Read all important information notices on page 3. Please adhere to instructions published in this manual.
Failure to do so may be hazardous and may void certain provisions of your warranty.
Electric Hot Air Blower
Fastrax® FEB Series
Installation, Maintenance, Repair &
Replacement Parts
Fastrax® is a leading manufacturer of complete engineered rail
heating packages for freight railroads and transit. We provide
the most efficient heat transfer products for rail track and switch
equipment. These products are designed for low maintenance
and long life for rugged use even in the harshest conditions. We
also custom design and manufacture energy saving automated
control packages to provide our customers with complete
heating solutions for rail industry applications.
The Fastrax
®
FEB Electric Hot Air Blower switch heater
prevents or removes ice and snow build up in the switch point
area by delivering high velocity heated air to nozzles located at
the switch point.
The Fastrax
®
FEB is assembled in a heavy-duty fully enclosed
housing with easily accessible internal components. These
components include a high velocity blower, rugged heating
module and advanced electronic controls. The Fastrax
FEB comes standard with Fastrax
and Fastrax
®
automatic aerial and ground snow sensing
®
FEDP Duct Package
®
equipment.
A. IMPORTANT NOTICES
CAUTION
CAUTION
This symbol indicates a potentially hazardous
situation, which, if not avoided, may result in
personal injury or damage to the equipment.
WARNING
WARNIN G
This symbol indicates an imminently hazardous
situation, which, if not avoided, can result in serious
injury or damage to the equipment.
WARNING
WARNIN G
Read and adhere to the following. FAILURE TO DO
SO MAY RESULT IN SEVERE OR FATAL INJURY.
Warranty will be void.
1. Read and follow all instructions in this manual.
2. Heater is to be connected and serviced only by a
qualified electrician.
3. Installation and wiring of the heater must adhere to all
applicable codes.
4. Disconnect heater from power supply at integral disconnect
or fuse box before opening enclosures or servicing heater.
IF INTEGRAL DISCONNECT IS BEING SERVICED, verify
power has been disconnected at fuse box or main panel.
Lock the switch in the “OFF” (open) position and tag the
switch to prevent unexpected power application.
5. This heater is equipped with a bimetal over temperature
high-limit. It is of the automatic reset type and therefore the
heater may restart without warning. The heater is not to be
operated with the high-limit disabled or disconnected from
the control circuit.
6. Operate the heater only while it is permanently mounted in
a horizontal position. Refer to Section B. Installation
for details.
7. Follow the recommended maintenance procedures in
Section H. Electric Blower Seasonal Maintenance.
8. Do not operate heater in ambient temperatures above
104°F (40°C).
9. Use factory approved replacement parts only.
10. See applicable electrical codes for seal requirements in
field installed conduits. Factory installed conduits require no
further sealing.
11. If there are any questions or concerns regarding the heater,
contact the factory. Refer to the last page of this manual
for details.
Important Notices
3
B. INSTALLATION
WARNING
WARNIN G
Read and adhere to the following installation
instructions. FAILURE TO DO SO MAY RESULT IN
SEVERE OR FATAL INJURY AND/OR POSSIBLE
VOIDING OF THE WARRANTY.
B.1 Recommended Tools & Equipment
• Picker truck or other means of lifting and placing the
electric blower unit (shipping weight with accessories is
• Electric impact wrench and sockets for running 9/16" lag
bolts
• 3/8" electric drill for pilot holes
• Portable generator for electric power tools
• Basic combination wrench set and basic socket wrench set
• Inch pounds torque wrench
• Tape measure
• Pry bar for the removal of crating materials
• Reciprocating saw for removal of crating materials and
trimming nozzles
• Shovel and rake for track ballast removal
• Lining and tamping bars
• Cold chisel and hammer
B.2 Torque Specifications
B.3 Site Preparation
1. The electric blower uses the FEDP Duct Package installed
between two permanent load bearing ties.
2. Refer to the duct layout diagram on page 5.
3. Take care not to damage aerial snow sensor when removing
the upper section of the shipping crate.
Aerial Snow Sensor
4. Remove the following and set aside for later assembly,
(refer to diagram on page 5):
Duct Pieces - Distribution Duct Sections, Isolation blocks
Discharge Nozzles
Flexible Duct
Hardware Kit
Rail Affixing Straps
WARNING
WARNIN G
Before testing tightness of any electrical connection,
disconnect, tag and lockout electrical feeder to
control panel to ensure entire panel is de-energized.
Electrical Equipment Torque Values
Part TypeDescription
TerminalsControl Circuits9
TerminalsHeater Load Circuits 27
TerminalsGround Block Terminals14
DisconnectUp to 100A50
Disconnect100–200A100
ContactorsPressure Plate Lugs15–2 0
ContactorsBox Lugs40–45
Pwr. Dist. BlockPrimary75
Pwr. Dist. BlockSecondary25– 35
Circuit BreakersHeater and Control Loads18
Installation
Torque
(in.lb.)
CAUTION
CAUTION
Ensure all equipment and components delivered match
the shipping list provided. Notify Thermon Heating
Systems factory of any missing or damaged parts.
5. Carefully consider the placement of the distribution duct,
bearing in mind the length and angle of the discharge
nozzles and their proximity to the switch points.
5.1 Once the optimal position is identified, proceed with
ballast removal allowing extra clearance for isolators
and bolting flanges to pass underneath the rail. More
information can be found in the Distribution Duct
Installation section of this manual on page 6.
5.2 Nozzles can be trimmed if necessary. A reciprocating
saw with a fine metal blade can be used for this
operation. Maximum trim length is 3 inches.
6. Excavate the ballast from the predetermined area between
two load bearing ties.
6.1 Allow a minimum of 10" of clearance below the rail for
10129061GASKET, TIE DUCT, GARLOCK 9850 - FASTRAX EB 20
11129822TIESTRAP - FASTRAXEB
12129832ISOLATION BLOCK c/w INTEGRATED BOLTS
x1
(NTS)
x1
(NTS)
x1
(NTS)
P#12983 / 12986
P#12983 / 12986
P#12906 / 13035
P#7406
x12
P#1516
x12
P#A10685-04
x12
x1
(NTS)
P#12983 / 12986
1. Assemble the distribution duct and electrical isolators as
detailed in the drawing below.
WARNING
WARNIN G
Do not exceed 50 in.lb. torque on the electrical
isolation joints or the isolation block will be damaged.
2. Repeat the process for the attachment of the flexible duct
and the distribution duct using the hardware and isolation
block supplied as detailed in the drawing below.
5
6
4
3
5
Item
#
6
4
3
Qty Description
3
5
1
4
Part Number
20 kW40/60 kW
112 piece tie duct, 76" Fastrax® FEDP1297212984
®
21Flex duct 60" - Fastrax
FEDP12971-60130 31- 60
324 Washer, 1/4 flat plated SAE1516
424Lockwasher 1/4" split740 6
524 Nut-1/4-20 UNC-H-SZPA10 6 85-04
62Isolation block c/w integrated bolts1298 312986
5
4
3
2
NOTE: Ducting connections are electrically isolated to
eliminate the possibility of short circuiting the rails.
Connections are designed and tested to withstand
3000 volts for a duration of 1 minute.
