Cci thermal technologies Fastrax g series User manual

Installation & Operations Manual

G Series - Control Panel Package

FastraxTM 1.855.244.3128 Fax: 1.303.979.7350 [email protected] www.fastraxind.com

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

FastraxTM 1.855.244.3128 Fax: 1.303.979.7350 [email protected] www.fastraxind.com

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.

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: (303) 979-7339 Fax: (303) 979-7350

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 #:__________________

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

FastraxTM 1.855.244.3128 Fax: 1.303.979.7350 [email protected] www.fastraxind.com

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.

FastraxTM 1.855.244.3128 Fax: 1.303.979.7350 [email protected] www.fastraxind.com

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

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

Double Crossover No. 20 or No. 24 Switches with Frogs

FA S T R A X

R R

12C. No.14

#20 / 24

FastraxTM 1.855.244.3128 Fax: 1.303.979.7350 [email protected] www.fastraxind.com

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.