only in accordance with recognized safe lifting
practices, as dened by applicable local laws and
regulations.

Read and fully understand these instructions prior to
attempting installation.

NOTE: Open combustion chamber access panel and remove

loose packaged contents including large gasket kit, and
if included with order, the precipitation detector, rail
thermostat and exible gas line.

G.1 Overview

The following are general guidelines for the installation of typical

HELLFIRE gas red systems. They should be followed in
conjunction with the specic site layout drawings provided with
each heater.

Instructions are intended for track forces, construction, gas

technicians, electricians, and signal maintainers.

G.2 Recommended Tools

• A source of power to operate drills (portable generator)

• Impact Drill, 1/2” drive with 1/2”, 9/16” and 3/4” sockets

• Drill, 3/8” drive

• Two 9/16” wrenches and/or socket wrench

• Lining and Tamping bars

• Sledge hammer

• Shovels

• Cold chisel and hammer

• 3” duckbill pliers

• Measuring tape

• 4 foot level

• Pipe wrenches

• Pipe thread sealant

G.3 Site Preparation - Typical Clearances

Installation

Figure 1 – 131” C lea ran ce

2525

Figure 2 – 140” Clearance

Installation

Figure 3 – 155” Clearance

26

26

Figure 4 – 155” Clearance Turned 90 Degrees

Installation

2727

G.4 Site Preparation

1. Identify the tie to be replaced by the tie duct, or the crib
for the crib ducts. Relative to the appropriate tie or crib,
prepare a foundation for the heater with ties, concrete pad,

or other suitable level mounting structure.

2. Note the location for the gas, electrical supply, and the
signal cable lines.

3. Refer to the local gas and electrical authority in order to

determine gas pipe and electrical line sizes.

4. At the heater, the gas inlet is a female 1” NPT pipe thread,
the power terminal block accepts #14 - #2 AWG wire sizes,
and the control and indicate wires connect to AAR 1/4”
post terminals.

G.5 Heater Installation

1. A typical complete system is composed of 4 parts, the
heater, a transition duct, a tie duct or crib duct set, and a
track duct set, each packaged separately.

2. Install the duct system components rst, as per Switch
Heater Duct Installation Manual, part number 16359.

3. Remove shipping cover attached to combustion chamber
ange. Remove thermostat box from shipping cover and

dis c a r d cov e r.

4. Remove banding strap securing access panels. Open
combustion chamber access panel and remove loose

packaged contents including large gasket kit, and
if included with order, the precipitation detector, rail
thermostat and exible gas line.

5. Lift heater, (565 lbs.), using lift pockets and place on the
foundation.

6. Level heater, adjusts leveling legs, and align with the
transition duct ange.

7. Fasten the heater and transition anges together with the
supplied gasket kit.

8. Fasten heater legs to foundation using lag screws supplied
or suitable fasteners.

G.6 Gas Supply Piping and Minimum Pressure Drop

WARNING. Personnel approved by the local gas
authority must perform gas line connection.

WARNIN G

1. Nominal supply pressure, 5 to 20 psi, with no more than
20% pressure drop, with all connected loads operating.

2. The minimum recommended supply pipe size is 1”.
Determine required pipe size based on supply pressure,
length of run, and the total demand of all connected loads.

CAUTION. Undersized gas piping will affect the light off

reliability of any connected appliance.

CAUTION

3. The heater is supplied with an internally mounted supply
regulator and an external dirt trap. The dirt trap inlet has a

Installation

1” NPT female tting.

4. Install a exible gas line between the customer supplied

28

28

gas line and the dirt trap inlet.

5. Prior to ring the heater, bleed the gas lines of any air and
dirt through the opened dirt trap.

6. Reinstall the dirt trap cap and check all joints for leaks.

G.7 Electrical Power Connections

WARNING. Risk of electrical shock or electrocution.

Disconnect power at service.

WARNIN G

Heaters must be wired in accordance with local
electrical codes.

The electrical grounding of the appliance shall be in
compliance with CSA C22.1, Canadian electrical code,
Part 1, or National Electrical Code, ANSI/NFPA 70.

Personnel approved by the local electrical authority
must perform electrical power connection.

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’
Thermon Heating Systesms, Inc’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.

G.8 Power Connections

1. Remove control cabinet lid and electrical sub component

cover plate.

2. Remove knockout plug. For conduit larger than ½”, punch
an appropriate size hole.

3. Terminate power cables to terminal block and ground wire
to grounding stud.

4. Three Phase Systems Only

CAUTION. For three phase systems only - verify
correct fan rotation.

CAUTION

Ground

Terminal

Punch appropriate size
hole for power conduit

4.1 Three phase systems only – Place selector switch in
OFF position.

4.2 Turn service power on and close the motor breaker.
Open the combustion chamber access panel.

4.3 Note the fan rotation arrow.

WARNING. Risk of cutting ngers or hand. Keep hands
clear of fan.

WARNIN G

4.4 Manually close the motor contactor momentarily,
enough to spin the motor. Verify the correct rotation.
If the rotation needs to be reversed, open the
service breaker and interchange two of the supply
phase wires at the heaters power terminal block.

Installation

2929

5. Conductor Sizing

1/2” Conduit
Knockout

5.1 Using the following table to aid in the selection of the appropriate size conductors between the heater and service.

Table 13 – Conductor Sizing

1

Wire Size

#10 #8 #6 #4 #2

Voltage

Phase

Circuit

Current

Breaker

Maximum Distance

2,3

m ft m ft m ft m ft m ft

240 1 13 30 136 447 217 712 345 1131 548 17 9 9 872 2860

208 3 8.3 20 247 810 393 128 9 624 2048 993 3257 1579 5179

440 3 4 15 512 16 81 815 2675 129 6 4250 2060 6758 3276 1074 6

575 3 3 15 683 2 241 1087 3566 17 28 5667 2 747 9 0 11 4368 14 328

1 As per Canadian Electrical Code, Part 1.

2 Assumed voltage drop of 5%.
3 Allowable voltage drop to be determined by local authority.

6. Local Safety Grounding

6.1 The service ground electrically grounds the heater.
If a local safety ground is required, drive in at least
one ground rod and connect it with a suitably sized
stranded copper conductor, of at least #8 AWG, to
one of the leveling leg bolts.

7. Signal and Communications Connections

7.1 Use the 1/2” conduit knockout, or punch a suitable
size hole for the signal cable.

Table 14 – Terminal s

Terminals Label Description

A1 - A2 REMOTE START A contact closure across these

terminals starts the heater when the
heater is in REMOTE RTC mode.

