Thermon HELLFIRE 400 Guide

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
Copyright©2022. All rights reserved.
2014
ISO 9001

TABLE OF CONTENTS
A. Important Notices And Warning Symbols 4
B. Identification 6
B.1 Heater Labels.......................................................................... 6
B.2 Model and Serial Number Tag.................................... 6
B.3 Components Diagram ......................................................7
B.4 Control Panel Diagram - 240V Single Phase
Example Shown .....................................................................7
B.5 Gas Manifold Diagram.......................................................8
C. Pre-Operation Inspection 9
C.1 Important Notices ................................................................ 9
C.2 Prior to Heater Start-Up....................................................9
D. Operation 11
D.1 Introduction.............................................................................11
D.2 Modes .......................................................................................... 11
D.3 Start-Up Sequence (All Modes)..................................11
D.4 Occurrences During Normal Operation.............. 11
D.5 Heat Output Adjustment..............................................12
E. Controls & Indications 13
E.1 AAR Signal Wiring - For non SCADA
installations ............................................................................. 13
E.2 Controller................................................................................... 13
E.3 Controls ......................................................................................14
E.4 Indications................................................................................14
E.5 Terminal Blocks .................................................................... 15
E.6 Data Communications ....................................................16
E.7 Controller EEPROM Memory.......................................16
E.8 Activating a COMMUNICATION Parameter......16
E.9 Mode Parameters ...............................................................16
E.10 Activating MODE Parameter ......................................17
E.11 Fan Mode...................................................................................17
E.12 Local EMS Mode ...................................................................17
E.13 RAIL THERMOSTAT Mode, Normal ..........................17
E.14 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
E.20 Terminal Blocks....................................................................20
E.21 Inputs and Outputs............................................................20
F. Troubleshooting 21
G. Installation 25
G.1 Overview ...................................................................................25
G.2 Recommended Tools......................................................25
G.3 Site Preparation - Typical Clearances ..................25
G.4 Site Preparation..................................................................28
G.5 Heater Installation.............................................................28
G.6 Gas Supply Piping and Minimum Pressure
Drop ............................................................................................28
G.7 Electrical Power Connections...................................28
G.8 Power Connections..........................................................29
G.9 Thermostat Installation.................................................. 31
G.10 Energy Management System (EMS) Options31
G.11 Inspection and Commissioning.................................34
H. Heater Specifications 35
H.1 Performance ..........................................................................35
H.2 Gas Firing.................................................................................35
H.3 Gas Conversion.................................................................... 35
H.4 Electrical.................................................................................. 35
H.5 Controls ....................................................................................35
H.6 Wiring Terminations........................................................ 35
H.7 Safety Features.................................................................... 35
H.8 Controller Terminal Identification..........................36
H.9 Schematics.............................................................................37
I. Maintenance 43
I.1 Thermostat Removal..........................................................43
I.2 Motor/Impeller/Base Removal...................................44
I.3 Impeller Removal................................................................44
I.4 Flame Rod and Spark Igniter Removal ...............44
I.5 Burner Removal................................................................... 45
I.6 Burner Defroster Removal ............................................45

J. Service 45
J.1 Recommended Service Schedule........................... 45
J.2 Gas Supply Pressure......................................................... 46
J.3 Gas Supply Leak Test....................................................... 46
J.4 Manifold Leak Test ............................................................ 46
J.5 Combination Gas Valve Seat Leak Test............... 46
J.6 Dirt Trap And Strainer..................................................... 46
J.7 Motor............................................................................................47
J.8 Vibration Specifications and Measurement....47
J.9 Lubrication...............................................................................47
J.10 Direct Spark 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 Communications49
J.16 Burner...........................................................................................49
J.17 Defroster .....................................................................................49
K. Parts 50
K.1 Parts - Heater Body ...........................................................50
K.2 Parts-Control Panel, 240V Single Phase.............51
K.3 Parts - Control Panel, 208V Three Phase ...........51
K.4 Parts - Control Panel, 460-575V Three Phase52
K.5 Parts - Control Panel, 460-575V Three Phase
with 120V Duplex Receptacle ....................................52
K.6 Parts - Gas Components...............................................53

