CCI Thermal Technologies Fastrax G Series User manual

Installation & Operations Manual
G Series - Control Panel Package

FastraxTM 1.855.244.3128 Fax: [phone] [email protected] www.fastraxind.com
2
Contents
Equipment Inspection
Review Equipment Paperwork................................................................................................................................ 4
Bill Of Material ....................................................................................................................................................... 4
Pick Ticket Example ............................................................................................................................................... 5
Equipment Check ................................................................................................................................................... 6
System Layout
Layout Guidelines................................................................................................................................................... 7
Single Stand Alone Switch With Frog ..................................................................................................................... 8
Crossover No. 20/24 Switches With Frogs............................................................................................................. 9
No. 9, 10 Or 11 Standard Switch Size - All Tie Styles........................................................................................... 10
No. 14, 15 Or 16 Standard Switch Size - All Tie Styles ........................................................................................ 11
No. 20 / 24 Standard Switch Size - All Tie Styles ................................................................................................. 12
Spring Frog & Movable Point Frog Heating Layout .............................................................................................. 13
Control Panel Installation
Assembling Fastrax®FCSA Panel Support Structure........................................................................................... 14
Installing Fastrax®FCSA Panel ............................................................................................................................ 15
Installing Wire Conduit Raceway To Panel........................................................................................................... 15
Installing Fastrax®Aerial Snow Sensor & Support Mast....................................................................................... 16
Junction Box Installation
Junction Box Placement ....................................................................................................................................... 17
Direct Burial Cable & Conduit Trenching .............................................................................................................. 17
Direct Burial Cable , Conduit & Junction Box Installation ..................................................................................... 18
SwitchBlade®Heater Installation
SwitchBlade®Heaters (Field Side Running Rail) Switches Up To No. 16 ............................................................ 19
SwitchBlade®Heaters (Field Side Running Rail) Switches No. 20 - 24................................................................ 21
Heater Power Wire To Junction Box..................................................................................................................... 22
SwitchBlade®Heater(s) For Gauge Side Of The Moving Rail .............................................................................. 23
SwitchBlade®Heater(s) For Spring Frog (Spring Frog Channel Style)................................................................. 24
SwitchBlade® Heater(s) For Spring Frog (Retrot Style) ...................................................................................... 25
Movable Point Frog - Switches No. 20 - 24 .......................................................................................................... 26
Crib Heater Installation
All Switch & Frog Systems.................................................................................................................................... 27
System Wiring
Control Panel Wiring............................................................................................................................................. 28
Control Panel Disconnect Feeder Wiring - Stand Alone/Extension Panels .......................................................... 28
Control Panel SwitchBlade®Heater Wiring - Stand Alone/Extension Panels Only............................................... 29
Master Control Wiring........................................................................................................................................... 29
FAS1A Aerial Snow Sensor Wiring ....................................................................................................................... 30
FGSP1A Ground Level Sensor Wiring At Panel ................................................................................................... 30