A3 - A4 RUN Dr y contact closes to provide a run

indication.

A5 - A6 ALARM Dry contact closes to provide alarm

indication.

A7 - A8 FORCE OFF Default is closed. If FORCE OFF

function is desired, remove shorting
link and replace with customer
supplied relay contact. Open
contact disables heater.

A9 - A10 TANK VALVE These terminals are intended to

operate a 120

VAC gas supply

solenoid shut off valve. They
energize when the motor contact
closes.

A11 RS-485 (+) Communications, RS-485 positive

terminal.

A12 RS-485 (-) Communications, RS-485 negative

7. 2 All signal and communications connections are

terminal.

made to the 1/4” AAR control and indicate terminal
block. The terminals are labeled A1 to A12.

Installation

30

30

G.9 Thermostat Installation

Install the thermostat sensor box as per instructions below:

1. Remove combustion chamber shipping cover.

2. Detach thermostat box from shipping cover.

3. Secure thermostats to the duct using SST machine screws

- ensure colour coded wires match.

4. Secure thermostat box to the sensor duct as depicted,
with the ground wire under the head of a bolt and washers.

5. Install thermostat cover to box using hardware supplied.

1.3 Remove the stops holding the controller and the
circuit breaker.

1.4 Install module onto DIN rail. Plug in 4-pin connectors

and ambient temperature RJ11 jack.

G.10 Energy Management System (EMS) Options

1. EMS Module

1.1 The module mounts onto the DIN rail to the right
of the controller in the space provided, and a
communication cable connects the two together.

1.5 Connect module to controller with supplied ribbon
cable.

NOTE: The precipitation detection and ambient temperature

sensor options require the EMS module be installed.

Installation

1.2 As received panel with no EMS module.

3131

2. Ambient Temperature Sensor

To route the sensor cable it is necessary to remove the air

intake.

2.1 Remove the 4 screws holding the extension to the
elbow. Leave the hood and extension fastened
together. Remove intake.

2.2 Mount the ambient temperature sensor inside the
air intake hood with a pair of 8-32 screws, nuts and
washers, in the location shown.

2.3 Route the cable through the screen, and down the
inside of the extension. Cut the diaphragm grommet
at the bottom of the extension and push the
connector and cable through, as shown.

2.4 Cut the diaphragm grommet on the control cabinet
and run the cable through. Insert grommet and
cable into hole.

2.5 Reassemble the intake, draw the excess cable into
the control cabinet and connect it to the mating
connector on the EMS module.

3. Precipitation Indicator

Remove the plug from the top hole marked ‘Precipitation
Sensor’. Pass the 4-pin connector through the hole, install
lock nut and tighten.

3.1 Insert jack into mating connector.

3.2 Mount the detector on the transition duct to sensor
duct ange facing forward as shown. Heat from the
duct will keep it clear of ice and snow build up.

Step 2.1

Step 2.2

Step 2.3

Installation

32

32

4. Rail Thermostat

Mount the rail thermostat on the eld or gage side of
the stock rail ahead of the points and tie duct, as shown.
Select a location shaded from the sun. Provide strain relief
in the cable, by leaving adequate slack, as shown, to allow
for rail pumping.

4.2 Pass the two (2) wires from the rail temperature
sensor through the hole, install the locknut and
tighten.

4.3 Insert, one each of the bared wires into the two
terminals on the surge suppression circuit board,
and tighten. There is no polarity.

4.4 Replace the cover, and tighten the four (4) Phillips
screws.

Remove the yellow shim washers when installed on 115 lb rail

or lighter. Loosen the two mounting bolts and attach the rail

thermostat to the rail ange by tapping it on with a hammer.
Once in place tighten mounting bolts to maximize grip.

4.1 Remove the four (4) Phillips screws, the cover, and
the plug from the hole in the rail temperature surge
protection box.

4.5 Connect the surge isolator two pin connector with the
mating plug located inside the electrical component
area, hanging immediately under the FSR.

Installation

3333

G.11 Inspection and Commissioning

Once the installation is complete review it against the following
checklist.

Point Nozzles

 Installed.

 Directed at, and tip within 2” to 6” of points, and clear of rail

head by 2.5”.

 Rodent screens installed between duct and silicone gasket

under adaptor collars.

 Electrical isolation shoulder washers installed.

Track Duct

 Installed.

 Rodent screens installed between duct and silicone gasket

under elbows.

 Access joint gap of 3”.

 Appropriate vents open and directing air at switch plates

and rods. Keep all openings closed between the ducts,
except where the switch rods are located. Open vent
openings no more than ¼”.

 Ductwork below top of rail and not interfering with switch

operation.

 Track duct deectors installed, 18” wide at points protecting

point nozzles and track duct and 8” at heel protecting track
duct.

Tie Duct

 All clips and insulators installed.

 Flex ducts and ballast retainer installed.

Electrical Power

 Voltage between 85% and 115% of nominal voltage with all

connected loads operating.

 Ground installed.

Gas System

 Supply pressure at rated supply pressure with all

connected loads operating.

 Gas supply leak tested.

Heater

 Level.

 Heater functions in “Manual”.

 “Run” indication function. With the heater running, the

contact between terminals A3 and A4 will close. Check for
continuity.

 “Alarm indication function. Put the heater into alarm by

turning the gas supply off. The heater retries three times.
Then the FSR will indicate alarm, and the alarm LED on the
controller will light. The contact between terminals A5 and
A6 will close. Check for continuity.

 Heater functions in “Remote” control. Toggle mode selector

switch to “REMOTE/AUTO”. If connected to dispatch, have
dispatch start heater.

 With heater running for at least 15 minutes, temperature at

closest point nozzle is 93°C - 121°C (200°F - 250°F) above

ambient.

EMS

 Precipitation detector installed on the transition duct, as

low to the ground and as close to the switch as possible,

and in the heated zone.

 Drop snow (or water) on precipitation detector sensing

grid. Snow melts and “SENSOR WET” LED lights on EMS

module.

 Ambient temperature sensor installed.

 Raise “SNOW-RAIN” set point, if required, above the

ambient temperature. The “AMBIENT” LED lights.

 Rail thermostat, if supplied, installed on rail ange.

 Return set points to desired settings.

Installation

34

34

H. HEATER SPECIFICATIONS

H.1 Performance

• Clears ice and snow from switches with up to 40-foot points or

longer. (Recommended heating, 10,000 to 22,500 BTU/hr per
foot of track coverage, based on severity of local climate).

• 2000 scfm of heated air delivered via a duct system, point

nozzles and track duct vents.