4
4
Important Notices and Warning Symbols
A. IMPORTANT NOTICES AND WARNING SYMBOLS
Keep this manual with the machine at all times. The purpose of this manual is to provide owners, operators, and installers with
the precautions and procedures essential for the safe and proper operation for its intended purpose.
CAUTION
CAUTION. This symbol indicates a potentially
hazardous situation, which, if not avoided,
may result in personal injury or damage to the
equipment.
WARNING. This symbol indicates an imminently
hazardous situation, which, if not avoided, can result
in serious injury or damage to the equipment.
WARNING
DANGER. Read and adhere to the following.
Failure to do so may result in severe or fatal injury.
Warranty will be void.
DANGER
NOTE: “NOTE:” indicates information or a company policy that relates directly or indirectly to the safety of personnel or protection of
property.
Table 1 – Operation Warning/Avertissements (Intended for Signal Maintainers)
Symbol Description
English French
Risk of electrical shock or electrocution.
Disconnect electrical power prior to servicing.
Risque de choc électrique ou d’électrocution.
Couper le courant avant d’entreprendre l’entretien.
The heater is designed and approved for use as a
commercial heater (gas) – railway switch, class 2902
05 in accordance with ANSI Z83.7 / CSA 2.14. Check
with local authority, if you have questions about
applications.
Cet appareil a été conçu et approuvé pour être utilisé
comme radiateur commercial (gaz) - aiguillage de
voie ferrée de classe 2902 05, conformément à la
norme ANSI Z83.7 / CSA 2.14. Communiquez avec les
autorités locales pour plus de renseignements sur le lieu
d’utilisation de cet appareil.
General hazard warning failure to comply with the
precautions and instructions provided with this
heater, can result in death, serious bodily injury
and property loss or damage from hazards of re,
explosion, burn, asphyxiation, carbon monoxide
poisoning, and / or electrical shock.
Only persons 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.
Mises en garde générales le non·respect des mises en
garde et des instructions fournies avec ce radiateur peut
entraîner la mort, des graves blessures et des pertes
matérielles ou des dommages à la propriété résultant
d’un incendie, d’une explosion, de brûlures, d’asphyxie,
d’empoisonnement au monoxyde de carbone et/ou d’un
choc électrique.
Seules les personnes aptes à comprendre et à suivre
les instructions devraient se servir de ce radiateur ou
le réparer. Si vous avez besoin d’aide ou d’informations
concernant ce radiateur, soit une notice d’instructions, une
étiquette, etc., Prière de communiquer avec le fabricant.

5
Important Notices & Warning Symbols
Symbol Description
English French
Fire, burn, inhalation, and explosion hazard. Keep
solid combustibles, such as building materials,
paper, or cardboard, a safe distance away from the
heater as recommended by the instructions. Never
use the heater in spaces which do or may contain
volatile or airborne combustibles, or products such
as gasoline, solvents, paint thinner, dust particles or
unknown chemicals.
Risque d’incendie, de brûlures, d’inhalation et
d’explosion. Garder les combustibles solides, tels
les matériaux de construction, le papier et le carton,
à bonne distance de ce radiateur, comme il est
recommandé dans les instructions. Ne jamais utiliser
cet appareil dans des endroits qui contiennent ou
pourraient contenir des combustibles volatiles ou en
suspension dans l’air tels l’essence, les solvants, les
diluants pour peinture, les particules de poussières ou
des produits chimiques inconnus.
Not for home or recreational vehicle use. Ne pas utiliser dans une maison ou un véhicule de
camping.
All persons employed in handling propane or
natural gas shall be trained in proper handling
and operating procedures, as required by local
authorities having jurisdiction.
Toute personne qui manipule le propane ou le gaz naturel
doit avoir suivi une formation sur les bonnes procédures
de manipulation et d’utilisation qui est conforme aux
exigences des autorités locales compétentes.
If you smell gas; immediately extinguish all sources
of ignition and turn off gas source. Call qualied
service technician to repair leak.
S’il y a une odeur de gaz : fermer immédiatement toute
source d’allumage et de gaz. Faire réparer la fuite par un
technicien qualié.
Do not attempt to manually light burner.
Heater equipped with an automatic electronic
ignition system.
Ne pas allumer le brûleur manuellement.
Radiateur équipé d’un système d’allumage électronique.
Risk of cutting ngers or hand.
Disconnect fan power prior to removing
combustion chamber access panel or air intake.
Risque d’amputation des doigts ou de la main.
Couper le courant au ventilateur avant d’enlever le
panneau d’accès à la chambre de combustion ou
l’entrée d’air.
Heater can start automatically.
Exercise caution when in close proximity.
Attention : le radiateur peut démarrer automatiquement.
Faire preuve de prudence près du radiateur.
Burn hazard / hot surfaces.
Do not touch track ducts, nozzles or any non-
insulated duct connected downstream of heater
during operation.
Surface chaude; risque de brûlure.
Ne pas toucher les conduits latéraux à la voie ferrée, les
buses ni aucun conduit non isolé branchés en aval d’un
radiateur en marche.
Sheet metal edges can be sharp.
Wear protective clothing when handling track
duct, insulted ducts and any other sheet metal
components.
Risque de coupure.
Les rebords de la tôle sont coupants. Porter des
vêtements protecteurs lors de la manipulation des
conduits isolés et tout autre composant en tôle.
For use with ductwork only. Pour utilisation avec réseau de gaines seulment.
Retain manual for future reference. Conserver le manuel pour consultation ultérieure.

6
6
B. IDENTIFICATION
B.1 Heater Labels
1. Each heater has a ratings label, a logo label, a model
and serial number tag and a voltage label.
2. The ratings label contains all identication and safety
information. It is fastened by a lanyard and stored in
the manual pocket inside the control enclosure next
to the gas manifold. The electrical specications are
indicated with a punch mark.
3. The logo, located on the side of the air intake hood
identies the series as HELLFIRE, and the size, either
400 or 900.
4. The model / serial number tag is a blue aluminum
plate. The model number is applied to an adhesive
backed 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 conguration.
B.2 Model and Serial Number Tag
1. There are two basic congurations, stand-alone and
bungalow enclosed.
2. The tag is located on the front of stand-alone
congurations and to the left of the door handle on
bungalow enclosed congurations.
3. Stand-alone congurations are identied on the
tag as model “HF 400” followed by a 5-digit number,
an optional 2-digit dash number and a revision
letter. For example, HF400 12345-01A (HF 400 BUNG
XXXXX-XXX - for bungalow enclosed heaters).
4. The operating voltage label is found on the electrical
access panel. Have this information available when
requesting parts or service.
Identication