1
Rail Affixing Straps
Main Tie Duct
Distribution Duct
Sections
Discharge Nozzles
Flexible Duct
Isolation Blocks
Main Electrical Wiring Entries
Automatic Ground
Snow Sensor
Optional Adjustable Stand
Structurally Reinforced
Lifting Points
Optional High
Profile Air Intake
Automatic Aerial
Snow Sensor
Installation
5
B.5 Distribution Duct Installation
1. Position the assembled distribution duct in the excavated
area between the ties by placing the closed end under the rail.
2. Slide the assembled distribution duct in the excavated area
until the nozzle discharge openings are at equal distances
between the rails.
5. Adjust the distribution duct position as necessary before
installing the tie straps as shown in the photo below. For
ease of installation, pre-drill pilot holes to facilitate threading
of the lag bolts into the railroad tie.
3. Use temporary blocking to raise the distribution duct until it
is flush with the undersides of both rails.
4. Temporarily insert the discharge nozzles into their sockets
in the distribution duct and verify that the nozzle tips will
not interfere with the switch points. Leave a minimum of 2"
clearance between the end of the nozzle and the rail web.
6. Carefully replace the ballast underneath and along each side
of the distribution duct. Ensure the duct remains level and
the discharge nozzles are aimed at the rail web of the switch
point, not above or below. Ensure the nozzle is positioned
correctly to remove snow between the switch points.
7. Remove the blocking and back fill with ballast as required.
Installation
6
B.6 Distribution Duct Installation For Concrete Ties
1. Position the assembled distribution duct in the excavated area
between the ties by placing the closed end under the rail.
4. Turn keeper nut down to secure each jack bolt into place.
Duct should now be secure at the height desired.
2. Temporarily block up ducting to a height where tie straps
can be attached. Attach the Tie Straps and remove blocking.
Ducting should hang from the ties by the tie straps.
5. Remove the tie straps and apply epoxy to both ends where
it will contact the ties.
6. Carefully place the tie straps back onto ties by aligning
bolting holes and securing with provided hardware.
3. Turn each jack bolt out until the points are secure against
concrete wall of ties. Tighten with wrench until tool tight.
10129061GASKET, TIE DUCT, GARLOCK 9850 - FASTRAX EB 20
11129822TIESTRAP - FASTRAXEB
12129832ISOLATION BLOCK c/w INTEGRATED BOLTS
x1
(NTS)
x1
(NTS)
P#12983 / 12986
P#12906 / 13035
1. Complete the installation of the nozzles using the hardware
as detailed in the drawing below. Follow the precise
installation order to ensure proper assembly.
1
4
6
3
2
4
3
2
5
2.1 Using a multimeter, verify the distribution duct sections
are electrically isolated from one another by checking
for lack of continuity.
Installation
8
Item
Qty Description
#
Part Number
20 kW 40/60 kW
12Discharge nozzle - Fastra x® FEDP1297 3129 85
212Washer, 1/4 flat plated SAE1516
312Lockwasher 1/4" split7406
412Bolt 1/4-20UNC x 1" LG, Hex Head5113
58Lag bolt, 3/8" x 2"12934
®
62Tie strap - Fastrax
FEB12982
2. Insert the discharge nozzles into their sockets. Aim the
nozzles at the rail web of the switch points and secure in
position.
B.8 Electric Blower Installation
1. Prepare the area where the electric blower unit will be placed.
1.1 The area should be clear of any foliage or foreign
objects that might be drawn into the Fastrax
®
FEB ‘s air
intake.
2. Ensure the grade is level before installation. A thick layer of
ballast material providing good drainage is recommended.
WARNING
WARNIN G
Ensure the unit is installed at least six inches above
the level at which ground water might accumulate.
Failure to do so could cause damage to the unit
and void the warranty.
4. Using the four lifting points, lift the unit and place it
perpendicular or parallel to the track bed.
4.1 Ensure it is close enough for the flexible duct to
reach between the connecting flanges on the blower
discharge and the distribution duct inlet without
obstruction or pinching.
5. Once the electric blower unit is in position remove the
remaining exterior crating except for the wooden base
blocks attached to the unit.
5.1 Ensure no projections on the unit interfere with the rail
line foul zone.
At least six inches
6"
above grade
3. The electric blower unit is shipped on pressure treated
wooden blocks which should be left in place to ensure
maximum protection from water ingress; an optional
adjustable metal stand is available.
4. Using a multimeter, verify the flexible duct and distribution
duct sections are electrically isolated from one another by
checking to ensure there is no continuity.
8
B.10 Ground Snow Sensor Installation
1. Select an elevated location for the ground snow sensor.
Bolting the ground snow sensor to the end of the rail tie,
where possible, is recommended.
1.1 Secure in place, as depicted in the pictures below.
Installation
10
1. Attach the flexible duct to the blower discharge flange
with the gasket and hardware provided as shown in
diagram above.
2. Draw the fasteners snug in an even diagonal pattern and
torque to 50 in.lb.
3. To eliminate excess strain on the duct and connections,
ballast may be used to support the flexible duct as required.
3.1 Additional ballast can be added around the perimeter of
the blower unit and between the blocking to keep the unit
firmly in place.
B.11 Electrical Termination
Surge Protection Recommendations
This electric blower 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 System’s surge mitigation efforts can only be effective if ALL
external remote circuits connecting to the electric blower 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 electric blower
control I/O circuits. These arresters should be located
“upstream” of the electric blower housing (within the
signal housing, which interfaces to the electric blower).
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 electric blower AC power feed. This surge
protection device should be located “upstream” of
the electric blower 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 electric blower 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.
3. Conductors are to be sized in accordance with the electrical
code and the minimum circuit ampacity data as detailed on the
unit’s data plate.
Thermon Heating Systems Inc.
4. Incoming supply lines should be connected directly to
the main disconnect switch. Where applicable the neutral
should be connected to the neutral lug and grounded at
the source.
See photo detail below for electrical connection points.
Electrical Connection Points
WARNING
WARNIN G
Electrical connections are to be performed by qualified
personnel and in accordance with the local electrical
code and the local electrical authority.
1. Connection entries for electrical conduits are located
on the right hand side of the discharge duct. The power
connection entry is 1 1/4" NPT and the remote signal entry
is 1/2" NPT.
2. The use of water tight connections for incoming conduits
is mandatory. See applicable electrical codes for seal
requirements of field installed conduits.
5. The control chassis and the rest of the main unit must be
connected to ground.
6. The maximum allowable deviation from rated voltage to
supply line voltage is 5%. Verify voltage is present on all
three lines for three phase units and two lines for single
phase units.
7. Customer requested external low voltage signal inputs and
outputs shall be routed through the secondary connection
point adjacent to the main power connection. Termination of
remote operator controls is found in Section D. Controls of
this manual under D.4 Remote Signalling.
8. Manually spin the blower shaft to ensure the blower turns freely.
9. The electric blower unit is electrically isolated from the track
by the isolation block between the distribution duct and the
flexible duct.
The Fastrax® FEB electric blower control panel located inside the
unit incorporates modern technology including a smart relay to
ensure efficient and economical operation and is designed for
ease of operation and servicing. Each control panel is NEMA 4
rated for protection against moisture.
The controls have been preconfigured for optimal snow melting
operation with minimum user input. If desired, advanced
diagnostics, troubleshooting and timing/mode adjustment features
are readily available.