• Heat output range 204,000 to 900,000 BTU/hr LPG or 230,000

to 900,000 BTU/hr NG, eld adjustable.

• Output air temperature limited to 193°C (380°F) maximum.

• Burner efciency, minimum 95%.

• SCADA network connectivity via RS-485 communications port.

H.2 Gas Firing

Table 15 – Gas Firing

Propane Natural Gas

Input rating, BTU/hr

(kW)

Manifold pressure,

inches of water (kPa)

Supply pressure,

1,2

(kPa)

psig

1 With no more than 20% pressure drop, with all connected loads operating.

2 Inlet gas tting, 1” NPT female.

204,000 - 900,000

(60 - 264)

2.5 - 9.0

(0.62 - 2.24)

230,000 - 900,000

(67 - 264)

3.5 - 16.0

(0.87 - 3.99)

5 - 20

(34 - 138)

H.3 Gas Conversion

1. Heaters are factory set for use with propane gas.

2. To convert to natural gas adjust gas pressure to within
nameplate rating. If higher output is required, select and

change the main gas pressure regulator spring, with
one supplied separately, and adjust within specications
detailed above. Afx separate gas type plate supplied.

Reverse procedure to change back to original gas.

H.4 Electrical

Table 16 – Electrical

Voltage Phase Wiring

240 1 3 wire, L1, L2, N 12.5 60

208 3 4 wire, L1, L2, L3, N 10.3 60

460 3 3 wire, L1, L2, L3 4.8 60

575 3 3 wire, L1, L 2, L3 3.9 60

1 On star t up, peak in rush current is usually 6-8 times the running amp.

2 Current drops to running amperage after 4 seconds.
3 Three horsepower fan drive motor for all congurations.

Running

Amps

1,2, 3

Frequency

(Hz)

H.5 Controls

Table 17 – Controls

Feature Description

Remote Start

Run and Alarm Indication

Contacts

Magnetic Motor Starter

Motor Thermal Overload

Protection

Thermostatically limited output

air temperature, cycling

Thermostatically limited output

air temperature, high limit

Flame Safety Relay

SCADA RS-485, MODBUS ASCII

Rail Thermostat

Provide dry contract, rated for 24

0.5 amp.

Ma ximum 240

Single phase, reset located on motor.

Three phase, thermal overload relay

193°C (380°F) maximum, open on rise,

216°C (420°F) ma ximum, close on rise,

Honeywell Burner Control, RM7895A,

9°C (49°F) close on rise, automatic

VAC or 24VDC, 10 amp.

Coil voltage 120

fastened to contactor.

automatic reset.

manual reset.

continuous pilot.

reset.

VAC

VAC.

H.6 Wiring Terminations

Table 18 – Wiring Terminations

Function Size Range Termination Type

Power

Control #22 to #4 AWG

RS-485

Communications

#14 to #2 AWG

#22 to #4 AWG or

#2 6-#12 AW G

copper

Barrier Terminal Block, Tubular

with clamping screw.

AAR terminal posts, #14-24

UNS

AAR terminal posts, #14-24

UNS or PCB plug in connector.

Tubular with clamping screw.

H.7 Safety Features

1. Minimum Air Pressure: Upon start up and request for
heat, the trial for ignition does not start until adequate
air pressure is developed. Burner is extinguished
immediately upon loss of air pressure.

2. High Temperature Limit: In the event the heated air
temperature exceeds 216°C (420°F), the burner is

extinguished, the heater is shut down and locked out. A

manual reset is required.

3. Loss of Flame: If, upon start up and request for heat,
the trial for ignition fails to light the burner, or the ame
signal is lost while heating, the burner is extinguished
immediately.

4. Ductwork Electrical Isolation: As per, AAR standards part

14.5.1D, “Recommended Design Criteria for Assembly and
Test of Insulated Track Fittings, Dielectric Requirements”,
ducting and nozzle connections are electrically isolated

to withstand a maximum of 3000VAC for 60 seconds to

eliminate possible interference with track circuits.

Heater Specications

3535

H.8 Controller Terminal Identication

Table 19 – Controller Terminal Identication

Terminal Block PIN Input Output Power Source

TB1

1

2 Neutral

3 Motor Contactor

4 Neutral

5

6 Neutral

120

VAC

VAC Transformer

120

120VAC

TB2

TB3

TB4

TB5

TB6

TB7

TB8

1

2 FSR Request

3

4

1 Run Indication Dry Relay Contact

2 Run Indication Dry Relay Contact

3 Alarm Indication Dry Relay Contact

4 Alarm Indication Dry Relay Contact

1 Rail Thermostat

2

3 RTC A1- A 2

4

5 Manual

6 Enable

1 Air Switch

2 Neutral

3 ALRM FSR

4 Valve Feedback

1

2 Cycling SW

3

4 High Limit SW

1 GND GND

2 POS Signal RS 485 Communication

3 NEG Signal RS 485 Communication

4 GND GND

1 FSR Reset + From FSR

2 FSR Reset - From FSR

3 Current Current Transformer

4 Current Current Transformer

VAC 120VAC

120

VAC

120

VAC 24VAC From Transformer

24

VAC 24VAC From Transformer

24

VAC

24

VAC

24

24

24

VAC

VAC

VAC

24

VAC

120

24VAC

Heater Specications

36

36

H.9 SchematicsMaintenance

THERMON HEATING SYSTEMS, INC.

Heater Specications

3737

38

38

THERMON HEATING SYSTEMS, INC.

Heater Specications

THERMON HEATING SYSTEMS, INC.

Heater Specications

3939

40

40

THERMON HEATING SYSTEMS, INC.

Heater Specications

THERMON HEATING SYSTEMS,INC.

Heater Specications

4141

42

42

THERMON HEATING SYSTEMS, INC.

Heater Specications

I. MAINTENANCE

Motor Junction Box

Motor Mount Bolts

I.1 Thermostat Removal

1. Remove cover from thermostat box to gain access to
the thermostats. There are two thermostats. The high
limit, which has a red and a white wire connected to it, and
the cycling thermostat, which has a black and a blue wire,

connected to it.

CYCLING THERMOSTAT
(BLACK AND BLUE WIRES)

HIGH LIMIT THERMOSTAT
(RED AND WHITE WIRES)

Figure 1 – Thermostat Wire Connections

2. The wires are connected by means of quick disconnects.
To disconnect, grip the terminals on each side of the
connection and pull rmly.

3. Using a 9/16” socket, remove the 4 mounting bolts that

hold the enclosure to the sensor duct. Remove the
thermostat box and gasket.