77
Identication
B.3 Components Diagram
The following component names are referred to in this manual. See Section L - Parts for part numbers and ordering.
B.4 Control Panel Diagram - 240V Single Phase Example Shown
1Direct Spark Ignition control module
2Controller
3 Programming key
4EMS module
5 Control circuit breaker
6Motor circuit breaker
7120V receptacle
8Contactor
9 Control transformer
10 Power terminal block
11 Circuit interrupters
12 Hour meter
13 Control and indication terminal block
14 Manifold terminal block
15 Resetable fuse, burner defroster
16 Rail thermostat receptacle
17 Precipitation detector receptacle
No. Label
1Track duct
2 Track duct elbow
3Rail mounting spring clip and
pad
4Ballast retainer
5Thermostat box
6Precipitation detector
7Burner
8Identication tag
9Condensation vent
10 Mode selector switch
No. Label
11 Gas manifold
12 Control cabinet lid
13 Air intake hood
14 Ambient air temperature sensor
15 Air intake extension
16 Electrical control access panel
17 Leveling leg
18 Control panel
19 Motor/Impeller/Base
20 Combustion chamber access
panel
No. Label
21 Transition duct
22 Sensor duct
23 Square to round adapter
24 Flex duct
25 Track duct deector
26 Tie duct
27 Rail thermostat
28 Point nozzle
29 Track duct mounting bracket

8
8
B.5 Gas Manifold Diagram
Identication
No. Label
1Burner
2Defroster
3 Flame rod
4Igniter
5 Union
6Manifold gas pressure gauge
7 Combination gas valve
No. Label
8 Gas supply pressure gauge
9 Gas supply inlet
10 Burner mounting bracket

99
Pre-Operation Inspection
C. PRE-OPERATION INSPECTION
C.1 Important Notices
To ensure trouble free operation during the winter months,
inspect the system annually at the start of the season.
WARNING
WARNING. All persons employed in handling
propane or natural gas shall be trained in proper
handling and operating procedures, as required by
local authorities having jurisdiction.
Gas leaks shall be repaired immediately or, gas
supply valve closed until repairs can be made.
All work performed on railway property must
be carried out in accordance with local railway
authorities instructions.
CAUTION
CAUTION. Do not operate this machine until it has
been installed and commissioned according to
requirements specied in the installation section
of this manual.
NOTE: Perform inspection and operations in accordance with
the instructions provided in the service section of this
manual.
NOTE: This inspection guide assumes that all applicable
service bulletins have been implemented on the heater
being inspected.
NOTE: The outcome of any inspection items that differ from
that expected indicates further service is required.
C.2 Prior to Heater Start-Up
Table 1 – Heater Inspection List
Inspect Action
Condition of all ducting, particularly any ex
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 Close vents that do not direct air at tie plates or rods.
Set vent openings to 1/8” - 1/4” maximum.
Track duct mounting Verify track ducts do not interfere with normal 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 cracked ceramic.
If evidence of soot is found, clean rod and investigate condition of burner,
gas manifold, and inspect tie duct, cross ducts and air intake for blockage.
Flame rod and ignition wires
Inspect boot for degradation, cracks and poor seals. Replace if necessary.
Inspect connectors for signs of corrosion. Clean connections, or replace wire
if necessary.
Combustion chamber Verify it is clear of any obstructions or debris, ie. animal nests.
Cycling and high limit thermostat installation
Verify thermostats are fastened and are in full contact with duct surface.
Replace any with damaged wire insulation.
Verify thermostat enclosure is sealed and dry inside.
Service surge protection Verify electric service has functioning surge protection.
Air switch port and vent Remove any obstruction.
DSI control module Verify it is installed.

10
10
Pre-Operation Inspection
Inspect Action
Gas source Verify propane tank is lled, or natural gas service is open and has pressure.
Open all manual gas shut off valves and inspect all gas lines for leaks.
Electrical service Verify electric service power is on. Close supply circuit breakers.
Electrical supply
Verify correct line voltages at each heater. Must be within +/- 5% of nominal
voltage.
Verify current draw is less than or equal to nameplate rating.
Gas supply Verify supply and manifold gas pressures are within nameplate limits when
heater and all connected loads are operating.
Flame signal strength
Verify ame signal strength is stable (+/- 0.5) and between 3.0 and 8.0 micro
amps DC.
If signal strength is low:
Clean or replace ame rod.
Clean ame rod wire connections, or replace wire.
If cleaning or replacement of ame rod and wire does not increase strength,
have burner serviced or replaced.
Burner operation
Note current 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 or replaced.
Return manifold pressure back to desired setting.
Air switch calibration
Block air intake 80%. Verify heater still operates.
Then block 90% and verify FSR alarms.
If heater fails with 80% or less blockage, recalibrate air switch.
Control and indication wiring Verify the correct control and indication wiring between the heater and the
signal bungalow.
Energy Management System (EMS)
If heater is operated automatically by an Energy Management System:
–Verify EMS module is installed and connected with POWER LED lit.
–Verify controller is in AUTO mode.
–Verify precipitation detector and ambient temperature sensor
installed and connected.
–Verify rail thermostat is mounted on rail and connected to surge
isolator.
–Verify its operation.
Aggressive retry
Verify operation.
Turn gas supply off, toggle heater to “Manual”.
Verify three attempts made followed by lockout.
Return heater to desired operating mode.
Open gas supply.
Reset controller.