D.1 Control Panel Features
Control System Features
• Automatic snow clearing operation driven by ground and
aerial snow sensors
• Local manual start/stop
• Remote start/stop
• User adjustable preset run time (1 minute to 100 hours)
• Counts and displays total number of operating hours in
service
• Selectable modes
• Hot/cold air and Remote timeout on/off
User Friendly Interface Features
• User friendly door mounted operators and LED indicators
• Local run status and fault indication
• Remote run and fault indication
• Advanced diagnostics and troubleshooting displays
including fault history
Equipment Protection Features
• Overheat protection system including:
• Automatic fan shutdown delay
• High temperature limiting devices including
separate primary automatically reset
and backup manually reset bimetal disc
thermostats
• Motor protection including class 10 overload relay
• Coordinated overcurrent protection of all electrical components
by resettable circuit breakers and motor controllers
• User adjustable remote start delay prevents simultaneous
inrush of multiple units
• Staggered starting of motor and elements to minimize
peak current draw
• Self monitoring and automatic adjustment to minimize risk
of damage while maintaining a reduced but effective level
of snow clearing and sensing operation in the event of
some installation issues or equipment failures
D.2 Control System Operating Modes
1. Timed Local Run Mode: The Fastrax
if the “MANUAL START” button is pushed for 3 seconds
or one of the snow sensors detects snow. The Fastrax
will run in this mode until the red “MANUAL START” button
is released and the snow sensors no longer detect snow, at
which point it will begin a timed run where it will continue to
run in this mode until the preset run time (2 hours by default)
has elapsed. The run timer will be reset if the “MANUAL
START” button is pushed or one of the snow sensors
detects snow again.
2. Timed Remote Run Mode: The Fastrax
after the remote start/stop contacts are held closed while
“REMOTE TIMEOUT MODE” is on (default). The Fastra x
FEB will begin a timed run and will continue to run until the
preset run time has elapsed or the remote start/stop contacts
are opened.
NOTE: Opening of the remote start/stop contacts will cancel
the timed run if the snow sensors are not currently
detecting snow.
3. Continuous Remote Run Mode: The Fastrax
mode while the remote start/stop contacts are closed and
“REMOTE TIMEOUT MODE” is off. The Fastrax
run in “CONTINUOUS REMOTE RUN MODE” until the
remote start/stop contacts are opened.
4. Cooldown Mode: If “COLD AIR MODE” is off, the Fastrax
FEB enters “COOLDOWN MODE” after exiting the run
®
modes. The Fastrax
FEB will run in “COOLDOWN MODE”
where the duct heater is off and the blower continues to run
until the preset cooldown time (3 minutes) has elapsed or
®
the Fastrax
FEB is forced to re-enter a run mode.
5. Cold Air Mode: This mode increases energy efficiency
in exchange for reduced snow clearing capability. While
“COLD AIR MODE” is inactive (default), the Fastrax
discharges heated air while it is running. While “COLD AIR
MODE” is active, the Fastrax
it is running.
The Fastrax
®
FEB may be forced to enter this mode
regardless of the setting of the “COLD AIR MODE” selector
switch if the primary high temperature limit trips repetitively
due to a serious issue with equipment or installation. In this
®
case, the Fastra x
FEB will remain in cold air mode until the
issue has been resolved and the unit has been manually
reset by pressing the “MANUAL START” button.
6. Remote Timeout Mode: This mode prevents the possibility
®
of the Fastrax
FEB running permanently if the remote start/
stop contacts are inadvertently left closed. While “REMOTE TIMEOUT MODE” mode is active (default), closure of the
remote start/stop contacts will activate timed remote run
mode. While “REMOTE TIMEOUT MODE” is inactive,
closure of the remote start/stop contacts will activate
“CONTINUOUS REMOTE RUN MODE”.
®
FEB enters this mode
®
FEB
®
FEB enters this mode
®
®
FEB is in this
®
FEB will
®
FEB
®
FEB discharges cold air while
®
Controls
15
D.3 User Interface
7. Blower On8. Heat On6. Control On
9. System Fault
10. High Temp Limit2. Manual Stop
3. Disconnect Off/On
Control Panel Interface
D. 3.1 Panel Door Operators and Lights
1. Manual Start Button: Upon holding this button down for 3
seconds and releasing it, the Fastrax
preset run time has elapsed.
2. Manual Stop Button: Pushing this button will end any
currently active run mode, and force the Fastrax
remain stopped for 5 seconds. This period may be used to
turn the disconnect switch to the “OFF” position and safely
disconnect the blower and duct heater element loads.
WARNING
WARNIN G
After this 5 second period the Fastrax
restart if inputs such as the snow sensors or the
remote start signal are active.
3. Disconnect Switch: Turning the handle of this switch to
the “OFF” position will de-energize the entire Fastrax
including the control circuit. Before performing any work on
the electrical connections of the Fastrax
should be in the “OFF” position. The smart relay may be
rebooted by turning this switch to the “OFF” position and
then back to the “ON” position.
4. Cold Air Mode Selector Switch: In the “ON” position,
“COLD AIR MODE” is active. In the “OFF” position,
“COLD AIR MODE” is inactive (unless forced on by a
repetitive primary high temperature limit tripping event).
By default, this switch is in the “OFF” position.
5. Remote Timeout Mode Selector Switch: In the “ON”
position, “REMOTE TIMEOUT MODE” is active. In the
“OFF” position, “REMOTE TIMEOUT MODE” is inactive. By
default, this switch is in the “ON” position.
®
FEB runs until the
®
FEB to
®
FEB may
®
FEB, this switch
®
FEB
1. Manual Star t
Hold 3 sec.
4. Cold Air Mode
Off/On
5. Remote Timeout OF F/ON
6. Control On Pilot Light: This white pilot light indicates the
control system is powered.
7. Blower On Pilot Light: This green pilot light indicates the
control system is attempting to run the blower.
8. Heat On Pilot Light: This green pilot light indicates the
control system is attempting to run the duct heater
elements.
9. System Fault Pilot Light: This pilot light indicates that one or
more of the system’s components are not working properly.
The system faults that can trigger this pilot light include:
9.1 Tripping of the primary high temperature limit
9.2 Past repetitive tripping event of the primary high
temperature limit (forced cold air mode)
9.3 Tripping of the backup high temperature limit
9.4 Tripping of the blower motor controller
9.5 Tripping of a snow sensor circuit breaker
9.6 Malfunction of a snow sensor
9.7 Malfunction of the smart relay
NOTE: The red “SYSTEM FAULT” pilot light is normally lit
immediately following power up during the booting
process of the smart relay.
High Temperature Limit Pilot Light: This red pilot light
10.
indicates the backup high temperature limit thermostat has
tripped and needs to be manually reset.
16
Controls
D.4 Remote Signalling
Remote Signalling Inputs
Remote Signal Terminal Block - Refer to Section C.
Wiring Schematics for Remote Signal Connections.
1. Remote Start/Stop Contacts: The Fastrax
started by closing TB2 terminals RSS-1 and RSS-2 using a
pair of remote dry contacts.
2. Remote Run Indication: The Fastrax
is currently running by closing a pair of dry contacts, TB2
terminals A1 and A2, and by opening another pair of dry
contacts, TB2 terminals A1 and A3. Either of these pairs of
dry contacts can be monitored remotely.
3. Remote System Fault Indication: The Fastrax
indicates that it is experiencing a system fault by opening
a pair of dry contacts, TB2 terminals A4 and A5, and by
closing another pair of dry contacts, TB2 terminals A4 and
A6. Either of these pairs of dry contacts can be monitored
remotely. Any of the system faults that would trigger the
system fault pilot light would also trigger these contacts.