4. Remove the two screws that fasten each thermostat to the
sensor duct. Remove thermostats.

5. The high limit and cycling thermostats are not
interchangeable. Each has unique connectors to prevent
interchange.

6. Reverse procedure to install.

I.3 Impeller Removal

NOTE: Motor/impeller sets not match balanced by Thermon

Heating Systems, Inc. void future warranty claims.

NOTE: Replacement of motor or impeller only. Dynamically

balance the motor/impeller and base assembly to

vibration levels of 0.2 in/sec or less in the bearing planes.

NOTE: Mark the position of the impeller on the shaft before

removing.

Third Empty Hole

Hub Set Screws

Tapered Hub

I.2 Motor/Impeller/Base Removal

WARNING. Risk of cutting ngers or hand. Disconnect
fan power prior to removing combustion chamber

WARNIN G

access panel or air intake.

1. Remove the combustion chamber access panel to gain
access to the motor.

2. Open the motor junction box and disconnect all wiring and
conduit elbow.

3. Remove the four motor mount bolts and remove the motor/

impeller assembly from the combustion chamber.

4. Install replacement motor/impeller/base assembly,
following reverse order.

The impeller is tted with a taper lock bushing. To remove

impeller from motor shaft:

1. Clamp the motor and anchor the impeller using a suitable
ba r.

2. Remove the two hub set screws.

3. Insert a set screw into the third previously empty hole and
tighten.

4. Tap the outer half of the hub with a hammer and bar to
knock the impeller off the tapered hub.

5. Slide hub off shaft, then remove impeller.

6. To install the impeller, reverse sequence except step 4.

Maintenance

4343

I.4 Flame Rod and Spark Igniter Removal

I.6 Burner Defroster Removal

NOTE: The defroster circuit is protected with a reset-enabled

fuse. If tripped, open then close the panel breaker to
reset.

If the ame rod (16) or spark igniter (15) requires inspection

or replacement, remove them as follows:

1. Gain access to the burner (17) by rst removing the
combustion chamber access panel.

2. The ame rod is to the left of the spark igniter. Gently
pull the wire from the terminal. Use a 7/8” deep socket
to unscrew and remove the ame rod. Apply a high
temperature anti-seize compound to threads prior to
reinstallation.

3. The spark igniter is to the right of the ame rod. Gently
pull the wire from the terminal. Using a 13/16” deep
socket, unscrew and remove the spark igniter. Apply a

1. Turn heater OFF and disconnect power.

2. Once impeller is at a complete stand still, remove
combustion chamber access panel.

3. Remove spring wedge holding defroster (14). Remove
cable strap from mounting bracket.

4. Pull defroster out and let it hang.

5. Open electrical access panel. Trace defroster wires to

terminal block (16), terminals 5 and 6, circled. Disconnect
last two wires on the bottom furthest right of terminal
block.

6. Reverse procedure to reinstall.

high temperature anti-seize compound to threads prior to
reinstallation.

4. Reinstall the ame rod and ignition wires. A red band
identies the ame rod wire.

I.5 Burner Removal

1. Turn heater OFF and disconnect power.

2. Once impeller is at a complete stand still, remove
combustion chamber access panel.

3. Remove spring wedge holding defroster (14). Remove
cable strap from mounting bracket. Pull defroster out and

let it hang.

4. Open pipe union (12).

5. Remove bolts fastening both mounting brackets (13) to

the combustion chamber. Leave brackets attached to the
burner.

6. Remove burner.

7. Reverse procedure to reinstall.

Maintenance

44

44

J. SERVICE

WARNING. Install and use Heater in accordance with

owners manual and local codes.

WARNIN G

In the absence of local codes, installation must comply
with CAN/CSA-B149 Installation code and National Fuel
Gas Code ANSI Z223.1 / NFPA 54, or Standard for the
Storage and Handling of Liqueed Petroleum Gases,
ANSI / NFPA 58.

For outdoor use only.

For use with ductwork only. Only duct work supplied
by Thermon Heating Systems shall be used with the

heater. Minimum clearance from combustibles: 2 in.

WARNING. To be installed in accordance with railroad
and all applicable local governing regulations by

WARNIN G

persons approved by the railroad having authority.

WARNING. If you smell gas; immediately extinguish all
sources of ignition and turn off gas source. Call

WARNIN G

qualied service technician to repair leak.

WARNING. Do not attempt to manually light burner.
Heater equipped with an automatic electronic ignition

WARNIN G

system.

WARNING. Risk of cutting ngers or hand. Disconnect
fan power prior to removing combustion chamber

WARNIN G

access panel or air intake.

WARNING. Heater can start automatically. Exercise
caution when in close proximity.

WARNIN G

WARNING. Burn hazard / hot surfaces. Do not touch

track ducts, nozzles or any non-insulated duct

WARNIN G

connected downstream of heater during operation

WARNING. Cut hazard. Sheet metal edges can be
sharp. Wear protective clothing when handling track

WARNIN G

duct, insulted ducts and any other sheet metal
components.

J.1 Recommended Service Schedule

Item Annually

Inspect ame rod X

Inspect ame rod wire and boot X

Inspect igniter X

Inspect igniter wire and boot X

Inspect ductwork X

Measure motor vibration X

Inspect and tighten all electrical

terminations

Inspect and replace any damaged

access panel gaskets

Inspect and replace any damaged duct

gaskets

Inspect gas supply pressure X

Perform gas supply leak test X

Perform manifold leak test X

Inspect burner X

Service burner X

Every 5

Years

X

X

X

Service

4545

1. Inspect heater annually.

2. Ensure the air intake and all ductwork are not obstructed.

3. Keep area around heater clear and free from combustible

material, gasoline and other ammable vapours and liquids.

4. Replace all damaged ducts, including intake, crossducts,
point and track duct nozzles.

5. Damaged ducts will degrade switch clearing ability.

6. With the supply power turned off, tighten all mounting and
electrical connections to the recommended tightening torque.

testing solution. If a gas leak is detected, replace any
cracked ttings or components, tighten any leaking pipe
connection, or disassemble, reapply pipe thread sealant,

and reassemble.

J.4 Manifold Leak Test

1. With the heater “OFF”, paint all the gas pipe connections
between the main (8), pilot (3) gas solenoid valves and
the supply inlet (6) with leak testing solution.

Thread Size

8 - 32 19

10 - 32 31

1/4 - 20, Power Terminal Lugs and AAR Terminals 75

Torque (in./lbs)

J.2 Gas Supply Pressure

WARNING. All persons employed in handling propane
or natural gas shall be trained in proper handling and

WARNIN G

operating procedures, as required by local authorities
having jurisdiction.

