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CCI Thermal Technologies Fastrax G Series Installation & Operation Manual

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Installation & Operations Manual
G Series - Control Panel Package

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Summary of Contents for CCI Thermal Technologies Fastrax G Series

  • Page 1 Installation & Operations Manual G Series - Control Panel Package...

  • Page 2: Table Of Contents

    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.
  • Page 3 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 CCI Thermal Technologies Inc.

  • Page 4: Equipment Inspection

    A. EQUIPMENT INSPECTION A.1 REVIEW EQUIPMENT PAPERWORK Table A.2-1 - Bill of Material by Standard Application Identify the switch and frog sizes to be heated on your SWITCH TYPE BILL OF MATERIAL - APPLICATION project. No. 9 No. 10 No. 11 Power Operated Turnout Ensure that the Pick Ticket (list of Fastrax heating...

  • Page 5: Pick Ticket Example

    20 ft overall length. (11) FRB600 Spring tension clamp kits included. No drilling required. Packed By Pulled By Checked By # of Cartons Total Weight Date Printed 09/21/2005 Page # 1 of 3 CCI Thermal Technologies Inc.

  • Page 6: Equipment Check

    Control Panel Support: A.4 EQUIPMENT CHECK Using a Phillips screwdriver, remove top and sides of Note: Notify your supervisor, purchasing department or panel support assembly crate. Fastrax of any missing or damaged parts. ® Ensure that each panel support size matches the corresponding panel size.

  • Page 7: System Layout Layout Guidelines

    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. Figure A.4.4 - Standard Ohms Reading CCI Thermal Technologies Inc.

  • Page 8: Single Stand Alone Switch With Frog

    B.2 SINGLE STAND ALONE SWITCH WITH FROG No. 9 - No. 11 Switch and Frog No. 14 - No. 16 Switch and Frog TYPICAL OVERALL LAYOUT FOR SINGLE SWITCH WITH FROG NO. 20 OR 24 STANDARD SWITCH AND FROG - ALL TIE STYLES No.

  • Page 9: Crossover No. 20/24 Switches With Frogs

    Single Crossover No. 20 or No. 24 Switches with Frogs Double Crossover No. 20 or No. 24 Switches with Frogs 12C. No.14 A S T R A X ® ® A S T R A X #20 / 24 CCI Thermal Technologies Inc.
  • Page 10 Fastrax 1.855.244.3128 Fax: 1.303.979.7350 sales@fastraxind.com www.fastraxind.com...
  • Page 11 CCI Thermal Technologies Inc.
  • Page 12 Fastrax 1.855.244.3128 Fax: 1.303.979.7350 sales@fastraxind.com www.fastraxind.com...

  • Page 13: Spring Frog & Movable Point Frog Heating Layout

    Movable Point Frog Heating Layout To Fastrax Control Panel ® Fastrax SwitchBlade Heaters on Frog Wing Rails ® ® Fastrax Junction Box ® with Ground Snow Sensor Fastrax Crib Heaters ® Fastrax SwitchBlade Heaters on Frog Point Plates ® ® CCI Thermal Technologies Inc.

  • Page 14: Control Panel Installation

    C. CONTROL PANEL INSTALLATION C.1 ASSEMBLING FASTRAX FCSA PANEL Slide one of the 3/8” channel nuts above and below ® SUPPORT STRUCTURE the four control panel mounting holes. Use one 3/8” x 1 1/2” bolt and place one split washer and two stainless SUPPORT STRUCTURE COMPONENTS: steel flat washers onto the bolt and fasten through •...

  • Page 15: Installing Fastrax Fcsa Panel

    Only install the conduits at the bottom of the control panel. Use proper fittings with locknuts and plastic or Remove temporary supports. metal bushings to protect conductors. Clamp conduit to the lower support channel with the provided clamp. CCI Thermal Technologies Inc.

  • Page 16: Installing Fastrax Aerial Snow Sensor & Support Mast

    C.4 INSTALLING FASTRAX AERIAL SNOW SENSOR ® & SUPPORT MAST Note: If constructing your own support mast, please contact Fastrax ® The aerial snow sensor support mast comes pre- assembled and packaged with the control panel support structure. Loosely hold the mast in position with the one-hole strap pre-installed on the back of the panel support channel.

  • Page 17: Junction Box Installation

    Figure D.1.2 - FJAM200SUP Junction Box with FGSP1A Ground Snow Sensor Figure D.1.5 - Trenching Bury direct burial cables or conduit a minimum of 2 ft below grade unless otherwise outlined by Railroad or National Electrical Code standards. Figure D.1.3 - Conduit Junction Box CCI Thermal Technologies Inc.

