Fastrax Hellfire 900 Installation, Operation & Maintenance Instructions Manual Download Page 1

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

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

IMPORTANT INSTRUCTIONS - SAVE THESE INSTRUCTIONS

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

Fastrax

is a registered trademark of Thermon Heating Systems, Inc.

ISO 9001

HELLFIRE 900

Gas Fired Railway Switch Heater

Installation, Operation, & Maintenance Instructions

Summary of Contents for Hellfire 900

Page 1: ...l instructions before installing or using the heater Please adhere to instructions published in this manual Failure to do so may be dangerous and may void certain provisions of your warranty Fastrax i...

Page 2: ...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 Reset 18 E 19 Energy Management System EMS 19 E 20 Termi...

Page 3: ...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 an...

Page 4: ...ons 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 Mise...

Page 5: ...chambre de combustion ou l entr e d air Heater can start automatically Exercise caution when in close proximity Attention le radiateur peut d marrer automatiquement Faire preuve de prudence pr s du r...

Page 6: ...s a sequential 6 digit number Installation Instruction Manual Location Voltage Label Rating Label B 2 Model and Serial Number Tag 1 The tag is located on the front and above the selector switch 2 This...

Page 7: ...mbustion chamber access panel 23 Transition duct 24 Sensor duct 25 Square to round adapter 26 Flex duct 27 Track duct deflector 28 Tie duct 29 Rail thermostat 30 Point nozzle 31 Track duct mounting br...

Page 8: ...ot 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 pressu...

Page 9: ...movement of the switch points and do not interfere with the signal system Flame rod and spark igniter Remove and visually inspect for cracks in the ceramic and evidence of soot Replace any with cracke...

Page 10: ...re is 140 F or less above ambient air temperature have burner serviced or replaced Return manifold pressure back to desired setting Air switch calibration Block air intake 80 Verify heater still opera...

Page 11: ...ovides inputs to the RCMS software 5 OFF to disable the heater toggle selector switch to OFF D 3 Start Up Sequence All Modes Once a start request is received the control sequence begins NOTE If the co...

Page 12: ...NG WARNING Do not operate above maximum manifold pressure as this can produce carbon monoxide in excess of maximum allowable of 0 08 AFCO WARNING WARNING Do not operate above or below the rated manifo...

Page 13: ...y 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 o...

Page 14: ...E 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 configure controller parameters E 4 Indications 1 On the control...

Page 15: ...losed Heated air temperature ABOVE set point Alternating High limit thermostat closed momentarily indicating air temperature exceeded set point MANUAL Manual operation On Selector switch in MANUAL pos...

Page 16: ...quested 1 Setting number equals alarm LED relay count 2 One time functions 3 The 8N1 configuration allows the heater to send status information only and is intended to aid service technicians This con...

Page 17: ...hat 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...

Page 18: ...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...

Page 19: ...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 4 2 When snow is no longer sensed...

Page 20: ...ses 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 s...

Page 21: ...o low i e 12 C 10 F Raise set point i e 3 C 37 F Precipitation detector damaged Replace detector head and or cable Precipitation detector disconnected Verify connection to panel Controller EMS ribbon...

Page 22: ...t thermal overload relay located on control panel below contactor Motor breaker open Close breaker Air switch closed when expected open Air switch jumped Air switch frozen Air switch out of calibratio...

Page 23: ...s open Handle in line with body Air in line Purge air from gas supply line No spark Inspect igniter and ignition wire Replace any damaged items fouled igniter corroded wire or cracked boot Inadequate...

Page 24: ...cated Controller LEDs POWER on ALARM red FSR ALARM alternating FSR LEDs POWER green ALARM red Marginal flame signal PILOT signal and MAIN signal occasionally dropping below 1 2 micro amps Measure flam...

Page 25: ...ble 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 larg...

Page 26: ...26 26 Figure 3 155 Clearance Figure 2 140 Clearance Installation...

Page 27: ...27 27 Figure 4 155 Clearance Turned 90 Degrees Installation...

Page 28: ...d of all connected loads CAUTION CAUTION Undersized gas piping will affect the light off reliability of any connected appliance 3 The heater is supplied with an internally mounted supply regulator and...

Page 29: ...2 Remove knockout plug For conduit larger than punch an appropriate size hole 3 Terminate power cables to terminal block and ground wire to grounding stud Installation Punch appropriate size hole for...

Page 30: ...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 1 2 Con...

Page 31: ...ostat cover to box using hardware supplied 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 com...

Page 32: ...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 in...

Page 33: ...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 2 P...

Page 34: ...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 co...

Page 35: ...ature Description Remote Start Provide dry contract rated for 24V AC 0 5 amp Run and Alarm Indication Contacts Maximum 240V AC or 24V DC 10 amp Magnetic Motor Starter Coil voltage 120V AC Motor Therma...

Page 36: ...former TB3 1 Run Indication Dry Relay Contact 2 Run Indication Dry Relay Contact 3 Alarm Indication Dry Relay Contact 4 Alarm Indication Dry Relay Contact TB4 1 Rail Thermostat 24V AC 2 24V AC 3 RTC A...

Page 37: ...37 37 Heater Specifications THERMON HEATING SYSTEMS INC H 9 SchematicsMaintenance...

Page 38: ...38 38 Heater Specifications THERMON HEATING SYSTEMS INC...

Page 39: ...39 39 Heater Specifications THERMON HEATING SYSTEMS INC...

Page 40: ...40 40 Heater Specifications THERMON HEATING SYSTEMS INC...

Page 41: ...41 41 Heater Specifications THERMON HEATING SYSTEMS INC...

Page 42: ...42 42 Heater Specifications THERMON HEATING SYSTEMS INC...

Page 43: ...chamber 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...

Page 44: ...eater 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 P...

Page 45: ...ater equipped with an automatic electronic ignition system WARNING WARNING Risk of cutting fingers or hand Disconnect fan power prior to removing combustion chamber access panel or air intake WARNING...

Page 46: ...ll 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 max...

Page 47: ...ed 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 namepl...

Page 48: ...probable maintenance of flame rod wiring pressure and burner is required J 12 Air Switch 1 To check the air switch operation while operating the unit block 80 of the air intake screens openings with...

Page 49: ...e any blockages If cracks are found replace the burner 2 Over time corrosion and or dirt restrict the burner orifice 3 Inspect burner for blocked gas orifice if 3 1 Signal strength is low even after r...

Page 50: ...CHMBR ASSY QIK RLSE Index Part No Description 13 or or or 17439 XX 01 02 03 MOT IMPLR ASSY HF900 240V AC 1PH HF900 208 230 460V AC 3PH HF900 575V AC 3PH 14 17437 02 LOCKING BAR FRONT 15 16685 LVL LEG...

Page 51: ...s list identifies the major components only Recommended spare parts highlighted red K 3 Parts Control Panel 208V Three Phase Table 22 Control Panel Parts List Index Part No Description 1 9012 0059 BUC...

Page 52: ...ed 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 0059 BUCHANAN TSB100012DS TU...

Page 53: ...89 0028 VALVE SOL PILOT GAS 1 4 NPT 50CFH 11 11700 BURNER HF900 12 11712 VENT ELBOW 13 11739 BRKT SUPPORT HF 900 BURNER 14 14978 ROD FLAME 3 L 1 4 NPT Index Part No Description 15 16952 PILOT REGULATO...

Page 54: ...54 54 NOTES...

Page 55: ...55 55 NOTES...

Page 56: ...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 r...

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