RECO 922 User manual

OPERATING MANUAL
MODEL 922 SWITCH HEATER CONTROL
230VAC/460VAC
MANUFACTURED
BY
RAILWAY EQUIPMENT COMPANY
525 9th STREET SOUTH
DELANO, MINNESOTA 55328
TEL. [phone]
FAX. [phone]
E-Mail: [e-mail]

(THIS PAGE IS INTENTIONALLY LEFT BLANK)

P/N R9220-0103D
Rev. F
© 2021 RAILWAY EQUIPMENT CO.
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Table of Contents
1. Warnings, Cautions, and Notes ............................................................................................... 1
2. Part Number Description......................................................................................................... 2
3. Customer Connections............................................................................................................. 3
3.1. Incoming AC.................................................................................................................... 3
3.2. Control.............................................................................................................................. 4
3.3. Indication.......................................................................................................................... 4
3.4. Heater Fault Resistors ...................................................................................................... 4
3.5. Heaters.............................................................................................................................. 5
3.6. Fault Indication Light....................................................................................................... 9
3.7. Temperature Sensor.......................................................................................................... 9
3.8. Optional Snow Detector................................................................................................... 9
3.9. Optional Rail Temperature Sensor................................................................................... 9
4. Control Module...................................................................................................................... 10
4.1. Description..................................................................................................................... 10
4.2. Set-Up and Adjustments................................................................................................. 11
4.3. Password 0 and 5 Menus................................................................................................ 12
4.4. Push Buttons and LED Status Indication Lights............................................................ 20
4.5. Master Connections........................................................................................................ 23
4.6. Operation........................................................................................................................ 25
4.6.1. Wave Mode Operation................................................................................................ 26
4.7. Fault Conditions............................................................................................................. 27
5. Output Module....................................................................................................................... 30
5.1. Description..................................................................................................................... 30
5.2. Set-Up and Adjustments................................................................................................. 30
5.3. LED Status Indication Lights......................................................................................... 31
5.4. Output Circuit Board Connections................................................................................. 32
5.5. Operation........................................................................................................................ 33
6. Troubleshooting..................................................................................................................... 34
6.1. Heater are not on when they should be.......................................................................... 34

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6.2. Control Module Does NOT Turn On............................................................................. 34
7. Specifications......................................................................................................................... 35
8. Drawings................................................................................................................................ 36
9. Limited Warranty .................................................................................................................. 37

P/N R9220-0103D
Rev. F
© 2021 RAILWAY EQUIPMENT CO.
Page 1
1. Warnings, Cautions, and Notes
Please read this manual completely before attempting to install, operate or service the model
922 Switch Heater Control System.
Read the information in the table below. Failure to observe the warnings and cautions can
lead to equipment damage or personal injury.
Symbol Description
WARNING indicates a potentially hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTION indicates a potentially hazardous situation which, if not avoided, may result
in minor or moderate personal injury. It may also be used to alert against unsafe
practices.
NOTE NOTE indicates explanatory information that applies to the next step in the procedure. It
is used to clarify and expand upon the importance of the procedural step when needed.
WARNING: THE MODEL 922 SWITCH HEATER CONTROL SYSTEM
OPERATES ON HIGH VOLTAGE LEVELS. CONTACT WITH
ELECTRICITY CAN BE HAZARDOUS, CAUSING SHOCK, BURNS, AND
DEATH.
WARNING: HIGH LEAKAGE CURRENT. EARTH CONNECTION IS
ESSENTIAL BEFORE CONNECTING SUPPLY.
WARNING: HEATER FAULT IS NOT FOR PERSONAL PROTECTION.
CAUTION: NUMEROUS COMPONENTS WITHIN THE CONTROL
SYSTEM ARE ELECTRICALLY “HOT”. BE AWARE WHEN WORKING IN
AND AROUND THIS SYSTEM.
CAUTION: THIS CONTROL SYSTEM CAN BE OPERATED REMOTELY
OR BY SNOW DETECTOR. THEREFORE, OPERATION MAY BEGIN
UNEXPECTEDLY.