1111
Operation
D. OPERATION
D.1 Introduction
The switch heater is a gas red, hot air heating system
that keeps a turnout clear of ice and snow during
winter storms by blowing hot air, between the stock
rail and moving points, at the tie plates on which the
points slide, and at the gage rods.
D.2 Modes
The heater can be operated in the following modes:
1. MANUAL - by toggling the mode selector switch
to “MANUAL”, the heater will turn on and operate
continuously. If installed, the rail thermostat will
cycle the burner on and off as required to maintain
the rail temperature.
2. AUTO – With the controller congured for LOCAL
AUTO MODE, toggling the mode selector switch
to “AUTO/REMOTE”, and with an EMS module,
precipitation and ambient temperature sensor
installed, the heater will turn on or off as required
based on the weather conditions. If installed, the
rail thermostat will cycle the burner on and off as
required to regulate the rail temperature.
3. REMOTE RTC- by toggling the mode selector switch
to “AUTO/REMOTE” and with a Rail Trafc Control,
RTC (dispatcher) operated control relay contact wired
to terminals A1 and A2 of the control and indication
terminal block. With RTC timer disabled, the heater
will operate continuously while the RTC contact is
closed, if the RTC timer is enabled, the heater will run
for the duration of the RTC timer then stop. RTC can
restart the heater for additional run time by resetting
the request. If installed, the rail thermostat will cycle
the burner on and off as required to maintain the rail
temperature.
4. REMOTE SCADA - With the controller congured for
REMOTE SCADA MODE, toggling the mode selector
switch to “AUTO/REMOTE” with the heater connected
to a Supervisory Control and Data Acquisition, SCADA,
network via the controllers’ RS-485 communications
port, and congured with a Remote Control and
Monitoring 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. 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 controller is in ‘REMOTE RTC’ mode then it waits
for the ‘DELAY START’ time before initiating.
Table 1 – All Modes
Conditions/Sequence Status LED
Heater is in an operational mode not OFF. ENABLE
Cycling thermostat is cold or closed. CYCLING
Motor contactor closed, fan starts. MOTOR
Air pressure develops, air switch closes. AIR SW
DSI requested. HEAT
Main gas valve opens. FSR CHECK
Run indication contact closed. RUN
To conrm the heater operation, the burner remains lit and
the rail thermostat status is ignored for the rst 2 minutes.
Normal operation Heater runs as long as requested.
D.4 Occurrences During Normal Operation
NOTE: The rail thermostat closes when the rail temperature is
above 9°C (49°F) and opens when below 3°C (37°F).
1. As long as the rail is cold and the thermostat is open,
the burner remains lit. Once the rail warms and the
thermostat closes, the burner is extinguished. This
cycle repeats as required while the heater operates.
If the rail temperature remains warm for more than
the post purge time then the fan is turned off. The
run indication is maintained during this time.
2. If the heater is in ‘REMOTE SCADA’ mode and
the ‘RCMS’ software is requesting performance
operation, the burner will remain lit regardless of rail
thermostat status.
NOTE: The cycling thermostat limits the heated air
temperature to a maximum of 193°C (380°F). Under
normal circumstances the air temperature remains
below this limit.
3. If the heated air temperature becomes excessively
hot, the cycling thermostat limit opens, and the
burner is extinguished immediately. Once the air
cools and the thermostat closes the burner is lit and
heating resumes. Run indication is maintained during
this time.

12
12
Operation
D.5 Heat Output Adjustment
1. Depending on the length of switch points, its’
priority, local climate conditions, and experience, the
operator can increase or decrease the heat output
accordingly. The recommended heat output is in the
range of 10,000 to 22,000 BTU/hr per foot of turnout
length.
2. The factory default setting is 400,000 BTU/hr
when operated on LPG, or 260,000 BTU/hr on NG.
The heater can be fueled with LPG or NG with no
component change.
3. Adjust the heat output as follows:
3.1 Using a at blade screwdriver, remove the
regulator adjustment screw cap (shown).
3.2 Turn on the gas supply, turn on the heater and
set the manifold pressures as per the natural
gas limits on the heater nameplate. Rotate
the adjustment screw clockwise to increase
pressure.
3.3 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°C
(100°F - 190°F) above ambient.
WARNING
WARNING. Do not operate above maximum
manifold pressure as this can produce carbon
monoxide in excess of maximum allowable of 0.08
air free carbon monoxide (AFCO).
WARNING
WARNING. Do not operate above or below the
rated manifold pressure limits. Operating outside
limits will result in weak ame signal and
unreliable operation.
3.5 Reinstall the cap to cover the regulator
adjustment screws.
3.6 The heat output can be estimated from the
manifold pressure and the following formulas:
200,000 + ((Manifold pressure –1.3)/3.7)*200,000 for LPG or
200,000 + ((Manifold pressure –2.3)/8.7)*200,000 for NG
Pressure is in inches of water column.
NOTE: These formulas are simplied, assume the equipment is
in good condition, and are strictly for estimation only.
CAP