CCI Thermal Technologies Inc. 3
System Wiring Diagrams
Stand Alone Control Panel Wiring Diagram (1) No. 9, 10, Or 11 Switch & Spring Frog Heating System............. 31
Stand Alone Control Panel Wiring Diagram (2) No. 9, 10, Or 11 Switch & Spring Frog Heating System ............ 32
Stand Alone Control Panel Wiring Diagram (1) No. 14, 15, Or 16 Switch & Spring Frog Heating System .......... 33
Stand Alone Control Panel Wiring Diagram (1) No. 20 Or 24 Switch & Spring Frog Heating System ................. 34
Stand Alone Control Panel Wiring Diagram (1) No. 20 Or 24 Switch & Movable Point Frog Heating System .... 35
Master Control Panel Wiring Diagram Up To (4) Fastrax®Extension Panels ....................................................... 36
Extension Control Panel Wiring Diagram (1) No. 20 Or 24 Switch & Movable Point Frog Heating System ....... 37
Master Control Panel Wiring Diagram Up To (8) Fastrax®Extension Panels ....................................................... 38
Extension Control Panel Wiring Diagram (1) No. 9, 10, Or 11 Switch & Spring Frog Heating System ............... 40
Extension Control Panel Wiring Diagram (2) No. 9, 10, Or 11 Switch & Spring Frog Heating System ............... 41
Extension Control Panel Wiring Diagram (1) No. 14, 15, Or 16 Switch & Spring Frog Heating System .............. 42
Extension Control Panel Wiring Diagram (1) No. 20 Or 24 Switch & Movable Point Frog Heating System ........ 43
Junction Box Connections .................................................................................................................................... 44
Junction Box Heater Connections ........................................................................................................................ 45
FGSP1A Ground Snow Sensor Wiring At FJAM200SUP Junction Box................................................................ 48
Control Panel General Equipment Procedures
Master & Stand Alone Panel FDC-6/FDC-7 Adjustment Instructions ................................................................... 55
Stand Alone Control Panel (Automatic Operation) ............................................................................................... 55
Stand Alone Control Panel (Manual Operation).................................................................................................... 56
Additional Features Stand Alone Control Panel.................................................................................................... 56
Master/Extension Control Panels (Automatic Operation) ..................................................................................... 57
Master/Extension Control Panels (Manual Operation) ......................................................................................... 57
Additional Features Master/Extension Control Panel .......................................................................................... 58
Options Available For The Master/Extension Control Panel ................................................................................ 58
Maintenance ......................................................................................................................................................... 58
SwitchBlade®Heating........................................................................................................................................... 59
Spring Frog Heating............................................................................................................................................. 59
Movable Point Frog Heating ............................................................................................................................. 60
Procedures
General Operation ................................................................................................................................................ 60
Installation Procedure........................................................................................................................................... 60
Maintenance Procedure........................................................................................................................................ 61

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A. EQUIPMENT INSPECTION
A.1 REVIEW EQUIPMENT PAPERWORK
1. Identify the switch and frog sizes to be heated on your
project.
2. Ensure that the Pick Ticket (list of Fastrax®heating
equipment and accessories) provided with the
shipment, matches the items listed on the complete
Bill of Material for your project.
3. Notify your supervisor, purchasing department or
Fastrax®of any missing or damaged parts.
A.2 BILL OF MATERIAL
Table A.2-1 provides the scope of Bill of Materials
available for standard switch and frog layouts and parts
packages. A custom Bill of Material for special layouts
is also available. A copy of the Bill of Material can be
acquired by contacting your supervisor or CCI Thermal
Fastrax®.
Table A.2-2 details a sample Bill of Material listing, refer to
your company Bill of Material for exact system parts.
Table A.2-1 - Bill of Material by Standard Application
SWITCH TYPE BILL OF MATERIAL - APPLICATION
No. 9 No. 10 No. 11
  -Power Operated Turnout
  - Power Operated Turnout with Spring Rail Frog
   Spring Rail Frog
- - Power Operated Turnout
- - Power Operated Turnout with Spring Rail Frog
No. 14 No. 15 No. 16
   Power Operated Turnout
   Power Operated Turnout with Spring Rail Frog
   Spring Rail Frog
No. 20 No. 24
  Power Operated Turnout
  Power Operated Turnout with Spring Rail Frog
  Spring Rail Frog
  Power Operated Turnout with Power Operated Movable
Point Frog
No. 30
Power Operated Turnout with Power Operated Movable Point Frog
Automatic Gas Snow Control Package
Platform Heating Package
Scanner and Dragging Equipment Detection Heating Package
Table A.2-2 - Bill of Material Example
(2) No. 20 / 24 Power Operated Turnout with (2) Power Operated Movable Point Frog
Hollow Metal Ties
Master Control with Extension Panels
Quantity
Required Fastrax®Part No. Description
1 FCM4 Fastrax®Master Control Panel - Controls maximum of 4 Extension panels. Minimum 10 AMP, 120V, 1-phase
required. Enclosure size: 36” H X 30” W X 10” D.
2 GDSM1-12148200
Fastrax®Extension Combination Switch & Movable Point Frog Control Panel - Controls heaters for (1) No. 20
switch with crib and moving rail heaters and (1) No. 20 movable point frog. 48 kW maximum capacity, 200 Amps,
240V, 1-phase disconnect. Enclosure size: 36” H X 30” W X 10” D.
3 FCSA3630U Fastrax®Control Panel Support Assembly - 36” H X 30” W overall panel size. 4” square vertical support risers.
Includes (2) 4” PVC raceways.
8 FSR32420 Fastrax®SwitchBlade®Rail Heater - 5,800W total, 240V. 300W per foot of active heater length. 20 ft overall
length. (11) FRB600 Spring tension clamp kits included. No drilling required.
4 FSE32408 Fastrax®SwitchBlade®Rail Heater - 2,200W total, 240V. 300W per foot of active heater length. 8 ft overall
length. (5) XTC-0193 Anchor spring tension clamp kits included. No drilling required.
12 FCH152409 Fastrax®Crib Heater Assembly - 1,350W total, 240V. 150W per foot of platform length. 8 ft L X 8” W X 2-1/2” H.
Includes (4) jack-bolt clamps.
4 FSM32412 Fastrax®SwitchBlade®Heater for Movable Point Frog - 3,400W total, 240V. 300W per foot of active heater length.
12 ft overall length.
8 FSM42403 Fastrax®SwitchBlade®Heater for Movable Point Frog - 750W total, 240V. 400W per foot of active heater length.
2 ft 9” overall length.
5 FJA200SU Fastrax®Junction Box Assembly
1 FJAM200SUP Fastrax®Junction Box with Snow Sensor Assembly
1 FA2032 Fastrax® Installation Kit - Includes entrance glands, insulated connector blocks, liquid tight extra exible protective
conduit, exible conduit connectors, stainless steel hose clamps, wire markers, test and tool accessories.