1. Heater is factory tested on propane at 10 psi supply
pressure.

2. With the heater on and all connected loads operating,
verify that the supply pressure, indicated on supply
pressure gage (7), is between 5 - 20 psi.

3. Natural gas pressures below 5 psi or LPG pressures
below 2 psi will limit the maximum capacity of the heater.

J.3 Gas Supply Leak Test

1. With the heater “OFF”, paint all the gas pipe connections

Service

between the supply inlet (6) to the gas source with leak

Tightening

2. With the heater operating in “MANUAL” mode and the
burner lit, paint all pipe connections between the main
and pilot gas solenoid valves to the elbow with leak test
solution.

3. If a gas leak is detected, turn heater “OFF”. Replace any

cracked ttings or components, tighten any leaking pipe
connection, or disassemble, reapply pipe thread sealant,

and reassemble.

46

46

J.5 Main And Safety Gas Solenoid Valves Leak Test

1. Turn heater OFF.

2. Verify supply pressure is between 5 – 20 psi.

3. Close the manual pilot gas shut off valve (5) upstream of
the pilot gas regulator (4), with the handle perpendicular
with the pipe.

4. With the manifold pressure gage (10) reading “0”, close the
manual gas shut off valve(11), downstream of the main and
safety gas solenoid valve (9).

5. After 10 minutes there should be no increase of pressure
on the downstream gauge. If there is an increase, refer to

the Honeywell gas valve manual in the component bulletin
section at the end of this manual, for service information.

J.8 Vibration Specications and Measurement

1. All motor/impeller/base sets are match balanced with
vibration levels lower than 0.20 in./sec RMS, at the four
points depicted.

1

2

3

J.6 Dirt Trap And Strainer

WARNING. All persons employed in handling propane
or natural gas shall be trained in proper handling and

WARNIN G

operating procedures, as required by local authorities
having jurisdiction.

1. If a dirty supply line is suspected, turn off the local gas supply,
remove the dirt trap cap and inspect for dirt and moisture.

2. If a strainer is installed, remove center plug and inspect for
blockage. If evidence is found, locate source and correct
problem.

3. If the strainer screen is clogged, remove the cap and
screen. Old gasket is not reusable. Clean screen. Apply
sealant to plug threads. Reinstall cleaned screen, cap with
new gasket, and plug.

4. Inspect manifold and clean if necessary.

5. Empty cap of any dirt or moisture. Apply thread sealant
and reinstall cap.

6. Turn on gas supply and leak test dirt trap.

7. Perform Main And Safety Gas Solenoid Valves Leak to
ensure valve seats seal.

4

2. Do not measure on covers or guards.

3. Mark locations 1, 2, 3 and 4 on motor to ensure repeatable
measurements for trend analysis.

4. Take measurements vertically at points 1 and 2, and
horizontally at 3 and 4.

Vibration Level (in./sec)

Acceptable Less than 0.20

Tolerable 0.21 to 0.29

Excessive 0.30 to 0.71

Extreme 0.72 or more

J.9 Lubrication

1. The motor has sealed bearings and does not require
lubrication.

2. When installing ame rod or igniter always apply high
temperature anti seize compound to threads.

J.7 Motor

Running amps greater than 115% of the motor rated full
load amps can indicate failed bearings, excessive air leaks
in the ductwork, inadequately sized power supply wires, or
poor electrical connections.

Voltage Phase Motor FLA Rating* FLA X 1.15**

240 1 12. 5 14.4

208 3 7.9 9 .1

460 3 3.6 4.1

575 3 3.0 3.5

* FLA (Full Load Amperage), as shown on motor nameplate.

** Maximum current draw under design operating conditions

of -40°C/°F ambient temperature at sea level and supply voltage.

Current draw drops with temperature, elevation or voltage increase.

NOTE: Measure current between motor and contactor, not at

the supply terminals.

J.10 Flame Safety Relay (FSR)

1. Ensure that adequate gas pressure is available.

2. Note the 5 LEDs on the front face of the FSR.

3. The following is the normal expected status LED sequence:

3.1 With adequate power, the green POWER will be lit and

will blink every 4 seconds, indicating standby mode.

3.2 Turn the mode selector switch to “MANUAL”. The

blower will start, followed by the trial for ignition. The
yellow PILOT LED will light.

3.3 Once the burner is lit and a ame signal is

established, the red FL AME LED lights.

3.4 After 10 seconds, the yellow MAIN LED lights, leaving

four lit LEDs, the POWER, FLAME, PILOT and MAIN.

3.5 The LEDs maintain this status until the cycling

thermostat reaches its set point and turns off the
request for heat.

Service

4747

4. As a further check, close the manual gas valve. The
FLAME LED goes out, followed by the MAIN and PILOT
LED, the red ALARM LED lights. Open manual gas valves.
Reset controller, which in turn resets FSR.

5. For further information see the Honeywell 7800 series
RM7895A Relay manual in the component bulletins
section at the end of this manual.

J.11 Flame Signal

NOTE: Flame signal strengths:

GOOD - 2.5V or greater, uctuating less than 0.5V

WEAK – between 1.2V and 2.5V and / or uctuating

more than 0.5V

INSUFFICIENT – below 1.2V

1. The ame signal strength can be monitored using a
voltmeter set to measure 0 - 10V DC, or using the plug in
Honeywell display module.

2. When using a voltmeter, insert the red lead into the
positive (+) jack and the black into the negative of the

ame signal amplier located on beneath the FSR.

3. Voltage is 0.0 with no ame, and a maximum of 5V with

ame.

4. Signals between 1.2V to 2.5V and / or uctuating more
than 0.5V are weak. They allow the heater to continue to

operate, however investigation and probable maintenance
of ame rod, wiring, manifold pressure and burner is

required. Expect irregular nuisance shutdowns.

5. Flame signals dropping below 1.2V cause the FSR to
extinguish the burner and indicate alarm.

6. Inspection and probable maintenance of ame rod, wiring,

pressure and burner is required.

3. Remove the blockage and reset the controller. The heater
starts.

J.13 Air Switch Calibration

1. With the heater operating, remove the red dust cover
cap on the air switch set screw, and turn the set screw
counter clockwise to lower the set point. Block 90% of

the air intake with cardboard.