®
FEB can be
®
FEB indicates that it
®
FEB
D.6 Smart Relay Display
1. Total Run Time: By default, while no run status, fault status
or fault history messages are active, the smart relay display
shows a status message similar to:
1.1 This message shows a count of the total number
of hours the Fastrax
air mode or cold air mode since the count was last
manually cleared.
1.2 If any run status, fault status or fault history messages
are active, the smart relay display will cycle through
them showing each message 5 seconds at a time.
D.6.1 Run Status Messages
Timed Run: While the Fastrax® FEB is running in timed local
1.
or remote mode, the smart relay display shows a message
similar to:
®
FEB has been running in hot
D.5 Smart Relay Operation
The EATON easy700 series smart relay is a rugged microprocessor
based programmable logic controller, which includes a myriad of
useful function blocks along with 12 inputs and 6 outputs that can
be used to achieve the same control functionality available with
traditional electromechanical relays and timers. There are many
advantages of the smart relay over traditional relay logic systems.
The system wiring using the smart relay is simpler and more
compact, which results in less risk of functionality issues caused
by wiring connections. The smart relay includes a built in display,
which shows diagnostic messages that are helpful in the event that
troubleshooting is required. If desired, the functionality of the smart
relay can be easily adjusted in the field using its display and buttons.
Finally, if desired, the smart relay can be reprogrammed to suit
application specific needs with little or no modification of wiring.
1.1 The preset run time is shown in hours and minutes to
the right of the “SET” label.
1.2 The run timer’s actual elapsed time is shown in hours
and minutes to the right of the “ACT” label.
1.3 The timed run ends when the run timer’s elapsed run
time equals the preset run time.
Controls
17
2. Continuous Remote Run: While in continuous remote run
mode, the smart relay display shows a message similar to:
2.1 The total time that Fastrax
®
FEB has run in continuous
run mode is displayed. The value to the right of the
“DAY” label indicates the portion of the elapsed time
in days, while the value to the right of the “HR” label
indicates the remainder of the elapsed time in hours
and minutes. For instance, the message indicates that
the Fastrax
®
FEB has been running for 3 days, 8 hours,
and 10 minutes in continuous remote run mode.
3. Cool Down: While the Fastrax
®
FEB is running in cooldown
mode, the smart relay display shows a message similar to:
1.1 This fault message indicates that the duct heater has
been disabled due to an over-temperature condition.
This condition may be a transient issue that happens
only in rare circumstances or a more serious issue
that happens regularly. If the primary high temperature
limit thermostat trips often enough, it will eventually
be forced into cold air mode and the snow clearing
performance of the Fastrax
®
FEB will be impaired.
Please see Section G. Troubleshooting for more
information.
2. Cold Air Mode Forced: If the primary high temperature limit
thermostat has tripped 10 times over the course of a day,
the smart relay display shows:
18
3.1 The preset cooldown time is shown in minutes and
seconds to the right of the “SET” label.
3.2 The run timer’s actual elapsed time is shown in minutes
and seconds to the right of the “ACT” label.
3.3 The cooldown ends when the cooldown timer’s
elapsed time equals 3 minutes.
D.6.2 Fault Status Messages
Primary High Temperature Limit Tripped: If the primary high
1.
temperature limit thermostat has tripped, the smart relay
display shows:
Controls
2.1 This fault message indicates that Fastrax
®
FEB has
been forced to run in “COLD AIR MODE” due to a
serious issue with the installation or the Fastrax
®
FEB
that caused the duct heater to repeatedly run at an
excessively high temperature. Potential causes for
this issue include a significant airflow restriction or a
malfunctioning blower. The snow clearing performance
of the Fastrax
®
FEB will continue to be impaired
until the issue is investigated and corrected and the
“MANUAL START” button is pressed.
NOTE: Do not simply reset this fault and walk away from the
unit without diagnosing and resolving this issue, as in
this case the fault will likely return.
Backup High Temperature Limit Tripped: If the backup high
3.
temperature limit thermostat has tripped and needs to be
manually reset, the smart relay display shows:
3.1 This fault message may indicate an issue with the
installation or the Fastrax
®
FEB causing the duct
heater to run at an excessively high temperature,
which may result in damage to the equipment if left
unchecked. The duct heater elements will be disabled
and the snow clearing performance of the Fastrax
®
FEB will continue to be impaired until the “HIGH LIMIT RESET” button is pressed. The cause of
such an issue should be investigated and corrected.
“HIGH LIMIT RESET” Button
4. Motor Controller or Circuit Breaker Tripped: If the motor controller
has tripped, the smart relay display shows the message:
5.1 This fault message indicates that one or both of the
snow sensors has been disabled for drawing excessively
high current and suggests that one or both of the snow
sensors has failed. The snow detection feature and
automatic snow clearing operation of the Fastrax
®
FEB
will continue to be impaired until the faulty sensor has
been replaced and the circuit breaker has been reset.
6. Snow Sensing Circuit Shorted: If the snow sensing circuit
of an installed optional aerial snow sensor or ground snow
sensor is shorted for a long period of time, the smart relay
display shows one of the following messages:
4.1 This fault message indicates an issue with the installation
or the Fastrax
®
FEB that causes the motor branch circuit
to draw an excessively high current, which may result in
damage to the equipment if left unchecked. If the blower
motor controller has tripped, the snow clearing operation
of the Fastrax
®
FEB will be disabled until the blower motor
controller is manually reset. Such an issue should be
investigated and corrected.
5. Snow Sensor Circuit Breaker Tripped: If either an installed
optional ground or aerial snow sensor circuit breaker has
tripped, the smart relay display shows:
6.1 Each of these messages indicates that the snow sensor
it mentions is likely malfunctioning and has been disabled.
The snow detection feature and automatic snow clearing
operation of the Fastrax
®
FEB will continue to be impaired
until the issue has been resolved.
NOTE: Only the affected snow sensor(s) will be disabled. If
there is another connected snow sensor, it will continue
to be used by the Fastrax® FEB to sense snow.
Controls
19
D.6.1 Fault History Messages
Trip History: If the automatically reset primary high
1.
temperature limit thermostat has tripped one or more times
since the trip history was last manually cleared, the smar t
relay display shows a message similar to:
1.1 This particular message indicates the primary high
temperature limit has tripped three times since the trip
history was last manually cleared.
D.7 Smart Relay Operation
1. Manual Starting: Push and hold the “UP ARROW (^)” button
for 3 seconds to enter local timed run mode and set the
®
Fastrax
2. Showing Input/Output Status: Push and hold the “DOWN
ARROW (v)” button to hide any active messages and show
the smart relay input/output status, date/time and run status
on the smart relay display:
FEB to run until the preset run time has elapsed.
3. Clearing Total Run Time and Trip History: Push and hold the
Left Arrow (<) button for 5 seconds to reset the count of total
run time and number of high temperature limit trips stored in
the smart relay to zero.
4. Preset Run Time Adjustment: The preset run time is the
duration of the timed run as described in the “D.2 Control
System Operating Modes” section. The preset run time
can be set from 1 minute to 99 hours and 59 minutes. The
following example illustrates how one can change the preset
run time from 2 hours to 3 hours:
4.1 Push the “RIGHT ARROW (>)” button. The adjustment
menu appears.
4.2 Push the “ALT” button. A flashing solid cursor appears
over the left digit of the remote start delay field.