CCI Thermal Technologies Inc. 5
A.3 PICK TICKET EXAMPLE
The Pick Ticket is included with the Fastrax®product shipment. The following sample Pick Ticket details the list of
Fastrax®products in a shipment. Please compare the Pick Ticket with the items listed on the Bill of Material to be sure you
have all required parts for your project.
Note: The Pick Ticket may not be available if the shipment was warehoused prior to project site delivery.
1
TermsOrder Date Comments
#20/24 Crossover w/ MPF and HST NET 30
Salesperson
FASTRAX
FOB
Call for more information
Special Instructions
BEST WAY
Ship Via
09/21/2005
Required
Class 1 Railroad Company Class 1 Railroad Company
Description
Bill To: Ship To:
Special Order Drop Ship
Item#
From Our Order#Date Required
123456
00001063
ContactCustomer ID
TelephoneCustomer PO
Anywhere, USA, Anywhere,
1500 W. Campus Drive
Littleton, CO 80120
Phone: [phone] Fax: [phone]
09/30/2005 003378
Facsimilie
Shipped
Bin Location
UOM
Pick Ticket# 003378
John Doe
1 Master Control Panel - Maximum 4 SlavesFCM4
NONE Fastrax Master Control Panel.
Control maximum of 4 Extension panels of any size.
Minimum 10 Amp 120 Volt 1-phase required.
Enclosure size: 36"H X 30"W X10"D.
Panel Serial #:__________________
A
erial Sensor Serial:_____________
_
EACH
2 Extension Panel-Combo. Switch & MP FrogGDSM1-12148200
NONE Fastrax Extension Control Panel.
Combination Switch and Moveable Point Frog Heater
Control Panel.
1 Switch and 1 Moveable Point Frog.
48KW maximum capacity.
200 Amp 240 Volt 1-phase disconnect
Control 2 switch heaters, 1 movable point frog heater,
4 FCH152409 crib heaters.
Enclosure size: 36"H X 30"W X10"D.
EACH
3 Fastrax
®
Panel Support StructureFCSA3630U
NONE Fastrax
®
control panel support structure assembly
36 Inch high X 30 inch wide overall panel size
4 inch square vertical support risers.
Includes (2) 4" PVC protective raceway assemblies.
EACH
8 Fastrax
®
SwitchBlade
®
Rail HeaterFSR32420
NONE Fastrax
®
SwitchBlade
®
Rail Heater -
5,800W total, 240V. 300W per foot of
active heater length. 20 ft overall length.
(11) FRB600 Spring tension clamp
kits included. No drilling required.
EACH
1 of 3Page #09/21/2005Date Printed
Packed By Total Weight# of CartonsChecked ByPulled By