2. Raise the set point by turning the screw clockwise until the
switch opens and causes the FSR to safety shutdown.

3. Remove blockage and reset FSR.

J.14 High Temperature Limit

1. Turn the mode selector switch “OFF”.

2. Open the thermostat box located on the sensor duct.
Disconnect the blue and black leads of the cycling
thermostat.

3. Use a jumper and short them together.

4. Turn the heater on, “MANUAL”, and let it run.

5. Increase the manifold pressure to the maximum rated
setting. Once the air temperature exceeds the 216°C
(420°F) set point, the controller removes the request for
heating, HEAT LED off, indicates alarm with STATUS LED
red, FSR ALARM LED red, ALARM LED red and HIGH LIM
LED alternating. The fan continues to run for 4 minutes of
post purge.

6. Return the mode selector switch to desired mode.

7. Reconnect the cycling thermostat and reset the controller.

J.12 Air Switch

1. To check the air switch operation, while operating the
unit, block 80% of the air intake screens openings with a
sheet of cardboard. The heater continues to operate.

2. Now block 90%. The FSR extinguishes the burner and

Service

48

48

indicates alarm.

J.15 AAR Terminals, Signals, and Communications

1. To verify remote star t:

1.1 Place the heater in REMOTE RTC mode, and make
a contact closure across AAR terminals A1 A2. The

heater star ts after the delay on period.

2. To verify RUN indication:

2.1 Measure continuity across AAR terminals A3 A4.

2.2 Closed contact indicates run, open indicates
stopped. Conrm against actual heater state.

3. To verify AL ARM indication:

3.1 Measure continuity across A AR terminals A5 A6.

3.2 Closed contact indicates alarm, open indicates
normal operation. Conrm against actual heater state.

4. To verify FORCE OFF:

4.1 Place the heater in MANUAL mode, open contact
closure across AAR terminals A7 A8.

4.2 The heater will stop after the post purge period.

5. To verify the tank valve switch:

5.1 Measure the voltage across terminals A9 A10. With
fan running the voltage is 120V AC.

6. To verify RS-485 communications:

6.1 Refer to controller LED indications for TD, RD, and TX.

J.16 Burner

1. Visually inspect mixing plates for cracks or blockage.
Remove any blockages. If cracks are found replace the
burner.

2. Over time corrosion and or dirt restrict the burner orice.

3. Inspect burner for blocked gas orice, if:

3.1 Signal strength is low even after replacing the ame

rod and wire,

3.2 Pilot pressure has to be raised signicantly to get a

good signal,

3.3 Manifold pressure is above the maximum gas

pressure setting to achieve a 121°C (250°F) increase

of output air temperature.

4. To correct the problem, remove the burner, ame rod
and igniter, following the removal instructions in the
maintenance section.

5. Drill out any blocked gas orice using a #47 (.0785) drill bit.

Ignitor

Flame Rod

Gas Orifice

Mixing Plates

J.17 Defroster

1. The defroster applies 30 watts of heat to the burner next
to the ame rod and igniter. This is enough to raise the
temperature of the end plate by approximately 90°F. It can
be difcult to tell it is heating by sense of touch, therefore
measure the current draw using a clip on ammeter. The

current draw is 1.25 amps. A resetable fuse mounted on

the terminal block protects this circuit.

If there is no current draw, open the 5-amp panel breaker,
then close it to reset the fuse. If there is still no current

draw, inspect defroster for damage.Parts

Service

4949

K. PARTS

K.1 Parts - Heater Body

Table 20 – Heater Body Parts List

Index Part No. Description

1 18929 LID, ELECTRICAL COMPARTMENT
2 174 37- 01 LOCKING BAR , TOP
3 1605 8 PLENUM, INTAKE, HF900
4 16 075 LEG, REAR, HF400/90 0
5 16 0 67- 01 EX T, INTAKE W/SCREEN, 13”L HF90 0
6 160 67-0 2 EXT, INTAKE W/SCREEN, 43”H HF900
7 1893 0 HOOD, AIR INTAKE

8 1642 6 TEMP SNSR AS SY, AMB

9

10

11 189 39 PANEL, ACCESS, COMB CHMBR, ASSY., BOLT ON

12 18938 PANEL, ACCESS, CO MB CHMBR, ASSY., QIK. RLSE.

18936-XX

-01

-02

-03

-04

189 35 -X X

-01

-02

-03

-04

PANEL, ACCESS, EL EC. CHMBR, ASSY., BOLT ON

240V Single phase

208V 3 Phase

460V 3 Phas e

575V 3 Phase
PANEL, ACCESS, EL EC. CHMBR, ASSY., QIK. RLSE.

240V Single phase

208V 3 Phase

460V 3 Phas e

575V 3 Phase

Parts

Index Part No. Description

13

or
or
or

14 1 7437- 02 LOCKING BAR, FRONT
15 16685 LVL LEG ASSY, HF900/400, SCREW
16 173 44 BOX, TOGGLE SW LOC K OUT
17 9038-0057 SW TOGGLE, SPDT ON-OFF-ON
18 9038-0060 SW BOOT, BLACK NEOPRENE
19 15948 SURGE ISOLATOR, RAIL T HERMO W/ CMPNTS
20 16 076 LEG, FRONT, HF400/900, BOLT ON
21 13032 BOX, TEMP PROBE

22 13340 -0 1 THERMO ASSY, TEMP CNTR L, HI LIMIT
23 13340- 02 THERMO ASSY, TEMP CNTRL, CYCLING

24 17895 ENCL, SNAP SW, RAIL W/ MTG

25 13340- 04 THER MOSTAT ASSY, RAIL, COR

26

or

or

27 9021-0005 VENT, CONDENSATION

28 1670 8- 02 SW AIR, HF900, CALIBR ATED
Note: This list identies the major co mponents only. Rec ommended spare parts

highlighted red.

174 39-X X

-01

-02

-03

164 41

16707

176 95

MOT/IMPLR ASSY

HF900 240VAC 1PH

HF900 208/230/460VAC 3PH

HF900 575VAC 3PH

PPT SNSR, C/W 6’ CABLE ASSY

PPT SNSR HEAD

KIT, PC BOARD, PPT SNSR W/CMPNTS

50

50

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

Table 21 – Control Panel Parts List

Index Part No. Description

1 9012- 0 05 9 BUCHANAN TSB100012DS=TUBULAR BARRI ER ST

2 9040-0018 RELAY, FS, BURNER CONTROL
3 9040-0022 AMPLIFI ER, FS, MDL

9040-0023 CARD, FS, PU RGE TIMER, 2 SEC

4

5 9040-0042 BASE, RELAY, FS, RM7800 PANEL MTG
6 9042-0044 CB, 1 POLE 5 A

7 9042-0046 CB, 2 POLE 32 A

8 9043-0004 BLOCK , TERM A AR 12 POLE C/W HDW

9 9043-0025 BLOCK, TERM 4 POLE, 600V 115A

10 9064-0021 TR FRMR, IGN, 120V PRI

11 9064-0030 TRFRMR, CONT 120>24V & 120V 100 VA
12 9069-0015 ME TER, ELAPSED TIME HRS, 120VAC 60HZ
13 90 7 7-003 3 FUSE, RESETTABLE
14 9 07 7- 0 034 CB, 1A, PNL MNT
15 907 7- 0 03 5 CB, 15A, PNL MNT