20
4.3 Press the “DOWN ARROW (v)” button. The flashing
solid cursor moves down to the left digit of the preset
run time field beside the “RUN” text.
2.1 The top line indicates the currently active inputs. The
bottom line indicates the currently active outputs
and whether the program is running or stopped. This
particular message illustration indicates that currently
inputs #5, #7 and #8 and output #4 are active, it is 8:56
AM on Thursday and the program is running.
Controls
4.4 Push the “OK” button. The left digit of the preset run
time field begins to flash.
4.6 Push the “OK” Button. The entered preset run time is
saved and the solid cursor begins flashing again.
4.5 Adjust the preset run time in HH:MM format.
4.5.1 Using the “LEFT ARROW (<)” and “RIGHT
ARROW (>)” buttons, move the cursor to the
digit to be changed. Using the “UP ARROW(^)” and “DOWN ARROW (v)” buttons, adjust
the value of the digit at the cursor position.
4.7 Push the “ESC” Button. The cursor disappears.
4.8 Push the “DOWN BUTTON (v)”. The adjustment menu
disappears.
5. Start Delay Adjustment: The remote start delay is the duration
that the Fastrax
®
FEB will wait before starting after the remote
start contacts are held closed, snow is detected or the unit is
power cycled during a run. The delay can be set from
0 seconds to 99 minutes and 59 seconds.
The following example illustrates how one can change the remote
start delay from 5 seconds to 10 seconds:
5.1 Push the “RIGHT ARROW (>)”. The adjustment menu
appears.
21
Controls
5.2 Push the “ALT” button. A flashing solid cursor appears
over the left digit of the remote start delay field beside
the “DLY” text.
5.3 Push the “OK” button. The left digit of the remote start
delay field begins to flash.
5.4 Adjust the remote start delay to the right of the “DLY”
text in MM:SS format.
5.4.1 Using the “LEFT ARROW (<)” and “RIGHT
ARROW (>)” buttons, move the cursor to the
digit to be changed. Using the “UP ARROW (^)” and “DOWN ARROW (v)” buttons, adjust
the value of the digit at the cursor position.
5.5 Push the “OK” Button. The entered remote start delay
is saved and the solid cursor begins flashing again.
22
Controls
5.6 Push the “ESC” Button. The cursor disappears.
5.7 Push the “DOWN BUTTON (V)”. The adjustment menu
disappears.
D.8 Protection
1. Primary High Temperature Limit Thermostat: The purpose
of this device is to provide a first line of defense against
overheating conditions that could otherwise cause equipment
damage or failure. If there is an issue with the installation
of the Fastrax
restriction or a malfunctioning blower, the heating elements
and ducting downstream of the elements could run at an
elevated temperature. If this temperature is sufficiently high to
be of concern, the primary high temperature limit thermostat
contacts should open, de-energizing the duct heater elements
to allow the Fastrax® FEB to cool down. Once the Fastrax®
FEB has cooled sufficiently, the primary high temperature
limit thermostat contacts should automatically reclose and
the duct heater elements should re-energize. If the cause
of the overheating condition is transient and goes away on
its own, then the Fastrax
it should. If, on the other hand, the cause of the overheating
condition is not rectified, the Fastrax
alternate between energizing and de-energizing the duct
heater elements during operation until cold air mode is
forced on indefinitely, which could negatively impact snow
clearing performance.
2. Backup High Temperature Limit Thermostat: The purpose
of this device is to provide a second line of defense
against overheating conditions that could otherwise cause
equipment damage. If there is an extreme overheating
condition that causes the equipment to run at a much
higher temperature than the threshold of the primary high
temperature limit, or if the primary high temperature limit
has malfunctioned, then the backup high temperature
limit thermostat contacts should open, de-energizing the
duct heater elements to allow the Fastrax
down. The contacts of the backup high temperature limit
thermostat will remain open and prevent the duct heater
elements from energizing until this thermostat is manually
reset. The backup high temperature limit thermostat should
only be manually reset if the heater has been thoroughly
checked and evaluated to be in proper working order.
®
FEB motor, such as a significant airflow
®
FEB will go back to operating as
®
FEB will continue to
®
FEB to cool
3. Motor Controller: The purpose of this device is to protect the
motor from medium and long term overcurrent conditions
that could otherwise damage it and result in a costly
replacement. There are many common causes of motor
overloads that must be mitigated, including excessive
loading on the blower impeller due to clogged ducting or
bearing friction. The class 10 tripping characteristic curve
of the motor controller has been carefully designed to
prevent degradation of the motor windings in these overload
conditions. Without this protection, the otherwise long life of
the motor could be cut short if an overload occurs.
4. Circuit Breakers: The purpose of these devices is to
protect and isolate the Fastrax
®
FEB electrical components
including the controls and duct heater elements from short
term overcurrent conditions and from line and ground faults.
The codes printed on the labels of these breakers and their
corresponding functions are listed in the table found in
subsection D.9 Control Panel Layout.
4.1 In the event of a fault, one of these breakers should trip,
disconnecting the faulted circuit from the rest of the
®
Fastrax
FEB’s circuits. After the fault is cleared and
its underlying cause is resolved, this breaker must be
manually reset to restore normal operation.
D.9 Smart Relay Inputs and Outputs
1. Inputs:
1.1 “MANUAL START” push-button
1.2 Aerial snow sensor
1.3 Ground snow sensor
1.4 Remote Start/Stop contacts
1.5 “MANUAL STOP” push-button
1.6 “COLD AIR MODE” selector switch
1.7 Primary high temperature limit trip feedback
1.8 Backup high temperature limit trip feedback
1.9 Motor controller feedback
1.10 Snow sensor circuit breaker trip feedback
1.11 “REMOTE TIMEOUT MODE” selector switch
2. Outputs:
2.1 Blower contactor control coil
2.2 Heater contactor control coil
2.3 Backup high temperature limit trip indication
2.4 System fault indication
Controls
23
D.10 Control Panel Layout
Control Relay
Customer Remote Signal
Connections
Duct Heater Contactor
Supply Line Entry
Duct Heater Circuit
Breaker
Disconnect Switch
Function
Blower MotorMS 2 08-1M S 24 0 -1 M S48 0 -1MS600-1
Duct Heater
Elements
Transformer BreakerCB208-2CB240 -2CB480 -2CB600-2
208V240V480V600V
CB 2 08-1C B240-1CB 4 8 0 -1CB600-1
Circuit Breaker Label
Smart Relay
Control Circuit Breaker
Aerial Snow Sensor Breaker
Ground Snow Sensor Breaker
Control
Transformer
Transformer Breaker
Combination Motor Starter
Motor Contactor
Control CircuitC B 24 -1C B24-1CB24-1CB 24 -1
Aerial Snow SensorCB24-2CB24-2CB 24-2CB24 -2
Ground Snow SensorC B24-3CB24-3CB24-3CB24- 3
Controls
24
E. INITIAL STARTUP/COMMISSIONING
1. Ensure there is no snow or moisture on the snow sensor
sensing heads and the remote start signals
are inactive.
NOTE: If keeping the remote start signal inactive is
impractical, temporarily disconnect the field wiring
from the remote start/stop terminals RSS-1 and
RSS-2.
Open the outer enclosure door to reveal the operator
2.
interface on the control panel door.
3. On the control panel door, close the disconnect switch.
The white “CONTROL ON” and red “SYSTEM FAULT”
pilot lights should illuminate. After about 5 seconds the
“SYSTEM FAULT” pilot light should turn off.