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2. Part Number Description

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L2
L1
L3
Three Phase Wye
Figure 1
Single-Phase
Center Tap
Figure 2
Single-Phase
480VAC
Figure 3
Three-Phase
Delta
Figure 4
L2
L1
L3
3. Customer Connections
3.1. Incoming AC
The incoming power, 460VAC/230VAC, 60Hz, 1 or 3 phase,
should be connected directly to the main circuit breaker. The
neutral should be connected to the ground lug located to the
right of the circuit breaker. An earth ground should also be
connected to the neutral bus bar.
NOTE: On some models, an adjustable main circuit breaker is
factory-adjusted for the load of each specific panel. The panel
nameplate will show what setting the circuit breaker is set for.
Refer to print 9224-5413, in the back of this manual, for the
various adjustments, in the event that changes are made to the
panel.
NOTE: The heater fault detection will only work properly if
the incoming power to the main panel is single-phase with a
center tap or three-phase Y. This is because, to detect a heater
fault, a return path through earth ground is necessary. Refer to
figure 1 and 2.
The system will not work properly if the input power is single
phase 460VAC without a center tap. Single-phase 460VAC
can be used only if the control panel for the heaters is made by
Railway Equipment and an additional jumper is used on the
panel (refer to figure 3, and print 9224-5413 Note 1).
NOTE: The ground fault detection circuit will not work with a
Three-Phase Delta, Figure 4. We do not recommend using a
Three-Phase Delta.

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3.2. Control
The system can be turned on by providing a circuit closure across terminals 1 and 2 on TB2.
3.3. Indication
NOTE: Refer to print 9224-5413 for all indication connections.
A 115VAC indication signal can be obtained from terminals 3 and 6 on TB2 by placing a
circuit closure between terminals 4 and 5 on TB2. This will provide 120VAC from terminals
3 and 6 on TB2, with terminal 3 “hot” and terminal 6 “neutral”. The electrical rating of this
contact is 2 amps @ 125VAC. A “dry” contact indication can be obtained between terminals
3 and 4 by removing the circuit closure across 4 and 5.
The 115VAC can be changed to 24VDC by removing the jumper from TB2-4 and TB2-5 and
adding the jumper between TB2-2 and TB2-3. The 24VDC indication will be between TB2-4
and TB2-9.
3.4. Heater Fault Resistors
A hard-wired connection should be made from each rail (at the switch) to a 100 ohm 40-watt
resistor (customer provided), and then to a good earth ground. This will ensure that there is
an electrical path from each rail to ground. This will allow the heater fault detection system
to function while maintaining isolation between the rails (refer to figure 5).
100 OHM
100 OHM
40 W
40 W
Figure 5

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3.5. Heaters
The heaters are connected to the three circuit breakers at the bottom of each output section.
First, you will need to remove the two bolts holding the terminal cover on.
Once removed, you then can access the circuit breakers to connect the heater’s wires to the
circuit breakers. Insert the pair of wires for each heater into the breakers and tighten down
the screw to secure them.
NOTE: Do not mix the heater wires to the different circuit breakers.
Pan Heater Wires
Rail 1 Wires
Rail 2 Wires

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Pan Heater Bracket Installation:
Pan Heaters may come with mounting brackets, lag bolts, and washers. Install mounting bracket
as shown below:
914130 SUPPORT BRACKET
Attach each bracket according to the picture below. Use at least two 2 lag bolts with washers to
ensure proper bracket stability.

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Pan Heater Wiring:
The Pan Heaters need to be wired back to the optionally supplied junction box, and then user
supplied wire is connected at the junction box back to the control panel. From the junction box,
the installer will need to provide the appropriate length of wire back to the Pan Heater
Controller. Refer to drawing # UPFG9222111-20A.
WARNING: Make sure ground is hooked up before proceeding to turn on the unit.
Rod Heater Bracket Installation:
Each flat rod heater will need a bracket every 20-24 inches along the rail to support the heater.
The flat rod heater must be placed against the bracket spring when the bracket is pounded onto
the rail.
9226-1010 FLAT HEATER TOOTH BRACKET
9226-1010 brackets installed along a rail

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Rod Heater Angle Bracket Installation:
If a flat rod heater is being installed on a switch rail, a rod heater angle bracket should be used.
9226-1017 ROD HEATER ANGLE BRACKET
To install, loosen the nut on the bolt far enough to be able to slide the angle bracket on. Slide the
bracket on behind the washer and nut. Place the heater rod against the bracket spring and tighten
the nut until the heater rod is firmly pressed against the rail.
9226-1017 installed along a rail
Rod Heater Wiring:
The Rod Heaters need to be wired back to the optionally supplied junction box, and then user
supplied wire is connected at the junction box back to the control panel. From the junction box,
the installer will need to provide the appropriate length of wire back to the 922 Control Panel.