  • Page 18: Direct Burial Cable , Conduit & Junction Box Installation

    D.3 DIRECT BURIAL CABLE , CONDUIT AND Note: For customer provided conduit, prepare and JUNCTION BOX INSTALLATION terminate the conduit into the junction box with Unscrew the four support flange bolts attached to the approved fittings such as terminal adaptors. junction box from the support pedestal.

  • Page 19: Switchblade ® Heater Installation

    After marking the rail for clamps, mark the other running rail in the same locations. Locate Model FRB600 spring rail clamps (Step 7.6 on opposite page) and install on the rail by hand. CCI Thermal Technologies Inc.
  • Page 20 Leave swivel screw and spring clip backed away from rail and slide heater in place. Place clamp on field side of rail Push the bottom of the clamp The end of the clamp body will base with swivel screw backed body firmly until it clicks into place wrap around the gage side of the completely out.

  • Page 21: Switchblade ® Heaters (Field Side Running Rail) Switches No. 20 - 24

    Install the second heater from the rear of the switch so that the point of the rear heater meets the point of the front heater. Tie the heater dead ends together with a stainless steel wire tie. CCI Thermal Technologies Inc.

  • Page 22: Heater Power Wire To Junction Box

    E.3 HEATER POWER WIRE TO JUNCTION BOX Heater power wires are standard 26 ft from the factory. Scratch a shallow channel in the ballast or dirt to bury Uncoil the power wire on each heater and lay it in the the orange conduit with the heater wire inside.

  • Page 23: Switchblade Heater(S) For Gauge Side Of The Moving Rail

    8 ft from the switch past the heater offset. point toward the switch heel. e) Mark the third and fourth bolts approximately 24” apart from other clamps. Locate the last clamp approximately 10 to 14” from heater termination end. CCI Thermal Technologies Inc.

  • Page 24: Switchblade Heater(S) For Spring Frog (Spring Frog Channel Style)

    E.5 SWITCHBLADE HEATER(S) FOR SPRING FROG Installing clamps: ® (SPRING FROG CHANNEL STYLE) a) Install clamps one at a time. b) Remove cotter key and loosen the first hex nut Many new style spring frogs have a rectangular channel leaving space to slide clamp body between the manufactured into the base of the frog casting.

  • Page 25: Switchblade ® Heater(S) For Spring Frog (Retrofit Style)

    Heater Inserted in milled slot or ® ® Heel of Frog Figure E.6.2 - SwitchBlade heater end clamp ® clamped to D-Bar of the Spring Rail Frog Figure E.6.4 - SwitchBlade heater retrofit installation location ® CCI Thermal Technologies Inc.

  • Page 26: Movable Point Frog - Switches No. 20 - 24

    E.7 MOVABLE POINT FROG - SWITCHES NO. 20 - 24 Slide each plate SwitchBlade heater into the channel ® provided under the base plate beneath the point area. Two of these channels will generally be located in each Many new style movable point frogs (MPF) have the hollow steel tie or between concrete ties where the following design features to allow easy access for the switch rods are located.

  • Page 27: Crib Heater Installation

    Figure F.1.2 - Hollow Steel Tie Mount Review Section B - Heater Layout for the crib heater placement. In extremely severe weather areas crib heaters may be applied under any moving rod on the switch or frog. CCI Thermal Technologies Inc.

  • Page 28: System Wiring

    G. SYSTEM WIRING Section B - System Layout shows generally used minimum For system designs not covered in this manual or wire sizes and number of conductors to be installed between questions please contact Fastrax or consult your Railroad ® panels and connection points for 240V and 480V systems.

  • Page 29: Control Panel Switchblade ® Heater Wiring - Stand Alone/Extension Panels Only

    Table G.3-1. Terminals marked SP are for spare conductors. Before testing tightness of any electrical connection disconnect electrical feeder to control panel to ensure entire panel is de-energized. CAUTION CCI Thermal Technologies Inc.

  • Page 30: Fas1A Aerial Snow Sensor Wiring

    G.5 FAS1A AERIAL SNOW SENSOR WIRING Mount and install FAS1A sensor and wire as instructed in the Control Panel section of this manual. Locate the wiring diagram for your panel style in this section. FAS1A sensors are only connected to master or stand alone panels.

  • Page 31: Fgsp1A Ground Level Sensor Wiring At Panel

    Use electrically approved sealing cement, duct seal or other approved material. Figure G.6.2 - Sealed Conduits CCI Thermal Technologies Inc.