4. The unit should now be idle in standby mode.
5. During steps E.6 to E.15, monitor the “SYSTEM FAULT”
and “HIGH TEMP LIMIT” pilot lights and verify these lights
remain of f.
6. Set the “COLD AIR MODE” selector switch to “OFF”, to set
the blower into “HOT AIR MODE”.
7. Push and hold the red “MANUAL START” button for
3 seconds.
8. Verify blower operation with illumination of the green
“BLOWER ON” and green “ H E AT ON ” pilot lights. For three
phase units verify the motor rotation is correct according
to the directional arrow on the motor fan cover or the arrow
cast into the blower housing. Interchange the supply line
conductors if correction is required.
WARNING
WARNIN G
Failure to verify correct blower rotation will cause
damage to the heater and void the warranty.
9. After waiting about 3 minutes for the unit to warm up, ensure
the air discharged from the point nozzles feels warm.
10. Set the “COLD AIR MODE” selector switch to “ON”, to set
the blower into cold air mode.
11. Verify the blower continues to run, the green “BLOWER
ON” pilot light remains illuminated and the green “HEAT O N”
pilot light turns off.
12. After waiting about 3 minutes for the unit to cool down,
ensure the air discharged from the point nozzles feels cool.
13. Push the red “MANUAL STOP” button. Verify the blower
stops and the green “BLOWER ON” and green “HEAT ON”
pilot lights are both off.
14. Ensure the aerial and ground snow sensors activate the
blower by adding snow to either sensor when it is below
40°F (4°C). The unit will automatically turn on after a period
of 10 to 30 seconds. If no snow is present use a can of
aerosol freeze spray and add water to the locations detailed
in Section H.18 Fall Maintenance.
15. Using the “COLD AIR MODE” and “REMOTE TIMEOUT
MODE” selector switches, set the blower into the desired
modes for the installation.
F. QUICK START GUIDE
1. Turn the disconnect switch to “ON” and wait a few seconds
for the red “SYSTEM FAULT” light to turn off.
2. During steps F.3 to F.6, monitor the red “SYSTEM FAULT”
and “HIGH TEMP” lights to ensure they remain off.
3. Make sure the unit does not run automatically (snow not
detected).
4. Push the star t button and verify the unit starts. The Fastrax
FEB will run for 2 hours in timed run mode unless snow
is detected.
5. To shut down the Fastrax
MODE” for a few minutes to cool the unit down.
®
FEB, switch to “COLD AIR
6. Push the manual stop button and verify that the unit stops.
Blower wheel spins in
the opposite direction of
the arrow on the blower
housing.
Weak inlet airflow or
discharge nozzle airflow
while running.
Feeder power has
a history of being
interrupted.
None of the above.
Weak inlet airflow or
discharge nozzle airflow
while running.
Ducting is not installed,
only partially installed, or
not properly sealed.
None of the above.
®
Fastrax
FEB control
settings must be changed.
The Fastrax
®
FEB power
supply lines are not
energized.
The main control
transformer primary circuit
breaker or control circuit
breaker is tripped.
The control transformer has
failed.
The smart relay is booting up.
There is a significant issue
that should be diagnosed
and resolved.
®
Fastrax
FEB's power
supply phase rotation is
reversed.
The blower inlet, ductwork,
or nozzles are obstructed
with accumulated debris.
®
Fastrax
FEB has sufferred
from one or more power
outages while running in hot
air mode.
The primary or backup high
temperature limit thermostat
is defective.
The blower inlet, ductwork,
or nozzles are obstructed
with accumulated debris.
The back pressure of blower
is insufficient.
The motor controller trip
setting is too low.
The motor has failed.
Set the Fastra x® FEB disconnect switch on the control panel
door to the "ON" position.
Ensure that the feeder supplying the Fastrax® FEB is energized
and that the rated power supply voltage is present at the
Fastrax® FEB disconnect switch line terminals.
De-energize the Fastrax
repeat the "Initial Startup/Commissioning" procedure.
If the measured voltage at the primary side of the control
transformer matches the nameplate rating but the measured
voltage at the secondary side of the control transformer is
not +/-20% 24 VAC, call the factory for a replacement control
transformer.
This behaviour is normal and does not indicate any issue with
the equipment.
See "Char t B: Troubleshooting - SYSTEM FAULT Light On".
See problem "Blower running backwards”.
De-energize the Fastrax® FEB and remove any accumulated
debris in the blower inlet, duct work and nozzles.
As long as these power outages do not occur ver y frequently,
this issue is no cause for concern. If these power outages occur
daily or more often, consider switching the Fastrax® FEB to
"COLD AIR MODE".
Call the factory for replacement high limit thermostats.
De-energize the Fastrax
debris in the blower inlet, duct work and nozzles.
Install the complete ducting package including nozzles and
ensure that there are no significant leaks in the ducting system.
Check all seals between flanges and replace gaskets as
required.
Check the motor controller trip setting dial and set it to
approximately 125% of the motor nameplate FLA. If in doubt of
the dial setting, round down to the nearest marked position.
De-energize the Fastrax
between the load side terminals of the motor contactor. If the
measured resistance is low, call the factory for a replacement
mo tor.
®
FEB, reset the circuit breaker(s) and
®
FEB and remove any accumulated
®
FEB and measure the resistance
26
Troubleshooting - General
Chart A: Troubleshooting - General
ProblemConditionProbable CauseSolution
®
Fastrax
FEB selector
switch on control panel
door is set to "COLD AIR
Fastrax® FEB control
settings must be changed.
Set the selector switch on the control panel door to "HOT AIR
MODE”.
MODE".
Cold air discharged
while running but hot
air is desired
®
FEB selector
Fastrax
switch on control panel
door is set to "HOT AIR
MODE" and "SYSTEM
FAULT" light is “OFF”.
One or more heater circuit
breakers are tripped.
Fastrax® FEB heater circuit
wiring connections are
loose.
One or more Fastrax® FEB
heater elements have failed.
De-energize the Fastrax® FEB, reset the heater circuit breakers
and repeat the "Initial Startup/Commissioning" procedure.
De-energize the Fastrax® FEB and check for loose wiring
connections in the heater element circuits.
De-energize the Fastrax® FEB and check the resistance at
each of the heater contactor load side terminals against the
Element Resistance Table - H.1 Fall Maintenance secton. If the
measured resistance is out of specification, call the factory for
replacement heating elements.
Blower wheel spins in
Blower running
backwards
the opposite direction of
the arrow on the blower
housing AND Fastrax®
FEB model is rated for 3
The Fastrax® FEB's power
supply phase rotation is
reversed.
De-energize the Fastrax® FEB and interchange two of the load
side leads at the Fastrax® FEB disconnect switch. For instance,
this interchanging can be achieved by connecting the lead
initially at T1 to T2 and connecting the lead initially at T2 to T1.
phase supply power.
De-energize the Fastrax® FEB and manually check the blower
wheel for play. If it is loose, tighten the blower wheel shaft
fastener.
Blower wheel is loose.
A blower wheel fastener has
loosened over time.
Ice or other foreign material
Excessive motor
vibration
Blower wheel is
unbalanced.
has accumulated on the
blower wheel.
Blower wheel fins are
cracked or broken.
De-energize the Fastrax
Call the factory for a replacement blower wheel.
Blower wheel spins in
Blower wheel seems fine.
the opposite direction of
the arrow on the blower
See problem "Blower running backwards”.
housing.