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3.6. Fault Indication Light
A 115VAC, 40W fault indicating light (provided by customer) may be connected to 8 and 6
on TB2. Then put a jumper on TB2-5 and TB2-7 together.
3.7. Temperature Sensor
A hole in the bottom of the enclosure has been drilled for the probe of the air temperature
sensor. Run the sensor wire up through the hole from underneath. Attach the probe to the
enclosure by tightening the nut. Plug the temperature sensor connector into terminal J32 on
the control module.
3.8. Optional Snow Detector
Either 1 or 2 sensing heads may be used. Each sensing head has three lead wires: black,
white, and green. Connection is as follows:
Green: One, or both, connected to terminal post TB2-9
Black #1: Connected to terminal post TB2-11
Black #2: Connected to terminal post TB2-12
White: One, or both, connected to terminal TB2-10
Refer to the connection diagram 9224-5413 when connecting wires for the sensing heads. It
is important to properly connect the sensing head wires. Improper connection of the sensing
head wires may result in damage to the control board and/or the sensing heads.
3.9. Optional Rail Temperature Sensor
This is a one hardwire rail temperature sensor that can be connected to the control module.
This sensor monitors rail temperature at one location and can be used to switch all outputs’
power modes.

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4. Control Module
4.1. Description
The 922 control module contains all of the elements and functions necessary for advanced
snow melter operation. The unique single-chip microcomputer has been programmed with
logic and timing sequences to provide complete heater control as well as operational control
and system interface. Some of the many features included in the control module are:
Auto-Off-Local selector buttons
Adjustable air temperature setting
Built-in snow detector (requires optional snow detector head)
Adjustable run timer for timed or continuous operation
Adjustable snow detect timer for use with optional snow detector
Operator control and indication
Control Module LED Status Indicators:
Inputs: Air Temperature
Moisture Detector
Remote Control
Rail Temperature
Outputs:
Panel Heater
Open Heater
Heater Fault
High Voltage Warning
Low Voltage Warning
Indication
Fail

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4.2. Set-Up and Adjustments
To change settings and adjust times, use the following buttons:
Right Arrow Button
Pushing the right arrow button will cycle forward through the menus. Each time you
press the right arrow button, you will advance one menu selection.
Left Arrow Button
Pushing the left arrow button will cycle back through the menus. Each time you press
the left arrow button, you will move back one menu selection.
Up Arrow Button
The up arrow button allows you to increase the values and switch through the menu
categories.
NOTE: Values will be saved.
Down Arrow Button
The down arrow button allows you to decrease the values and switch through the
menu categories.
NOTE: Values will be saved.
NOTE: When you do not touch any of the buttons for 15 seconds, you will see the following
screen. This screen just lets you know that your current settings and values are being saved.

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4.3. Password 0 and 5 Menus
NOTE: The following items listed below are for password 5 only. Password 0 has a similar
set of categories, but it does not have all the items in each one. It will be denoted which ones
you can only see with password 5.
4.3.1. Master
a. Default Screen
This screen will go into screen saver mode when the user controls have been
idling for 60 minutes and the screen will go blank. To wake the screen up, simply
press one of the four arrow buttons. Once the screen is awake, the screen will
always display the current air temperature on the top line (if a sensor is installed).
On the bottom line, it will display the preset value (temperature setpoint).
b. Fault Test All Outputs
This screen will allow you to initiate the heater fault test to all active outputs. To
begin the test, push the up button. The test will continue to run until all the
outputs have been tested (the 922 needs to either be switch to LOCAL or AUTO
to access this).
c. Faults
If there currently is a fault, the screens will display which fault is occurring. If
more than one fault is happening, the screen will scroll through them. To clear
this, push the OFF button. You may also flip the main circuit breaker off, wait 30
seconds, and then back on to clear faults.

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4.3.2. Output
NOTE: Each enabled output will have the next 7 menus. There can be up to 12 outputs
enabled. Each output has three separate circuits. Each circuit consists of a power
contactor with a 60 amp circuit breaker. The outputs are listed as Pan Heater, Rail 1, and
Rail 2. The three outputs help in determining faults and open heaters. If a heater fault
occurs, only the individual output (circuit breaker) with the fault will be locked out, the
other ones will remain on. During an open heater fault, all outputs remain on.
a. Current
This shows the current that is being drawn by the output you have selected.
b. Auto Heater Setup
The auto heater measures the current of each breaker of the output and then saves
the value to memory. When the outputs are running it compares the running
current to the value in memory if the current is less than the value in memory it
will trigger an open heater fault.
To initiate the auto heater setup for this individual output, make sure the mode is
either Local or Auto, and then press the up arrow button. The test will take 30
seconds and check each of the heaters corresponding to the individual output. The
contactor LED will light up on the output module and then turn off. It will display
their currents on the screen.
c. Voltage
(Password 5)
This screen displays the voltage at the output and the power currently being
consumed by the output in watts.
d. Diff I / Fault Set
Diff I is the difference between the current being drawn and the total current.
The fault current set is the amount of ground fault current that is leaking to
ground from the heaters. The fault set current default is 30mA. If the fault current
is above the set point for longer than the Differential Current Fault Timer it will
lock out the individual circuit of the output that has the fault and a fault message
will appear on the Master screen. The range is from 10mA to 500mA.