  • Page 32: System Wiring Diagrams

    H. SYSTEM WIRING DIAGRAMS H.1 STAND ALONE CONTROL PANEL WIRING DIAGRAM (1) NO. 9, 10, OR 11 SWITCH & SPRING FROG HEATING SYSTEM Fastrax 1.855.244.3128 Fax: 1.303.979.7350 sales@fastraxind.com www.fastraxind.com...

  • Page 33: Stand Alone Control Panel Wiring Diagram (2) No. 9, 10, Or 11 Switch & Spring Frog Heating System

    H.2 STAND ALONE CONTROL PANEL WIRING DIAGRAM (2) NO. 9, 10, OR 11 SWITCH & SPRING FROG HEATING SYSTEM CCI Thermal Technologies Inc.

  • Page 34: Stand Alone Control Panel Wiring Diagram (1) No. 14, 15, Or 16 Switch & Spring Frog Heating System

    H.3 STAND ALONE CONTROL PANEL WIRING DIAGRAM (1) NO. 14, 15, OR 16 SWITCH & SPRING FROG HEATING SYSTEM Fastrax 1.855.244.3128 Fax: 1.303.979.7350 sales@fastraxind.com www.fastraxind.com...

  • Page 35: Stand Alone Control Panel Wiring Diagram (1) No. 20 Or 24 Switch & Spring Frog Heating System

    H.4 STAND ALONE CONTROL PANEL WIRING DIAGRAM (1) NO. 20 OR 24 SWITCH & SPRING FROG HEATING SYSTEM CCI Thermal Technologies Inc.

  • Page 36: Stand Alone Control Panel Wiring Diagram (1) No. 20 Or 24 Switch & Movable Point Frog Heating System

    H.5 STAND ALONE CONTROL PANEL WIRING DIAGRAM (1) NO. 20 OR 24 SWITCH & MOVABLE POINT FROG HEATING SYSTEM Fastrax 1.855.244.3128 Fax: 1.303.979.7350 sales@fastraxind.com www.fastraxind.com...

  • Page 37: Master Control Panel Wiring Diagram Up To (4) Fastrax ® Extension Panels

    H.6 MASTER CONTROL PANEL WIRING DIAGRAM UP TO (4) FASTRAX EXTENSION PANELS ® CCI Thermal Technologies Inc.

  • Page 38: Extension Control Panel Wiring Diagram (1) No. 20 Or 24 Switch & Movable Point Frog Heating System

    H.7 EXTENSION CONTROL PANEL WIRING DIAGRAM (1) NO. 20 OR 24 SWITCH & MOVABLE POINT FROG HEATING SYSTEM Fastrax 1.855.244.3128 Fax: 1.303.979.7350 sales@fastraxind.com www.fastraxind.com...

  • Page 39: Master Control Panel Wiring Diagram Up To (8) Fastrax ® Extension Panels

    H.8 MASTER CONTROL PANEL WIRING DIAGRAM UP TO (8) FASTRAX EXTENSION PANELS ® CCI Thermal Technologies Inc.
  • Page 40 Fastrax 1.855.244.3128 Fax: 1.303.979.7350 sales@fastraxind.com www.fastraxind.com...

  • Page 41: Extension Control Panel Wiring Diagram (1) No. 9, 10, Or 11 Switch & Spring Frog Heating System

    H.9 EXTENSION CONTROL PANEL WIRING DIAGRAM (1) NO. 9, 10, OR 11 SWITCH & SPRING FROG HEATING SYSTEM CCI Thermal Technologies Inc.

  • Page 42: Extension Control Panel Wiring Diagram (2) No. 9, 10, Or 11 Switch & Spring Frog Heating System

    H.10 EXTENSION CONTROL PANEL WIRING DIAGRAM (2) NO. 9, 10, OR 11 SWITCH & SPRING FROG HEATING SYSTEM Fastrax 1.855.244.3128 Fax: 1.303.979.7350 sales@fastraxind.com www.fastraxind.com...

  • Page 43: Extension Control Panel Wiring Diagram (1) No. 14, 15, Or 16 Switch & Spring Frog Heating System

    H.11 EXTENSION CONTROL PANEL WIRING DIAGRAM (1) NO. 14, 15, OR 16 SWITCH & SPRING FROG HEATING SYSTEM CCI Thermal Technologies Inc.