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A.4 EQUIPMENT CHECK
Note: Notify your supervisor, purchasing department or
Fastrax®of any missing or damaged parts.
1.0 Control Panel:
1. Using a Phillips screwdriver or Phillips driver head
and power drill, remove top and sides of panel crate.
Note: Inside each stand alone or master control panel
crate there is one FAS1A Aerial Snow Sensor located
in a box. Keep the sensor in a safe place until the panel
support and panel installation are complete.
2. Using a socket wrench, remove lag bolts from the
crate.
3. Open the panel and check that the nameplate
information matches the Bill of Material list.
2.0 Control Panel Support:
1. Using a Phillips screwdriver, remove top and sides of
panel support assembly crate.
2. Ensure that each panel support size matches the
corresponding panel size.
3.0 Heating Equipment:
Figure A.4.1 - Typical Packaging
1. Unpack each heater at the project site, prior to
installation.
2. Ensure the correct voltage is marked on each heater
for your project.
3. Ensure the part number on each heater matches the
Bill of Material for your project (refer to page 4 - A.2-1
Bill of Material and Figure A.2.2).

CCI Thermal Technologies Inc. 7
Figure A.4.2 - Heater part number and voltage
4. Test each heater using the 500 Volt DC scale on a
standard meg ohm meter.
a) Connect one lead of the meg ohm meter to the
metal jacket of the heater and the insulation
resistance should read at least 20 meg ohms from
conductor to outer meter jacket (refer to Figure
A.4.3). Do not come into contact with heater while
performing the meg ohm test.
Figure A.4.3 - Meg Ohms Reading
Note: If any heater does not reach 20 meg ohms,
contact Fastrax®and do not install the heater.
b) Using a standard ohm meter, connect each lead
from the ohm meter to each heater lead (see
Figure A.4.4).
Figure A.4.4 - Standard Ohms Reading
c) Record the ohm readings for each heater on the
“System Checkout” sheet located at the back of
the manual.
4.0 Junction Box Assembly:
Ensure that each junction box has a corresponding
support pedestal.
5.0 Installation Accessories:
Unpack the installation accessory kit and check that the
contents matches the description on the Pick Ticket.
B. SYSTEM LAYOUT
B.1 LAYOUT GUIDELINES
1. Prior to installation of any of Fastrax®equipment, mark
or tag the location for product installation.
2. Locate equipment for each switch or frog.
3. Place the equipment near the location but out of the way
of cable or conduit trenching and general construction.
Note: For systems that are not standard sizes or
grouping of equipment as covered in this manual or
in Bill of Material, please contact Fastrax®or your
company system standards for assistance.
Note: Typical layouts are not to scale and are to be
used for general positioning of equipment only. Review
your company standards for exact equipment layout.

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B.2 SINGLE STAND ALONE SWITCH WITH FROG
No. 9 - No. 11 Switch and Frog
No. 14 - No. 16 Switch and Frog
No. 20/24 Switch and Frog
FA S T R A X
R R
R
TYPICAL OVERALL LAYOUT FOR SINGLE SWITCH WITH FROG
NO. 20 OR 24 STANDARD SWITCH AND FROG - ALL TIE STYLES
12C. No.14
#20 / 24
®
®

CCI Thermal Technologies Inc. 9
B.3 CROSSOVER NO. 20/24 SWITCHES WITH FROGS
Single Crossover No. 20 or No. 24 Switches with Frogs
FA S T R A X
R R
R
Double Crossover No. 20 or No. 24 Switches with Frogs
FA S T R A X
R R
R
12C. No.14
#20 / 24
®
®

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10
B.4 NO. 9, 10 OR 11 STANDARD SWITCH SIZE - ALL TIE STYLES
Typical layouts are not to scale and are to be used for general positioning of equipment only. Review your company standards for exact equipment layout.
TYPICAL SYSTEM LAYOUT - EQUIPMENT DETAIL
NO. 9, 10, OR 11 STANDARD SWITCH SIZE - ALL TIE STYLES
Fastrax®FJA or FJAM
Junction Box
Fastrax®Stand Alone or Extension
Control Panel
Fastrax®Ground Snow Sensor
at each Switch or
Switch Heated Frog Location
Fastrax®Crib Heaters
Fastrax®SwitchBlade®Heaters