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e. Fault Test
If the module or the output you wish to test is in a heater fault, you may not start
the test and you cannot see the associate screens for the test. Press the Off button
to clear the fault(s) or flip the main breaker on and off.
To initiate a fault test for this individual output, make sure that it is either in Local
or Auto and press the up arrow button. The test is to check that the output can
detect a leakage to ground.
After the test is completed, the output will have either passed or failed:
•PASS
oFor the test to pass, the outputs must see at least
230mA +/- 35mA for 480V
100mA +/- 35mA for 230V
oYou will see “Pass” on the display
•FAIL
oThe test will fail if it does not see at least 50mA of leakage current.
oYou will see “Fail” on the display
If failed, it will be in a state that will not allow it to run. To fix this, you need to
clear the fault by first going to the OUTPUT menu, find which output(s) has a
fault, find CLEAR FAULT, and then press the up arrow button. Or click the OFF
button. All the lights that were on will then turn off.
NOTE: It is recommended to run the Fault Test for the output(s) every month.
f. Clear Faults
This screen will only show if there is a fault for the output you are on. Press the
up button to clear all faults for this output.
g. Program Revision / Power Up Counter
(Password 5)
Shows the current program revision level and the date it was compiled.
Power up counter is the total number of times the output has turned on. This value
is resettable by clicking either the up or down button.

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h. Output Enabled / Disabled
NOTE: Enable is the default
(Password 5)
Options are output enabled or output disabled. To enable or disable, click either
the up or down arrow button. Use this to disable any active output you do not
wish to run or have any faults/indication for this output to be shown on the control
module.
4.3.3. Fault History
NOTE: Some faults may not show up in the fault history until there is an actual
fault. To reset the counters, press either the up or down arrow button.
a. Day Counter and Power Up Counter Master
The Day Counter is the number of days the unit has been powered up.
The Power up Counter is the total number of times the control module has been
turned on.
b. Output 1-12 Open Heater Fault Counter
Output open heater fault counter increments every time the output senses an open
heater fault.
c. Phase 3 Line Voltage Fault Counter
The total number of times the line voltage on phase 3 has been too high or too
low.
d. Phase 2 Line Voltage Fault Counter
The total number of times the line voltage on phase 2 has been too high or too
low.
e. Phase 1 Line Voltage Fault Counter
The total number of times the line voltage on phase 1 has been too high or too
low.

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4.3.4. Setpoints
NOTE: To change any of the setpoints, use the up or down arrow buttons.
a. Password
The default password is 0. Basic setpoints can be changed using 0; critical
setpoints require 5 to be entered.
b. Number of Outputs
(Password 5)
This screen is used to tell the 922 control module how many outputs are
connected to it. The range is from 1 to 12.
c. Select Temperature Setpoint
The ambient temperature below which the 922 unit will energize is set on this
screen. When the outside temperature is below this setpoint, the 922 will be
allowed to operate if requested. The factory default is 38°F. The range is from
10°F to 99°F.
d. Select Temperature for Pan Heater
This setting is used to enable the first breaker of each output to run pan heaters
constantly when the air temp is below the set point. The pan heater mode can also
be disabled by setting the temperature below the temperature set point. When the
pan heater mode is disabled the first breaker on each output will only turn on if
the unit is being called for.
e. Cabinet Temp
(Password 5)
This setting is used to set the temperature inside the 922 cabinet. When the inside
temperature is below this setpoint, the 922 will be allowed to operate the heater
inside the unit. The factory default is 60°F. The range is from 0°F to 99°F.
f. Differential Current Fault Set
(Password 5)
The fault current set is the amount of ground fault current that is leaking to
ground from the heaters. The fault set current default is 30mA. If the fault current
is above the set point for longer than the Differential Current Fault Timer it will
lock out the individual circuit of the output that has the fault. The range is from
10mA to 500mA.