Thermon HELLFIRE 400 Installation, Operation & Maintenance Instructions Manual Download Page 1

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Part No. HF17811.Rev.4.00 January 2022 Printed in Canada

ANSI Z83.7-2017 / CSA 2.14-2017

Gas Fired Unvented Construction Heaters (Unattended Type)

HELLFIRE 400

Gas Fired Railway Switch Heater

Installation, Operation, & Maintenance Instructions

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

ISO 9001

Summary of Contents for HELLFIRE 400

Page 1: ...Installation Operation Maintenance Instructions IMPORTANT INSTRUCTIONS SAVE THESE INSTRUCTIONS Read all instructions before installing or using the heater Please adhere to instructions published in th...

Page 2: ...4 RAIL THERMOSTAT Mode Reverse 17 E 15 Failure Shutdowns and Alarm Indications 17 E 16 Indications and Conditions 17 E 17 Aggressive Retry Feature 18 E 18 Reset 18 E 19 Energy Management System EMS 19...

Page 3: ...park Ignition Control Module DSI 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 4...

Page 4: ...accordance with ANSI Z83 7 CSA 2 14 Check with local authority if you have questions about applications Cet appareil a t con u et approuv pour tre utilis comme radiateur commercial gaz aiguillage de v...

Page 5: ...ely extinguish all sources of ignition and turn off gas source Call qualified service technician to repair leak S il y a une odeur de gaz fermer imm diatement toute source d allumage et de gaz Faire r...

Page 6: ...ked label bonded to the tag and the serial number is engraved The serial number is a sequential 6 digit number The tag is located in one of two spots depending on the configuration B 2 Model and Seria...

Page 7: ...fuse burner defroster 16 Rail thermostat receptacle 17 Precipitation detector receptacle No Label 1 Track duct 2 Track duct elbow 3 Rail mounting spring clip and pad 4 Ballast retainer 5 Thermostat b...

Page 8: ...Diagram Identification No Label 1 Burner 2 Defroster 3 Flame rod 4 Igniter 5 Union 6 Manifold gas pressure gauge 7 Combination gas valve No Label 8 Gas supply pressure gauge 9 Gas supply inlet 10 Bur...

Page 9: ...t Action Condition of all ducting particularly any flex ducts Repair or replace damaged ductwork Inside of all tie duct and cross ducts Remove any blockages such as debris and mud Track duct vents Clo...

Page 10: ...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 o...

Page 11: ...ng 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 O...

Page 12: ...3 If the burner fails to light after repeated attempts it may be necessary to purge the main gas line of air 3 4 After 15 minutes of running verify the nozzle temperatures are in the range of 38 C 88...

Page 13: ...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...

Page 14: ...tch 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 configure controller parameters E 4 Indic...

Page 15: ...thermostat open for more than 10 minutes HIGH LIM High limit thermostat On Thermostat closed Heated air temperature ABOVE set point Alternating High limit thermostat closed momentarily indicating air...

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: ...e 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 Wit...

Page 18: ...ls for ignition attempts within 2 minutes 3 Between attempts the STATUS LED alternates red and green and after 20 seconds the DSI is reset as indicated by a pulse of the RES LED and the clearing of th...

Page 19: ...y 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 sense...

Page 20: ...es it senses precipitation that can be in the form of rain or snow Snow landing on the detector s heated sensing head melts to form water drops The 360 sensing surfaces detect blowing snow detect blow...

Page 21: ...Install ambient temperature sensor Raise set point above 0 C 32 F SNOW RAIN set point too low i e 12 C 10 F Raise set point i e 3 C 37 F Precipitation detector damaged Replace detector head and or ca...

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: ...urge air from gas supply line No spark Inspect igniter and ignition wire Replace any damaged items fouled igniter corroded wire or cracked boot Inadequate flame signal Inspect flame rod and wiring Rep...

Page 24: ...Heater starts and runs normally for a period of time then stops unexpectedly Alarm indicated Controller LEDs POWER on ALARM red FSR ALARM alternating DSI LED 3 flashes Marginal flame signal Signal occ...

Page 25: ...ws 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...

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

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

Page 28: ...the light off reliability of any connected appliance 3 Install dirt trap and strainer to supply inlet 4 Install a flexible gas line between the gas line riser shutoff valve and the dirt trap strainer...

Page 29: ...it larger than punch an appropriate size hole 3 Terminate power cables to terminal block and ground wire to grounding stud CAUTION CAUTION For three phase systems only verify correct fan rotation 4 Th...