CCI Thermal Technologies Inc. 11
B.5 NO. 14, 15 OR 16 STANDARD SWITCH SIZE - ALL TIE STYLES
Typical layouts are not to scale and are to be used for general positioning of equipment only. Review your company standards for exact equipment layout.
TYPICAL SYSTEM LAYOUT - EQUIPMENT DETAIL
NO. 14, 15, or 16 STANDARD SWITCH SIZE - ALL TIE STYLES
Fastrax®FJA or FJAM
Junction Box
Fastrax®Stand Alone or Extension
Control Panel
Fastrax®Ground Snow Sensor
at each Switch or
Switch Heated Frog Location
Fastrax®Crib Heaters
Fastrax®SwitchBlade®Heaters

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12
B.6 NO. 20 / 24 STANDARD SWITCH SIZE - ALL TIE STYLES
Typical layouts are not to scale and are to be used for general positioning of equipment only. Review your company standards for exact equipment layout.
TYPICAL SYSTEM LAYOUT - EQUIPMENT DETAIL
NO. 20 / 24 STANDARD SWITCH SIZE - ALL TIE STYLES
®
Fastrax
®
FJA or FJAM
Junction Box Fastrax
®
FJA Junction Box
Fastrax
®
Stand Alone
Control Panel
Fastrax
®
Ground Snow Sensor
at each Switch
Fastrax
®
Crib Heaters
Fastrax
®
SwitchBlade
®
Heaters
Fastrax
®
SwitchBlade
®
Heaters

CCI Thermal Technologies Inc. 13
B.7 SPRING FROG AND MOVABLE POINT FROG HEATING LAYOUT
Typical layouts are not to scale and are to be used for general positioning of equipment only. Review your company
standards for exact equipment layout.
Spring Rail Frog Heating Layout
Toe of Frog
To Fastrax®Control Panel
Heel of Frog
Fastrax®Junction Box
Fastrax®SwitchBlade®Heater
Inserted in milled slot or clamped
to D-Bar of the Spring Rail Frog
Movable Point Frog Heating Layout
Typical Moveable Point Frog Layout - Equipment Detail
No. 20 / 24 Standard Size - All Tie Styles
Fastrax®SwitchBlade®Heaters on Frog Point Plates
Fastrax®SwitchBlade®Heaters on Frog Wing Rails
Fastrax®Crib Heaters
Fastrax®Junction Box
with Ground Snow Sensor
To Fastrax®Control Panel

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14
C. CONTROL PANEL INSTALLATION
C.1 ASSEMBLING FASTRAX®FCSA PANEL
SUPPORT STRUCTURE
SUPPORT STRUCTURE COMPONENTS:
• 2 - 4” X 4” X 10’ Bronze Powder-coated
Support Posts
• 1 - Upper Support Channel
• 1 - Lower Support Channel
• 2 - 4” Raceways
• Channel Nut Bolt Assembly - (9) 3/8” Channel
Nuts, (9) 3/8” X 1 1/2” Bolts, (9) Split Washers,
(18) Stanless Steel Flat Washers
1. Place the support posts where the control panel will be
installed with the unistrut channel facing up.
Figure C.1.1 - Unistrut channel position
2. Place the control panel on top of the unistrut channels
at the 11” mark.
Figure C.1.2 - Control panel positioning
3. Slide one of the 3/8” channel nuts above and below
the four control panel mounting holes. Use one 3/8” x 1
1/2” bolt and place one split washer and two stainless
steel at washers onto the bolt and fasten through
each of the four control panel mounting holes and into
the spring channel nuts and tighten.
Figure C.1.3 - Nut and bolt positioning
4. Mount the upper support channel (this piece has a
1/2” conduit clamp attached to the back) at the 2” mark
from the top of the post with the channel nut and bolt
assembly.
Figure C.1.4 - Upper support channel positioning
5. a) Measure 20” below the base of the control panel.
b) Mount the lower support channel with the channel
nut and bolt assembly.
Figure C.1.5 - (a) Figure C.1.6 - (b)