1313
Controls & Indications
E. CONTROLS & INDICATIONS
E.1 AAR Signal Wiring - For non SCADA installations
Table 1 – AAR Signal Wiring
Terminals Label Description
A1 - A2 REMOTE START A contact closure across these terminals starts the heater when the heater is in REMOTE RTC
mode.
A3 - A4 RUN Dry contact closes to provide a run indication.
A5 - A6 ALARM Dry contact closes to provide alarm indication.
A7 - A8 FORCE OFF Default is closed. If FORCE OFF function is desired, remove shorting link and replace with
customer supplied relay contact. Open contact disables heater.
A9 - A10 TANK VALVE These terminals are intended to operate a 120Vac gas supply solenoid shut off valve. They
energize when the motor contact closes.
A11 RS-485 (+) Communications, RS-485 positive terminal (for RCMS 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 or be part
of a network of heaters.
2. The controller monitors various inputs, controls the
heater functions, communicates status and provides
indication LEDs.
3. The controller is DIN rail mounted and all wiring
connections are made with plug connectors to allow
quick replacement in the event of a failure.
4. With the addition of the EMS package, a stand alone
heater can operate automatically based on weather
conditions, or when connected to a network, act as a
weather station providing input to a SCADA system.
5. Its’ RS-485 serial communications port allows the
heater to interface with SCADA systems, and be
operated and managed by a Remote Control and
Monitoring System,.
NOTE: Controllers are not interchangeable between HELLFIRE
400 (24Vac) and HELLFIRE 900 (120Vac).

14
14
Controls & Indications
E.3 Controls
1. Power: This switch turns the power supply to the
board ‘ON’ or ‘OFF’.
WARNING
WARNING. TB1 and TB2 120Vac inputs to controller
can remain energized.
2. Reset: This push button is used to reset the
controller in case of a lockout.
3. Delay Start: This dial sets the length of the delay, 0 to
60 seconds, before starting the heater. It is intended
to allow the stagger start of multiple heaters
connected to one power service thereby reducing
the maximum current draw. This setting is true for
REMOTE RTC mode only. Under MANUAL, AUTO and
REMOTE SCADA modes there is no delay.
NOTE: This setting is overridden when operated in REMOTE
SCADA mode by the corresponding Fastrax® RCMS
software parameter.
4. Post Purge: This dial sets the length of the delay, 5
seconds to 4 minutes, once the heater is no longer
requested, before stopping the fan. It is intended
to purge the remaining heat and moisture from the
combustion and duct system. This setting is true for
all modes.
5. RTC Time: (RTC stands for Rail Trafc Control dispatch)
This dial limits the run time between 20 minutes to 4
hours, when requested by RTC dispatcher, and with
the RTC SW switch ON, and the heater is in REMOTE
RTC mode. When the RTC request exceeds the time
limit, the heater turns off, and the run indication is
maintained as long as the heater is requested.
Timer is reset once the RTC request is removed. RTC
can then request the heater for another cycle.
It is intended to save fuel by avoiding unnecessary
heater operation by the dispatcher. This setting is
true for RTC MODE only. Under MANUAL, AUTO, and
REMOTE SCADA modes there is no limit.
6. RTC SW: This switch 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 congure controller parameters.
E.4 Indications
1. There are a number of status LEDs on the controller
intended to aid the user’s understanding of the
heater state of operation. See Table 6 - Controller
LED Descriptions for full description.
NOTE: With the exception of the communications TD, RD, and
TX LED’s. Solid green, solid green with a red pulse, or
yellow LED’s indicates normal status. Solid red and
alternating LED’s indicate a failure. This is true for the
controller only, not the EMS module.
2. Refer to Section F - Troubleshooting for explanation of
problem condition LED codes.
3. The LEDs listed can be found on the controller from
top left to bottom right on the board.
Table 1 – Controller LED Descriptions
LED Name Description State Indication
TD, RD, TX RS-485
communications
TD, RD on and
pulsing
TX off and pulsing
Heater in REMOTE SCADA mode.
TX off
TD and RD on Heater in LOCAL AUTO mode.
TD, TX off and
pulsing
RD on
8N1 COM communications mode.
Status Processor status
Solid green with a
red pulse Normal operation.
Alternating red and
green FSR failure alarm. Aggressive retry mode in process.
Solid red
Failure alarm.
Note any alternating LEDs and refer to Section F - Troubleshooting.
Controller must be reset.
Solid green or off Processor has stopped functioning.
ENABLE Heater enable
On
Mode selector switch is either in MANUAL or REMOTE/AUTO
position.
Heater can be started in AUTO REMOTE RTC or REMOTE SCADA
modes.
Off Mode selector switch is in OFF position. Heater is in OFF mode and
will not start.
FSR CHECK Flame Safety
Relay/DSI check
On Gas valve energized. Used to conrm correct operation of DSI.
Alternating The DSI did not energized the main gas solenoid valves when
expected.