Index Part No. Description

16 9 078-0 043 CONTACTOR, 2 POLE, 25A, 120V COIL
17 9078-0044 PROTECTIVE COVER, CONTACTOR,2 POLE
18 9079-0004 RCPT, DUPLEX 15A-125V, G FCI SMARTLOCK
19 1853 2 LABEL, AAR CONNECTOR, VINYL

20 18783 -0 2 CONTROLLER, 900 HEATER

21 18784 EMS MODULE

22 18 931 BRKT, FUSE & HR METER
23 18934 RESET MODULE
24 19018 PROGRAMMING KEY, CONTROLLER

Note: This list identies the major co mponents only. Rec ommended spare parts

highlighted red.

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

Table 22 – Control Panel Parts List

Index Part No. Description

1 9012- 0 05 9 BUCHANAN TSB100012DS=TUBULAR BARRI ER ST

2 9040-0018 RELAY, FS, BURNER CONTROL
3 9040-0022 AMPLIFI ER, FS, MDL

9040-0023 CARD, FS, PU RGE TIMER, 2 SEC

4

5 9040-0042 BASE, RELAY, FS, RM7800 PANEL MTG
6 9 040 -0151 T HERMAL OVERLOAD REL AY, 3.2 - 16.0 A, 3PHASE
7 9042-0044 CB, 1 POLE 5 A
8 9042-0049 CB, 3 POLE 13A

9 9043-0004 BLOCK, TERM A AR 12 POLE C/W H DW
10 9043-0025 BLOCK, TERM 4 POLE, 600V 115A

11 9064-0021 T RFRMR, IGN, 120V PRI

12 9064-0030 T RFRMR, C ONT 120>24V & 120V 100 VA
13 9069-0015 METER, EL APSED TIME HRS, 120VAC 60HZ
14 907 7- 0 033 FUSE, RESETTABLE
15 907 7- 003 4 CB, 1A, PNL MNT

Index Part No. Description

16 907 7- 0 03 5 CB, 15A, PNL MNT

17 9078 -0126 CO NTACTOR, 12A C/W 120V COIL
18 9079-0004 RCPT, DUPLEX 15A-125V, G FCI SMARTLOCK
19 1853 2 LABEL, AAR CONNECTOR, VINYL

20 18783 -0 2 CONTROLLER, 900 HEATER

21 18784 EMS MODULE

22 18 931 BRKT, FUSE & HR METER

23 18934 RESET MODULE

24 19018 PROGRAMMING KEY, CONTROLLER

Note: This list identies the major co mponents only. Rec ommended spare parts

highlighted red.

Parts - Control Panel, 460 - 575V Three Phase

Parts

5151

Table 23 – Control Panel Parts List

Index Part No. Description

1 9012- 0 05 9 BUCHANAN TSB100012DS=TUBULAR BARRI ER ST

2 9040-0018 RELAY, FS, BURNER CONTROL
3 9040-0022 AMPLIFI ER, FS, MDL

4 9040-0023 CAR D, FS, PURGE TIMER, 2 SEC

5 9040-0042 BASE, RELAY, FS, RM7800 PANEL MTG

90 40- 0151

6

or

90 40 - 0150

7 9042-0044 CB, 1 POLE 5 A
8 9042-0046 CB, 2 POLE 32 A

9 9043-0004 BLOCK, TERM A AR 12 POLE C/W H DW
10 9043-0025 BLOCK, TERM 4 POLE, 600V 115A

11 9064-0021 T RFRMR, IGN, 120V PRI

9064-0033

12

or

9064-0031

13 9069-0015 METER, EL APSED T IME HRS, 120VAC 60HZ
14 9 07 7- 0 0 28 FUSE HOLDER, PANEL MOUNT
15 9 077- 0031 FUSE, 1.5 AMP 600V

THERMA L OVERLOAD REL AY, 3.2 - 16.0 A, 3PHASE
(use with 460V conguration)

THERMA L OVERLOAD REL AY, 1.0 - 5.0 A, 3PHASE
(use with 575V conguration)

TRFRMR, CONT 460/575>120V 15A/24V 4A (shown)
(for congurations with 120V duplex receptacle)

TRFRMR, CONT 460/575>120V 4A /24V 4A
(for standard conguration, no receptacle)

Index Part No. Description

16 90 7 7-003 3 FUSE, RESETTABLE
17 907 7- 0 03 4 CB, 1A, PNL MNT
18 9078 -0126 CO NTACTOR, 12A C/W 120V COIL
19 1853 2 LABEL, AAR CONNECTOR, VINYL

20 18783 -0 2 CONTROLLER, 900 HEATER
21 18784 EMS MODULE

22 18 931 BRKT, FUSE & HR METER
23 18934 RESET MODULE

24 19018 PROGRAMMING KEY, CONTROLLER
Note: This list identies the major co mponents only. Rec ommended spare parts

highlighted red.

K.4 Parts - Control Panel, 460V/575V ThreePhasewith120V Duplex Receptacle

Table 24 – Control Panel Parts List

Index Part No. Description

1 9012- 0 05 9 BUCHANAN TSB100012DS=TUBULAR BARRI ER ST

2 9040-0018 RELAY, FS, BURNER CONTROL
3 9040-0022 AMPLIFI ER, FS, MDL

4 9040-0023 CAR D, FS, PURGE TIMER, 2 SEC

5 9040-0042 BASE, RELAY, FS, RM7800 PANEL MTG

90 40- 0151

6

or

90 40 - 0150

7 9042-0044 CB, 1 POLE 5 A
8 9042-0046 CB, 2 POLE 32 A

9 9043-0004 BLOCK, TERM A AR 12 POLE C/W H DW
10 9043-0025 BLOCK, TERM 4 POLE, 600V 115A

11 9064-0021 T RFRMR, IGN, 120V PRI

9064-0033

12

or

9064-0031

13 9069-0015 METER, EL APSED T IME HRS, 120VAC 60HZ
14 9 07 7- 0 0 28 FUSE HOLDER, PANEL MOUNT

52

52

Parts

THERMA L OVERLOAD REL AY, 3.2 - 16.0 A, 3PHASE
(use with 460V conguration)