CCI Thermal Technologies Inc. 15
C.2 INSTALLING FASTRAX®FCSA PANEL
Note: For system operation and maintenance, see
Reference Material pages 31 - 48.
1. Mark where the two, 10 ft support posts will be placed
in the ground.
2. Install two, 12” sonotubes.
3. Set panel support posts in the sonotubes and adjust
so that the channel support is 6 ft above ground level.
Note: For panels 4 ft or higher, place the top channel
7 ft above ground level.
4. Using temporary supports, level the panel support
structure.
5. Pour concrete around the panel support posts, lling
the sonotubes to ground level.
6. Allow concrete to cure completely.
7. Remove temporary supports.
C.3 INSTALLING WIRE CONDUIT RACEWAY TO
PANEL
1.0 If Panel is Pre-punched for Conduit:
1. Trench below each punched hole to bury the conduit
2 ft below nished grade. Temporarily support the
panel if necessary.
Note: Be careful not to weaken the panel support when
trenching and installing conduit/underground cables.
2.0 If PVC Conduit is provided:
1. Two, 4” conduits are provided. One conduit is for
the direct burial conductors coming from the switch
and frog junction boxes. The other conduit is for the
panel feeder wires coming from the service fused
disconnect switch.
2. Install 4” PVC conduits for protecting direct burial
wiring where the wire leaves the ground and enters
the panel.
3.0 If PVC Conduit is Directly Connected From
the Control Panel to the Junction Box or
Service Equipment:
1. Only use materials approved by UL, CSA or FM third
party test agencies. Install a minimum of 2” trade size
conduit to each junction box or service equipment.
2. Locate and mark the holes needed for the conduit by
holding a piece of the conduit vertically level with the
panel support and against the bottom conduit support
channel. Cut proper size conduit openings in the
bottom of the control panel.
3. Only install the conduits at the bottom of the control
panel. Use proper ttings with locknuts and plastic or
metal bushings to protect conductors.
4. Clamp conduit to the lower support channel with the
provided clamp.

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16
C.4 INSTALLING FASTRAX®AERIAL SNOW SENSOR
& SUPPORT MAST
Note: If constructing your own support mast, please
contact Fastrax®.
1. The aerial snow sensor support mast comes pre-
assembled and packaged with the control panel
support structure.
2. Loosely hold the mast in position with the one-hole
strap pre-installed on the back of the panel support
channel.
3. Locate, mark and cut the preferred location for the 1/2”
tting to enter the bottom of the control panel.
4. Using the 1/2” opening in the panel bottom, install the
tting, if provided.
5. Thread the wire attached to the FAS1A snow sensor
through the 1/2” conduit support mast, through each
elbow and into the panel.
6. Without twisting the snow sensor wire pull the wire
snug so the 1/2” union provided with the snow sensor
mates with the 1/2” conduit mast.
7. Tighten the 1/2” union with snow sensor in place.
8. Leave excess wire inside the panel until system is
wired.

CCI Thermal Technologies Inc. 17
D. JUNCTION BOX INSTALLATION
D.1 JUNCTION BOX PLACEMENT
1. Loosely assemble each junction box to the support
pedestal.
2. Place each junction box assembly near the area of
installation. Refer to the System Layout section of this
manual, to ensure each junction box is placed in the
correct location.
Note: There are various types of junction boxes, refer
to Figures D.1.1 - D.1.4, for product description.
Note: Always place the junction box in an area that
provides good drainage. Excess water can enter the
box causing ground fault tripping.
Figure D.1.1 - FJA200SUP Junction Box
Figure D.1.2 - FJAM200SUP Junction Box with FGSP1A Ground Snow
Sensor
Figure D.1.3 - Conduit Junction Box
Figure D.1.4 - Direct Burial Cable Junction Box
Note: Follow Railroad guidelines and specifications for
trenching to prevent damage to existing buried lines.
Always locate and mark existing cables before digging.
3. For the placement of the junction box support pedestal,
dig a trench a minimum of 1 ft in diameter and 2 ft
below grade.
4. Adjust the depth of the hole to position the junction
box above the nished grade. We recommend that
the bottom of the junction box extend a minimum of 2”
above the nished grade.
D.2 DIRECT BURIAL CABLE AND CONDUIT
TRENCHING
Note: Follow Railroad guidelines and specifications for
trenching to prevent damage to existing buried lines.
Always locate existing cables before digging.
1. For direct burial cable or conduit raceways, dig a trench
a minimum of 2 ft below grade.
Figure D.1.5 - Trenching
2. Bury direct burial cables or conduit a minimum of 2 ft
below grade unless otherwise outlined by Railroad or
National Electrical Code standards.