1515
Controls & Indications
LED Name Description State Indication
RES FSR Reset On Controller clears DSI control module alarm.
EMS REQ EMS request
On EMS module request for heater to run.
Heater only acts on this request if in AUTO mode.
Pulsing Local EMS mode. Installed EMS module can request heater operation
ON or OFF.
POWER Power supply On Controller energized.
MOTOR Motor On Contactor closed, motor turned on.
HEAT Controller request
for heat On DSI control module requested. Ignition sequence started or burner operating.
RUN IND Heater run
indication On Indication contact closed. Turns on after 60 seconds of normal operation.
ALARM Heater alarm
indication On Alarm indication contact closed. Heater off and locked out. Controller must be reset manually.
FSR ALARM Flame safety
relay/DSI alarm
On DSI control module in ALARM, or controller is preventing its
operation.
Alternating DSI control module in ALARM. Heater failed 4 times in 5 minutes.
AIR SW Air pressure
switch
On Contact closed. Sufcient air ow to allow burner operation.
Alternating Air switch did not operate as intended. Air switch either did not
close with fan ON or did not open with fan OFF.
On or off with pulse FAN MODE enabled locally.
On or off with 2
pulses FAN MODE enabled remotely by SCADA CEMS.
CYCLING Cycling
thermostat
On Thermostat closed. Heated air temperature is BELOW set point.
Alternating Cycling 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
temperature exceeded set point.
MANUAL Manual operation On Selector switch in “MANUAL” position. Heater in MANUAL mode.
RAIL TH Rail thermostat On Thermostat open. Rail temperature is BELOW set point (normal
mode COR).
On or off with pulse Rail thermostat congured for OOR (reverse mode).
RTC Rail trafc control
mode
On Indicates selector switch is in “REMOTE/AUTO” position and AAR
terminals 1 and 2 are closed.
On or off with pulse Indicates selector switch is in “REMOTE/AUTO” position and
requested by RCMS.
E.5 Terminal Blocks
The controller interconnects with the control panel by means of 8 board level headers, TB1 to TB8, which accept the various
wire harness plug connectors. The controller and EMS module connect via a ribbon cable that plugs into the 10-pin header
found on each.
Table 1 – Terminal Block Description
Name Description
JP1 Jumper. Used to congure EEPROM settings
TB1 120V power, transformer primary and motor contactor coil
output
TB2 Transformer secondary 24V power and FSR request output
TB3 RTC run and alarm indication contacts outputs
TB4 Rail thermostat, RTC request, Manual, and Enable inputs
TB5 Air switch, FSR/DSI alarm, gas valve inputs
TB6 Cycling and high limit thermostats inputs
TB7 Communication port, RS-485
TB8 FSR reset and current transformer inputs
10-pin header* EMS module power and signal connection
*Located in the upper right corner next to TB8.

16
16
Controls & Indications
E.6 Data Communications
1. The RS-485 serial communications port, and
an EEPROM, allows the heater to be part of a
Supervisory Control and Data Acquisition (SCADA)
network and Remote Control and Monitoring System
(RCMS) software.
2. The RS-485 port runs at 9600 baud and allows
communication over long distances of up to 1000’
and possibly longer.
NOTE: Cable construction: Cat5 24 AWG twisted pair is a very
common cable type used for RS-485 systems. Adding
shielding to the cable enhances noise immunity, and
thereby allows greater distance. If used, connect one
end only of shield to ground.
3. The 8-bit memory address allows a maximum of 254
heaters to connect to the same communications bus.
E.7 Controller EEPROM Memory
1. EEPROM memory chip stores parameters and an address.
2. EEPROMs can be switched between controllers.
In the event a controller needs to be replaced the
EEPROM can be removed from the old and put in the
replacement. The parameters and address remain
with the heater and no RCMS software modications
are required.
WARNING
WARNING. Electrostatic discharge can damage ICs.
Have qualied personnel remove and install
EEPROM IC.
3. Parameters activated locally or remotely by the RCMS
software are stored on the EEPROM.
NOTE: There are two parameter types, ‘COMMUNICATION’ and
‘MODE’.
Table 1 – Communication Parameters (Activated Locally)
Name Setting1Function
LOCAL AUTO
MODE 1Disables communications and enables local EMS control.
REMOTE SCADA
MODE
2
Enables RS-485 MODBUS
communication.
Disables local EMS control.
Enables weather station mode.
DEFAULT ADDRESS 3Writes 254 to processor address.2
ADDRESS SET 4Writes new address to EEPROM. 2
8N1 COM 5Enables 8N1 communication.3
Enables local EMS control.
LOCAL EMS,
enabled 6Enables local EMS control.
LOCAL EMS,
disabled 7Disables local EMS control.
FAN MODE ----
When enabled, the fan runs
continuously.4
When disabled, the fan runs only
when heating is requested.
1 Setting number equals alarm LED/relay count.
2One time functions.
3 The 8N1 conguration allows the heater to send status information only and is
intended to aid service technicians. This conguration does not allow the heater
to be part of a network.
4 See CONTINUOUS FAN MODE section for instructions.
E.8 Activating a COMMUNICATION Parameter
NOTE: Read and understand the following procedure before
starting. COMMUNICATION parameters require a
hardware programming key to make changes, MODE
parameters do not.
1. Toggle mode selector switch to “OFF”. If installed,
disconnect EMS cable from controller. Plug
programming key into the mating EMS 10-pin
connector. Then the red LED on the key lights.
2. Press the RESET button, and short jumper JP1.
3. Release the RESET button. The RTC, MANUAL,
CYCLING, and AIR SWITCH LEDs will each pulse, one
after the other for one sequence. Then the RUN
indication LED pulses and the green LED on the
programming key alternates on and off.
4. After ve RUN indication pulses, the red ALARM LED
lights for 3 seconds. This cycle continues as long as
the jumper, JP1, is shorted.
5. Count the number of times the red ALARM LED lights.
6. Once the count equals the parameter number,
remove the jumper before the ALARM LED turns
off. For example, when the ALARM LED lights for
the second time removing the jumper will activate
REMOTE SCADA MODE, parameter #2.
7. Function performed.
8. Parameter or new address is stored on the EEPROM.
9. Repeat sequence as required to activate other
parameters.
E.9 Mode Parameters
Table 1 – Mode Parameters
Name Parameter1Function
FAN MODE
ENABLE 1Turns the motor on and keeps it running continuously.
FAN MODE
DISABLE 2Motor runs only when heater is requested.
LOCAL EMS
MODE
ENABLE
3Local EMS controls the heater.
LOCAL EMS
MODE
DISABLE
4The local EMS will not turn the heater
on.
RAIL
THERMOSTAT
MODE
NORMAL
5
Congures operation to new
thermostat, open when cold, closes
on temperature rise (COR).
RAIL
THERMOSTAT
MODE
REVERSED
6
Congures operation to older rail
thermostats that are closed when
cold, open on temperature rise
(OOR).
1 Parameter number equals alarm LED/relay count.