A motor bearing has failed.Call the factory for a replacement motor.
®
FEB and clean the blower wheel.
27
Troubleshooting - General
Smart Relay Display
Message
PRIMARY HIGH
TEMPERATURE LIMIT
TRIPPED!
COLD AIR MODE
FORCED!
PUSH START TO
RESET
BACKUP HIGH
TEMPERATURE LIMIT
TRIPPED!
Chart B: Troubleshooting - System Fault Light “ON”
ConditionProbable CauseSolution
Message shows
intermittently while
running with "HOT AIR
MODE" selected.
The primary high
temperature limit
thermostat has tripped due
to overheating.
See problem "System overheating" in Chart A:
Troubleshooting - General.
There is a poor connection
in the of primary high
temperature limit
De-energize the Fastrax
connections and tighten as needed.
thermostat or relay wiring.
De-energize the Fastrax® FEB, disconnect the primary
Message shows
permanently.
The primary high
temperature limit
thermostat or other another
related component has
failed.
thermostat quick disconnect terminals and check the
resistance between the thermostat terminals.
If the measured resistance is greater than 5 Ω, call the
factory for a replacement thermostat.
If the measured resistance is lower than 5 Ω, call the factory
for further assistance."
Message shows
permanently AND air at
discharge nozzles is cold
while running regardless
of whether "COLD AIR
MODE" or "HOT AIR
MODE" is selected.
The primary high
temperature limit
thermostat tripped more
than 10 times in one day
due to overheating.
Push the "MANUAL START" button on the control
panel door and repeat the "Initial Startup/Commissioning"
procedure.
Also, see problem “System overheating” in Chart A:
Troubleshooting - General.
De-energize the Fastrax
The backup high
temperature limit
thermostat has tripped due
to overheating.
RESET" button on the thermostat and repeat the "Initial
Startup/Commissioning" procedure.
If this message goes away after reseting but reappears
while running, see problem “System overheating” in Chart A:
Troubleshooting - General.
There is a poor connection
Message shows
permanently AND
Red "HIGH TEMP LIMIT"
light is lit.
in the of backup high
temperature limit
thermostat or relay wiring.
De-energize the Fastrax
connections and tighten as needed
De-energize the Fastrax® FEB, disconnect the backup
thermostat quick disconnect terminals and check the
resistance between the thermostat terminals.
The backup high
temperature limit
thermostat or other another
related component has
failed.
If the measured resistance is greater than 5 Ω, tr y applying
firm pressure to the "HIGH LIMIT RESET" button on the
thermostat (push hard). The thermostat should click while
being reset. If the measured resistance is still greater than 5
Ω, call the factory for a replacement thermostat.
If the measured resistance is lower than 5 Ω, call the factory
for further assistance.
®
FEB, check for loose wiring
®
FEB, push the "HIGH LIMIT
®
FEB, check for loose wiring
28
Troubleshooting - General
Smart Relay Display
Message
BLOWER MOTOR
CONTROLLER
TRIPPED!
SNOW SENSOR
CIRCUIT BREAKER
TRIPPED!
AERIAL SNOW
SENSOR BAD! PUSH
START TO RESET
AND/OR
GROUND SNOW
SENSOR BAD! PUSH
START TO RESET
HIGH TEMP LIMIT
TRIPS: ##### < TO
RESET
Smart relay status
screen showing active
input numbers in top
row, date/time in middle,
and active output
numbers in bottom row
Blank
Chart B: Troubleshooting - System Fault Light “ON”
ConditionProbable CauseSolution
De-energize the Fastrax
Message shows
permanently
The motor controller's
short circuit or overload
protection device has
tripped.
controller. If it has tripped, reset it and repeat "Initial Startup/
Commissioning" procedure.
Also, see problem "Blower motor overloaded" in Chart A:
Troubleshooting - General.
De-energize the Fastrax
Message shows
permanently.
The aerial snow sensor
circuit breaker, ground
snow sensor circuit breaker,
or both have tripped.
breakers. Repeat the "Initial Startup/Commissioning"
procedure.
If a snow sensor breaker trips again, call the factory for a
replacement snow sensor.
De-energize the Fastrax® FEB, disconnect the bad snow
sensor indicated by the message. The control panel SSA-1
Message shows
permanently AND
Fastrax® FEB does not
respond to snow on
indicated snow sensor.
The aerial or ground snow
sensor in the indicated
circuit has failed with it's
snow sensing contacts
permanently closed.
and SSA-2 terminals correspond to the aerial snow sensor
while the SSG-1 and SSG-2 terminals correspond to the
ground snow sensor.
Repeat the "Initial Startup/Commissioning" procedure. If
this message disappears and the Fastra x® FEB operates as
it should except for the disconnected snow sensor, call the
factory for replacement of the disconnected snow sensor(s).
Message shows
permanently.
Message shows
permanently.
The primary high
temperature limit
thermostat tripped at least
once since the trip count
was last cleared.
The smart relay program is
not present or not running.
See problem "System overheating" in Chart A:
Troubleshooting - General.
If the problem is resolved, push and hold the "<" button on
the smart relay to reset the trip count.
Call the factory for assistance.
Nothing displayed on
smart relay screen but
white "CONTROL ON"
The smart relay has failed.Call the factor y for a replacement smart relay.
light is lit.
®
FEB and check the motor
®
FEB and reset all snow sensor
Troubleshooting - General
29
H. ELECTRIC BLOWER SEASONAL MAINTENANCE
WARNING
WARNIN G
Disconnect heater from power supply at integral disconnect or
fuse box before opening enclosures or servicing heater.
Lock the switch in the “OFF” (open) position and tag the switch
to prevent unexpected power application.
H.1 Fall Maintenance (Before Heating Season)
Inspect all duct work, nozzles and flexible duct for internal
1.
debris and physical damage. Manually remove any
accumulation of foreign matter or obstructions from the duct
work and nozzles.
2. Replace any duct components showing signs of physical
damage or excessive corrosion.
3. Verify the electrical isolation of the two distribution duct
sections using a multimeter and checking for lack
of continuity.
4. If the unit has been placed in storage be sure to remove the
discharge blanking plate prior to attaching the flex
duct connection.
5. Ensure the disconnect switch is set to the “OFF” position
and locked out prior to inspecting the duct heater and
blower for accumulations of foreign matter, physical damage
or excessive corrosion. All deficiencies must be corrected
before the unit can be placed in service.
6. Manually turn the blower wheel to ensure it rotates freely and
there is no bearing noise from the electric motor.
7. Ensure the disconnect switch is set to the “OFF” position
and locked out. Inspect for loose, damaged or frayed wiring.
Inspect for burned or overheated connections. Replace any
damaged electrical components. Correct any deficiencies
before proceeding. Retighten all electrical connections to
the proper torque specifications listed in Section B.2 Torque
Specifications.
8. Remove the cover from the duct heater terminal box
and inspect for moisture and corrosion. If conditions are
acceptable, check all bus bar connections for proper torque
specifications listed in Section B.2 Torque Specifications.
9. Check electrical cables for proper connection to the bus bars
and ensure all fasteners are properly secured.
10. Using a multimeter, verify the resistance across the bank of
elements from the load side of the element contactor. Any
significant deviation from the element resistance table should
be investigated as this would suggest one or more elements
are open or in short circuit.
This heater should only be serviced by qualified personnel with
electrical heating equipment experience.