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D.3 DIRECT BURIAL CABLE , CONDUIT AND
JUNCTION BOX INSTALLATION
1. Unscrew the four support ange bolts attached to the
junction box from the support pedestal.
Figure D.1.6 - Support Flange Bolts
2. Install direct burial cable or conduit from the junction
box to the control panel and position it for the nished
location and height of the junction box.
Figure D.1.7 - Direct Burial Cable Junction Box
Note: For direct burial cables, use the glands provided
in the accessory kit to properly terminate the cable for
entry into the junction box.
Note: For customer provided conduit, prepare and
terminate the conduit into the junction box with
approved fittings such as terminal adaptors.
3. After the cables or conduits are in the junction box,
replace the four support ange bolts and fasten the
box in place.
4. Fill in trench, leaving an area around the junction box
clear for easier heater lead installation.
Figure D.1.8 - Junction Box Installed

CCI Thermal Technologies Inc. 19
E. SWITCHBLADE®HEATER INSTALLATION
E.1 SWITCHBLADE®HEATERS (FIELD SIDE
RUNNING RAIL) SWITCHES UP TO NO. 16
1. Locate the SwitchBlade®heater(s) for the running rail.
Check that the proper voltage and length heater is
placed near the installation location.
2. Uncoil the heaters, being careful not to bend or kink
the heaters.
3. Place one heater on the eld side of the rail and
through the openings in the rail braces on one rail
only.
1. Position the heater end where the lead wire enters
the round metal area approximately 2 ft in front of
the switch point. (Up to 4 ft in front of the switch
point is acceptable if necessary).
2. Position the heater so a spring base style rail clamp
can be installed about 10” from where the lead wire
enters the heater, just beyond the heater o󰀨set.
3. Position the heater so a clamp can be placed at the
‘dead end’ of the heater.
Figure E.1.1 - Heater Installed with FRB600 spring rail clamp
Note: Allow proper clearance for heater to move freely.
4. Mark the rail where clamps are to be installed. Heaters
should be clamped about every 2 ft. A common rule of
thumb is to clamp each heater in every crib space. It
is acceptable to space the clamps a bit further apart
when necessary to avoid obstructions.
5. After marking the rail for clamps, mark the other
running rail in the same locations.
6. Locate Model FRB600 spring rail clamps (Step 7.6 on
opposite page) and install on the rail by hand.
7. Important: The spring clamp body female thread
is left handed. Turn swivel screw to the left or
counter-clockwise to reinstall the spring body. When
completely on, the spring clamp will travel freely on
the swivel screw head so it can align with the heater
position.
8. When tightening the spring clamp on to the heater
apply gentle pressure on the spring clamp body
toward the swivel head screw so the left handed
treads do not catch or bind.
Note: The spring base rail clamp should be installed
and removed by hand. Do not use a sledge hammer
or other tools to install the clamp. The clamp body can
be removed by backing the screw out all the way and
pushing rmly on the top of the clamp body towards
the rail.

FastraxTM 1.855.244.3128 Fax: [phone] [email protected] www.fastraxind.com
20
1. Place clamp on eld side of rail
base with swivel screw backed
completely out.
2. Push the bottom of the clamp
body rmly until it clicks into place
on the base of the rail. (Note:
pushing on the top of the clamp
will prevent it from seating on the
rail).
3. The end of the clamp body will
wrap around the gage side of the
rail when seated properly.
4. Tighten each clamp by turning the
swivel screw with an Allen wrench
until the spring clamp U shaped
edges surround the heater and are
snug against the rail.
5. Tighten the keps nut. 6. Tie o󰀨 the tow hook at the heater
‘dead end’ with the stainless steel
wire tie provided with the spring
base clamp kits.
9. Leave swivel screw and spring clip backed away from rail and slide heater in place.