THERMA L OVERLOAD REL AY, 1.0 - 5.0 A, 3PHASE
(use with 575V conguration)

TRFRMR, CONT 460/575>120V 15A/24V 4A (shown)
(for congurations with 120V duplex receptacle)

TRFRMR, CONT 460/575>120V 4A /24V 4A
(for standard conguration, no receptacle)

Index Part No. Description

15 9 077- 0031 FUSE, 1.5 AMP 600V
16 90 7 7-003 3 FUSE, RESETTABLE
17 907 7- 0 03 4 CB, 1A, PNL MNT
18 907 7- 0 035 CB, 15A, PNL MNT
19 9078 -0126 CO NTACTOR, 12A C/W 120V COIL
20 9079-0004 RCPT, DUPLEX 15A-125V, G FCI SMARTLOCK

21 185 32 LABEL, AAR CONNECTOR, VINYL

22 18 783 - 02 CONTROLLER, 900 HEATER

23 18784 EMS MODULE

24 18931 B RKT, FUSE & HR ME TER
25 18934 RESET MODULE

26 19 018 PROGRAMMING KEY, CONTROLLER
Note: This list identies the major co mponents only. Rec ommended spare parts

highlighted red.

12

10

15

3

14

6

5

2

11

18

4

17

7

9

8

1,16

13

Table 25 – Parts - Gas Components

Index Part No. Description

1 19 30 4 HTR, 2”DIA 30W 24VAC 18”L LEADS SI

2 9045-0085 CONN, 1/4TUBE MALE * 1/8NPTM, BR
3 90 45 -0160 VALVE, BALL 1/4” NPT 1/4 TURN

4 904 5 -10 0 3 REGULATOR, PILOT 125PSI/9 - 13”WC

5

9069-1015 HOSE, PRPNE 1/4”NPTF F/SWVL* 12”L

6
7 9081-0066 REGULATOR, 12.5-20”WC (HSR)

8 1497 0 IGNTR, SPARK

9 9089-0026 VALVE, SOL, GAS, 1”NPT 120V (HONE YWEL L)
10 9089-0028 VALVE, SOL, PILOT, GAS, 1/4”NPT 50CFH

11 117 0 0 BURNER, HF900

12 11712 VENT ELBOW
13 117 3 9 BRKT, SUPPORT, HF 900 BURNER

14 14978 ROD, FLAM E 3”L 1/4”NPT

Index Part No. Description

15 16952 PILOT REGULATOR, MODIFIED

16 1792 7

17 HF9069-1020 GAUGE, PRESSURE, 0-30”WC 1/8”NPT

18 HF9069-1021 G AUGE, PRESSURE, 0-30 PSI, 1/8” NPT

Not

Shown

Note: This list identies the major co mponents only. Rec ommended spare parts

highlighted red.

13142 -04 CABLE ASSY, IGN 21”L P/NG HF900
15165-04 CABLE ASSY, FLAME ROD 22”L P/NG HF90 0

SPRING WEDGE, 2”X2”, SST,HF900 BURNER

DEFROSTER

Parts

5353

NOTES

54

54

NOTES

5555

For further assistance, please call 1.855.244.3128

PLEASE ADHERE TO INSTRUCTIONS IN THIS MANUAL

Failure to do so may be dangerous and may void certain provisions

of your warranty.

WARRANTY: Under normal use the Company warrants

to the purchaser that defects in material or workmanship
will be repaired or replaced without charge (from date of
shipment) for a period of:

• 84 months - SwitchBlade® Heaters

• 60 months - DC Heaters

• 36 months - DC Control Panels

• 12 months - HELLFIRE Heaters, FEB Heaters

• 12 months - All other Fastrax® Products

Any claim for warranty must be reported to the sales of ce where

the product was purchased for authorized repair or replacement

within the contract terms.

Subject to State or Provincial law to the contrary, the Company

will not be responsible for any expense for installation, removal

from service, transportation, or damages of any type whatsoever,

including damages arising from lack of use, business interruptions,

or incidental or consequential damages.

The Company cannot anticipate or control the conditions of

product usage and therefore accepts no responsibility for the

safe application and suitability of its products when used alone or

in combination with other products. Tests for the safe application

and suitability of the products are the sole responsibility of the

use r.

This warranty will be void if, in the judgment of the Company, the

damage, failure or defect is the result of:

• Vibration, radiation, erosion, corrosion, process

contamination, abnormal process conditions, temperature

and pressures, unusual surges or pulsation, fouling, ordinary

wear and tear, lack of maintenance, incorrectly applied

utilities such as voltage, air, gas, water, and others or any

combination of the aforementioned causes not speci cally

allowed for in the design conditions

No warranty applies to paint  nishes except for manufacturing

defects apparent within 30 days from the date of installation.

The Company neither assumes nor authorizes any person to

assume for it any other obligation or liability in connection with the

product(s).

The Purchaser agrees that all warranty work required after the

initial commissioning of the product will be provided only if the

Company has been paid by the Purchaser in full accordance with

the terms and conditions of the contract.

The Purchaser agrees that the Company makes no warranty or

guarantee, express, implied or statutory, (including any warranty

of merchantability or warranty of  tness for a particular purpose)

written or oral, of the Article or incidental labour, except as is

expressed or contained in the agreement herein.

LIABILITY: Technical data contained in the catalog or on

the website is subject to change without notice. The Company

reserves the right to make dimensional and other design changes

as required. The Purchaser acknowledges the Company shall

not be obligated to modify those articles manufactured before

the formulation of the changes in design or improvements of the

products by the Company.

The Company shall not be liable to compensate or indemnify

the Purchaser, end user or any other party against any actions,

claims, liabilities, injury, loss, loss of use, loss of business,

damages, indirect or consequential damages, demands,

penalties,  nes, expenses (including legal expenses), costs,

obligations and causes of action of any kind arising wholly or

partly from negligence or omission of the user or the misuse,

incorrect application, unsafe application, incorrect storage and

handling, incorrect installation, lack of maintenance, improper

maintenance or improper operation of products furnished by the

Company.

• Or, any act or omission by the Purchaser, its agents,

servants or independent contractors which for greater

certainty, but not so as to limit the generality of the

foregoing, includes physical, chemical or mechanical

abuse, accident, improper installation of the product,

improper storage and handling of the product, improper

application or the misalignment of parts.

1500 W. Campus Drive
Littleton, CO 80120 USA

1-855-244-3128
1-303-979-7339
F 303- 979-7350