1717
Controls & Indications
E.10 Activating MODE Parameter
NOTE: Read and understand the following procedure before
starting.
1. The controller must be powered on for a minimum of
60 seconds, the mode selector switch toggled OFF,
and terminals A1 A2 open (i.e. no RTC request).
2. Short jumper JP1. The RUN indication relay and LED
pulses on and off. After ve RUN indication pulses,
the red ALARM LED lights for 3 seconds. This cycle
continues as long as the jumper, JP1, is shorted.
3. Count the number of times the red ALARM LED lights.
4. Once the count equals the parameter number,
remove the jumper before the ALARM LED turns off.
For
5. I.e. when the ALARM LED lights for the second
time removing the jumper will activate FAN MODE
DISABLE, parameter #2.
6. Function performed.
7. Parameter or new address is stored on the EEPROM.
8. Repeat sequence as required to activate other
parameters.
E.11 Fan Mode
1. When enabled for continuous operation, this mode
can be benecial for locations with difcult to
detect drifting snow conditions that cause snow
accumulation in the turnout and or in the duct
system.
2. When enabled, and with the mode selector switch in
either the MANUAL or REMOTE/AUTO position, the
fan will run continuously, with heating requested or
not.
NOTE: The fan will stop when the mode selector switch is in
the OFF position.
3. This parameter can be set, either, locally, or remotely
by the RCMS software.
4. Refer to RCMS documentation for remote activation.
E.12 Local EMS Mode
1. This parameter enables the locally installed EMS
module to control the heater according to the
module set points. If connected to a SCADA system,
all weather data will be transmitted to the system. No
other functions are affected by this mode.
2. The HEAT LED pulses to indicate that 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
1. With the introduction of the 2014 model Hellre,
the rail thermostat operation was reversed. The
thermostat now opens when cold and closes when
warm.
2. When enabled, the controller is congured to operate
with the new, close on rise, COR, thermostat.
E.14 RAIL THERMOSTAT Mode, Reverse
1. When enabled, the controller is congured to
operate with the previous, open on rise, OOR,
thermostat.
E.15 Failure Shutdowns and Alarm Indications
1. In the event of a failure, the controller ceases the
heater operation and indicates alarm.
2. While the heater is shutdown and indicating alarm
the controller continues communications with the
RCMS software. All start requests, local or through
the RCMS software, are ignored until the problem is
resolved.
3. The controller indicates the nature of the failure in
three ways. LED’s on the controller, an alarm contact
closure, and error codes communicated via the RS-
485 serial port when under RCMS control.
NOTE: With the exception of the communications TD, RD, and
TX LED’s. Solid green, solid green with a red pulse, or
yellow LED’s indicates normal status. Solid red and
alternating LED’s indicate a failure. This is true for the
controller only, not the EMS module.
4. There are two types of failure alarms, minor and major.
Both cease the heater operation, however, minor
alarms clear when the condition that caused the
failure recties itself. Major alarms, which are more
serious and require inspection, must be manually
reset.
E.16 Indications and Conditions
1. A failure exists when the STATUS and the ALARM
LED’s are solid red.
2. In addition, an alternating LED of equal duration
on and off, or red and green indicates the failure
condition.
3. Heaters connected via the RS-485 port to a network
and RCMS software will communicate fault codes.