Install and use the heater in accordance with local codes and
this Owner’s Manual.
kWVolts Ph
20811.92.4
20833.94.8
24012.63.2
20
40/60
24035.16.5
480110 .312.9
480
60032 .140.3
48020.625.8
60032 .140.3
11. Inspect cover gasket and repair any defects prior to replacing
the electrical cover.
12. Enable line power. Using a multimeter, confirm the supply
voltage is correct and within acceptable tolerances according
to Section B.10-6.
13. Set the disconnect switch in the control panel to the “ON”
position, set the Fastrax
test for correct blower rotation by starting the blower using
the “MANUAL START” button. If motor rotation is incorrect,
reverse the phase alignment and verify correct rotation.
14. Using a current clamp, measure the current draw on the
motor and confirm it is within the Full Load Amps rating of the
motor as shown on the motor data plate.
15. During the motor run test, make note of any excessive
vibration or bearing noise.
15 .1 Address blower imbalance by replacing the blower wheel.
15.2 Address bearing failure by replacing the motor.
16. Grease the front and back bearings of the electric motor
using a grease gun and a low temperature grease such as
Arrowshell 7 or Mobile 28.
CAUTION
CAUTION
Do not over grease, 0.5 grams or 1 pump in each grease
fitting will be adequate.
Element Resistance
Min.
Resistance/Leg
20.625.8
3
®
FEB to “COLD AIR MODE” and
Max. Resistance/
Leg
30
Electric Blower Seasonal Maintenance
17. Set the Fastrax
using the “MANUAL START” button. Measure the current
draw of each phase at the main disconnect and confirm
against the specification on the unit’s data plate within +/- 5%.
®
FEB to “HOT AIR MODE” and star t the unit
18. Verify the operation of the aerial and ground snow sensors by
testing using the following procedure:
18 .1 Ensure the main disconnect is turned to the “ON” position.
Add water/snow here
Freeze spray to
cool temperature
sensor
18.2 The white “CONTROL ON” pilot light should be lit.
18.3 Switch “COLD AIR MODE” to “OFF”. Apply several
teaspoons of water to the aerial snow sensor.
18.4 Use a can of aerosol freeze spray to cool the ambient
temperature sensor.
18.5 If the aerial sensor is functioning the blower will start
within 5 seconds and the green “BLOWER ON”
and green “H E AT ON” indicators lights should be
illuminated.
18.6 Once the test is complete shut the unit down at the
main disconnect and dry the aerial sensor. Return
the disconnect to the “ON” position
18.7 Repeat the procedure for the ground sensor applying
water and freeze spray to the location shown below:
2. Manually cycle the blower motor on by pressing the red
“MANUAL START” button for 3 seconds. Check for any
unusual vibration or bearing noise. Ensure any remaining
debris is discharged from the main duct outlet. Turn off the
blower by pressing the red “MANUAL STOP” button.
3. Excessive vibration indicates the blower wheel is out of
balance and may need to be replaced. Bearing noise from the
electric motor should be addressed before the unit is returned
to service. See Section H.1-16 Fall Maintenance for motor
lubrication. If bearing noise persists replace the motor.
4. Disconnect the flexible duct from the main unit. With a
flashlight inspect the duct heater for any foreign matter or
signs of damage. Remove any accumulated debris. Any
bent, damaged or corroded heating elements must be
replaced prior to the unit being returned to service.
NOTE: Follow steps H.2-5 to H.2-8 for indoor unit storage.
Ensure that line power is turned off and locked out. Remove
5.
supply lines from the main disconnect and install a plug
1 1/4" NPT in the conduit entry to prevent the ingress of
insects and moisture into the control panel.
6. Inspect the gasket around the control panel door to ensure
there is a good moisture proof seal. Replace any damaged
gasket material prior to placing the unit into storage.
7. If the heater section is clear and in serviceable condition,
seal the discharge with a blanking plate and bolts to prevent
ingress of insects or vermin while in storage.
8. Storage in a cool dry location is recommended.
Add water/snow here
Freeze spray to
cool temperature
sensor
H.2 Spring Maintenance (After Heating Season)
1. Ensure the disconnect switch is set to the “OFF” position
and locked out.
1.1 Remove the blower intake guard. Inspect the blower
intake and wheel for any accumulations of foreign
material or blade damage. Manually remove any debris.
1.2 Inspect the blower wheel for cracks or damaged and
missing blades. If any of these conditions exist, tag the
unit as unsuitable for use and replace the blower wheel.
1.3 If the blower wheel and housing are in good condition,
replace the intake guard.
Electric Blower Seasonal Maintenance
31
I. PART ASSEMBLY DIAGRAMS
I.1 Fastrax® FEB Electric Hot Air Blower Parts List - 20 kW
9
10
17
16
3
1
4
12
5
13
6
11
8
Item #
7
1Transition Duct12917
DescriptionPart Numbers
2
14
15
20 kW
2Gasket for Transition Duct13 016
3Element BundleContact Factory
4Element Gasket13017
5Backup High Temperature Limit13 015
6Primary High Temperature Limit13014
7Blower WheelContact Factory
Motor, 240V, 1 Phase, 3HP13008
240V, 3 Phase, 3HP129 01
8
480V, 1 Phase, 3HP1300 9
480V, 3 Phase, 3HP12901
575V, 3 Phase, 3HP13010
9Aerial Snow SensorFAS1A
10Back Panel128 91
11Air Intake Side Panel, Low Profile12888
12Side Panel, Control Panel128 89
13Control Panel Access Door128 94
14Front Panel12892
15Ground Snow SensorFGSP1A
16Top Panel, Hinged128 93
Parts Assembly Diagrams
17Blower Assembly128 90
32
I.2 Fastrax® FEB Electric Hot Air Blower Parts List - 40/60 kW
17
9
10
17
11
3
16
1
4
5
2
12
13
14
6
8
7
Item #Description
15
Part Numbers
40/60 kW
1Transition Duct13018
2Gasket for Transition Duct13016
3Element BundleContact Factory
4Element Gasket130 34
5Backup High Temperature Limit13015
6Primary High Temperature Limit13 014
7Blower WheelContact Factory
480V, 3 Phase, 7.5HP130 12
8
575V, 3 Phase, 7.5HP13013
9Aerial Snow SensorFAS1A
10Back Panel13019
11Air Intake Side Panel, Low Profile130 20
12Side Panel, Control Panel130 21
13Control Panel Access Door130 22
14
Front Panel
130 23
Parts Assembly Diagrams
15Ground Snow SensorFGSP1A
16Top Panel, Hinged13024
17Blower Assembly13126
33
I.3 Control Panel Parts List
5
Customer Remote Signal
Connections
2
Supply Line Entry
10
4
13
Item #Description
1
7, 8, 9, 14
12
6
3, 15
11
Part Numbers
20 kW, 3 PH, 600V
1Smart RelayFD C-7
2Duct Heater Contactor13165
3Motor Contactor13165
4Disconnect SwitchOT63F3
5Control RelayRCP800 2 24AC
6Circuit Breaker - Control Transformer13162
7Circuit Breaker - 24V Control CircuitSU201M- C3
8Circuit Breaker - Aerial Snow SensorSU201M-C 2
9Circuit Breaker - Ground Snow SensorS U201M -C4
10Circuit Breaker - Duct Heater12085-25
11Combination Manual Motor Starter13164
12Control Transformer13170
13Auxiliary Contact - Combination Manual Motor Starter13171