Page 30: ...ably 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 s...

Page 31: ...using hardware supplied G 10 Energy Management System EMS Options 1 EMS Module applies to heaters without EMS module 1 1 The module mounts onto the DIN rail to the right of the controller in the space...

Page 32: ...rough Insert grommet and cable into hole Reinstall intake 2 6 Pass cable through hole into control panel and repeat procedure for grommet install 2 7 Remove wire through cover and route cable to a poi...

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 c...

Page 35: ...dry contract rated for 24Vac 0 5 amp Run and Alarm Indication Contacts Maximum 240Vac or 24Vdc 10 amp Magnetic Motor Starter Coil voltage 120Vac Motor Thermal Overload Protection Single phase reset l...

Page 36: ...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 24Vac 2 24Vac 24Vac 3 RTC A1 A2 24Vac 4...

Page 37: ...E RAIL TEMP SWITCH 1 2 3 4 1 2 SURGE ISOLATOR 15948 A1 A2 T1 T2 L1 L2 HIGH LIMIT CYCLING TB6 SWITCH SWITCH ALARM AIR SWITCH TB5 NEUTRAL 24V VALVE REQUEST RTC TB4 24V AC ENABLE RAIL TEMP SWITCH INDICAT...

Page 38: ...P1 SNOW SENSOR 24V AC CONNECTOR HEATER CONTROLLER GND CONNECT AT TRANSFORMER HELLFIRE 400 2014 SCHEMA 240 V 1 PHASE SNOW SENSOR UPDATED 4 NOVEMBER 2019 G REV DRAWING NUMBER SHEET 2 2 THERMON HEATING S...

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

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

Page 41: ...41 41 CCI THERMAL TECHNOLOGIES INC Heater Specifications...

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

Page 43: ...eater can start automatically Exercise caution when in close proximity WARNING WARNING Burn hazard hot surfaces Do not touch track ducts nozzles or any non insulated duct connected downstream of heate...

Page 44: ...ve impeller from motor shaft 1 Clamp the motor and anchor the impeller using a suitable bar 2 Remove the two hub set screws 3 Insert a set screw into the third previously empty hole and tighten 4 Tap...

Page 45: ...es on the bottom furthest right of terminal block 5 Reverse procedure to reinstall J SERVICE J 1 Recommended Service Schedule Item Annually Every 5 Years Inspect flame rod X Inspect flame rod wire and...

Page 46: ...ace any cracked fittings or components tighten any leaking pipe connection or disassemble reapply pipe thread sealant and reassemble J 5 Combination Gas Valve Seat Leak Test 1 Turn heater OFF 2 Verify...

Page 47: ...ith vibration levels lower than 0 20 in sec RMS at the four points depicted 2 Do not measure on covers or guards 3 Mark locations 1 2 3 and 4 on motor to ensure repeatable measurements for trend analy...

Page 48: ...et of cardboard The heater continues to operate 2 Now block 90 The DSI extinguishes the burner and indicates alarm with the FSR ALARM LED lit 3 Remove the blockage and reset the controller The heater...

Page 49: ...blockage Remove 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 l...

Page 50: ...19293 03 MOT IMPLR ASSY HF400 240VAC 1PH MOT IMPLR ASSY HF400 208 230 460VAC 3PH MOT IMPLR ASSY HF400 575VAC 3PH 12 17436 02 LOCKING BAR FRONT Index Part No Description 13 16685 LVL LEG ASSY HF900 40...

Page 51: ...CIRCUIT INTERUPTS HR METER Note This list identifies the major components only Recommended spare parts highlighted red K 3 Parts Control Panel 208V Three Phase Table 3 Control Panel Parts List Index...

Page 52: ...ommended spare parts highlighted red K 5 Parts Control Panel 460 575V Three Phase with 120V Duplex Receptacle Table 5 Control Panel Parts List Index Part No Description 1 9038 0067 SW TOGGLE DPDT ON O...

Page 53: ...CABLE ASSY FLAME ROD 22 L P NG HF400 5 16659 BRKT BURNER HF400 COMB CHMBR 6 16729 BURNER ASSY 400 KBTU HR 7 16984 DIRT TRAP GAS INTAKE 3 4 NPT C W Y STRN Index Part No Description 8 17450 VALVE GAS CO...

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

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

Page 56: ...g 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...

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