18
18
Controls & Indications
Table 1 – Fault Condition Codes and LED States
Code Alarm
Type
Fault Condition LED State
1Minor Selector switch
left in OFF position
for more than 60
minutes.
ENABLE Dark
2Major Air switch does not
open after fan motor
turned off.
AIR SW Alternating
3Major Air switch does not
close after fan motor
turned on.
AIR SW Alternating
10 Major Flame failure at start
up.
FSR
ALARM
Alternating
11 Major Loss of ame signal
while running.
FSR
ALARM
Alternating
12 Major 4 FSR alarms within 2
minutes.
FSR
ALARM
Alternating
13 Major Gas valve does
not energize when
expected.
FSR CHECK Alternating
14 NA FSR in alarm. FSR
ALARM
Solid Red
20 Minor Cycling thermostat
failed to close after 10
minutes.
CYCLING Alternating
21 Major Maximum output air
temperature exceed.
High limit thermostat
closed momentarily.
HIGH LIM Alternating
30 Minor Controller in
conguration mode.
JP1 jumper shorted.
(none)
31 Minor EMS module TEST
switch on.
SENSOR
WET
Solid Red
E.17 Aggressive Retry Feature
1. The controller has an aggressive retry feature. It is
intended to avoid nuisance failure shutdowns and
alarm indications due to temporary conditions, such
as condensation on the igniter and or ame rod,
which are rectied with repeated attempts.
2. In the event of an DSI alarm, as indicated by the FSR
ALARM LED, occurring at start up or under normal
operation, this feature will reset the FSR and allow up
to 4 trials 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 the FSR ALARM LED.
4. After 4 failures within 2 minutes, the heater ceases
operation, the controller locks out, the STATUS LED
turns solid red, the run indications are removed and
the alarm indications applied with the ALARM FSR
LED alternating on and off.
E.18 Reset
1. Prior to performing a reset:
WARNING
WARNING. If you smell gas; Immediately
extinguish all sources of ignition and turn off gas
source.
Call qualied service technician to repair leak.
1.1 Toggle the selector switch to OFF.
1.2 Gain access to the controller by removing the
electrical access panel.
NOTE: Note the status of the controller LEDs, contactor
thermal overload relay reset (three phase models only),
control panel circuit breaker, and motor circuit breaker.
1.3 Close any tripped or open breakers. Green
means safe and red means danger circuit
energized.
1.4 In the case of three phase models, if found
tripped, reset the thermal overload relay located
on the panel and connected to the contactor.
WARNING
WARNING. Risk of cutting ngers or hand.
Open motor circuit breaker before opening
combustion chamber access panel. Keep clear of
fan.
1.5 In the case of single phase models, OPEN
THE MOTOR CIRCUIT BREAKER. Remove the
combustion chamber access panel and, if
tripped, reset the thermal overload switch
found on the motors junction box. Close the
combustion chamber access panel and close
the motor circuit breaker.
2. Press and release the controller reset.

1919
Controls & Indications
E.19 Energy Management System (EMS)
Adding the EMS allows a heater to operate
automatically, or to act as a weather station when part
of a network of heaters controlled by the Fastrax®
RCMS.
The system includes a module, a precipitation
detector, ambient temperature sensor, and rail
thermostat. Once installed, the controller recognizes
the EMS module and works in conjunction with it.
Controls:
NOTE: These settings are true for AUTO mode only, with the
exception of the TEST switch.
These setting are overridden when operated in REMOTE
SCADA mode by the corresponding Fastrax® RCMS software
parameter.
1. SNOW-RAIN:
1.1 This dial adjusts the temperature set point
between -12°C to +12°C.
1.2 Precipitation detected when the ambient
temperature is below this set point is
considered snow or above it is rain.
2. LOW TEMP:
2.1 This dial adjusts the temperature set point
between –55°C to +5°C.
2.2 The EMS will not request the heater to operate
when the ambient temperature is below this set
point and snow is detected.
3. DELAY ON:
3.1 This dial sets the length of the delay, 0 to 30
minutes, before making the heater request.
3.2 When snow is sensed continuously for the
duration of the delay on period the heater
request is made. If at any 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 the heater
request is held for the duration of the timer. If
at any time during the delay snow is sensed the
timer is reset.
5. TEST:
5.1 This switch simulates precipitation when ON.
Used to test the module operation.
6. SENSITIVITY:
6.1 This dial adjusts the precipitation detector
sensitivity between the least, 1, and most, 6. For
example, when set at 1 the detector has to be
very wet to indicate precipitation.
7. INDICATIONS:
7.1 On the module are a number of status LED’s
intended to aid the user’s understanding of the
state of operation. See table for full description.
Table 1 – Status LED’s
LED
Name Description State Indication
STATUS Processor status
Green with
a red pulse
Processor
functioning
normally.
Off
Solid green
Solid red
Processor failed.
POWER Power supply On Module energized.
COMM Communications Flashing
Indicates
communications
with controller.
HEAT ON Heater request On EMS request to
turn on heater.
LOW
TEMP Low Temperature On
Ambient
temperature is
below set point.
Heater will turn off
or not turn on if
requested.
DELAY
TIME Delay Time
On with a
pulse off
Delay active.
Delay on when
HEAT ON is off.
Delay off when
HEAT ON is on.
Off with a
pulse on No delay.
SENSOR
WET
Precipitation
sensor wet On Precipitation above set point.

20
20
Controls & Indications
E.20 Terminal Blocks
1. The controller interconnects with the control panel
by means of 2 board level headers, TB-1 and TB-2,
which accept wire harness plug connectors.
2. The controller and EMS module connect via a ribbon
cable that plugs into the 10-pin header found on each.
The ambient temperature sensor connects via the
RJ11 header.
Table 1 – Terminal Blocks
Name Description
TB-1 Precipitation detector 24Vac power supply
TB-2 Precipitation detector
JP1 Ambient air temperature sensor RJ11 header
10-Pin
header* EMS power and signal connection
* Located in the upper left corner.
E.21 Inputs and Outputs
1. PRECIPITATION DETECTOR: As its name implies, 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 blowing snow as well as
falling snow.
See the installation section for mounting instructions.
There are no adjustments on the detector itself.
Sensitivity adjustments are made on the controller.
2. AMBIENT TEMPERATURE SENSOR: The ambient
temperature sensor is mounted beneath the air
intake hood. The controller compares the measured
temperature to the SNOW-RAIN and the LOW TEMP
set point.
3. RAIL THERMOSTAT: The rail thermostat optimizes
fuel consumption and performance while the heater
is requested. It functions independently of the
EMS module, cycling the heater off when the rail
temperatures rises above 9°C (49°F) then back on
again once the temperature drops below 3°C (37°F).