  • Page 44: Extension Control Panel Wiring Diagram (1) No. 20 Or 24 Switch & Movable Point Frog Heating System

    H.12 EXTENSION CONTROL PANEL WIRING DIAGRAM (1) NO. 20 OR 24 SWITCH & MOVABLE POINT FROG HEATING SYSTEM Fastrax 1.855.244.3128 Fax: 1.303.979.7350 sales@fastraxind.com www.fastraxind.com...

  • Page 45: Junction Box Connections

    FC Insulated Connectors Used For Wire Connection In Junction Box ® Table H.13-1 - Insulated Connector Torque & Strip Chart Wire Size (AWG) Torque (in/lb) Strip Length (in) #14 - #10 11/16 11/16 #4 - #6 11/16 CCI Thermal Technologies Inc.

  • Page 46: Junction Box Heater Connections

    H.14 JUNCTION BOX HEATER CONNECTIONS Wire entrances are located as shown in Figure H.14.1. Note: When using conduit, cable connectors or glands, please be sure there are no burrs or sharp edges that will damage wire insulation inside the junction box. 1”...
  • Page 47 Green Wire to be Terminated at Junction Box Grounding Lug Fastrax FC3/414 Insulated ® Multi-Cable Connector Blocks 3C#12 Cable From Crib Heaters Figure H.14.3 - Crib Heater Typical Connections - (4) Crib Heaters at Switch Point Junction Box CCI Thermal Technologies Inc.
  • Page 48 Individually Tape 5C#6 Cable From Stand Unused Connectors Alone or Extension Panel 2C#10 Cable From SwitchBlade ® Heater for Spring Frog Figure H.14.4 - SwitchBlade Heater for Spring Frog Typical Connections ® 2C#10 Cable From (2) SwitchBlade Heaters for ® 5C#6 Cable From Movable Point Frog Wing Rail Stand Alone or Extension Panel...

  • Page 49: Fgsp1A Ground Snow Sensor Wiring At Fjam200Sup Junction Box

    H.15 FGSP1A GROUND SNOW SENSOR WIRING AT FJAM200SUP JUNCTION BOX FGSP1A snow sensors are only found at various switch locations as shown in the System Layout section of this manual. If there is no sensor located in your junction box, square cut conductors, fold back a minimum of 2 inches and tape the conductor end.
  • Page 50 Photocopy this page for reuse. DATE: TECH: 1500 W. Campus Drive Littleton, Colorado 80120 PH: 855.244.3128 FAX: 303-979-7350 www.fastraxind.com MASTER PANEL STAND ALONE PANEL PROJECT: CUSTOMER: LOCATION: CONTRACTOR: CONTACTS: PHONE CELL CONTACTS/DIRECTIONS: ACTUAL INPUT TRANS OUTPUT VOLTAGE: VOLTAGE: SERIAL NUMBER: MODEL NUMBER: SENSORS QUAN: FAS1A...
  • Page 51 Photocopy this page PAGE 2 - STAND ALONE PANEL for reuse. DATE: 1500 W. Campus Drive Littleton, Colorado 80120 TECH: PH: 855.244.3128 FAX: 303-979-7350 www.fastraxind.com STAND ALONE PANEL VOLTAGE: AMPS: SERIAL NUMBER: MODEL NUMBER: OPERATION CHECKOUT INSTRUCTIONS: (QUALIFIED PERSONNEL ONLY) Disconnect (lockout &...
  • Page 52 Photocopy this page CHECK EXTENSION PANELS AND RELATED EQUIPMENT for reuse. SLAVE PANEL ___ OF ___ 1500 W. Campus Drive Littleton, Colorado 80120 DATE: PH: 855.244.3128 FAX: 303-979-7350 www.fastraxind.com TECH: EXTENSION POWER OPERATION (EACH EXTENSION PANEL) VOLTAGE: AMPS: SERIAL NUMBER: MODEL NUMBER: INSTALLATION CHECKOUT STRUCTURE...
  • Page 53 Photocopy this page for reuse. 1500 W. Campus Drive Littleton, Colorado 80120 PH: 855.244.3128 FAX: 303-979-7350 HEATER CIRCUIT READINGS www.fastraxind.com FORM 0004ET PROJECT: PAGE: LOCATION: DATE: TECH: (*2) LOCATION SWITCH FASTRAX (*1) TERMINAL ® (POSITION) DESIGNATION MODEL NUMBER VOLT NUMBERS OHMS NOTE NOTES:...
  • Page 54 Ohm’s Law R X I 1500 W. Campus Drive Littleton, Colorado 80120-4519 R X I 2 PH: 855.244.3128 FAX: 303-979-7350 www.fastraxind.com √ P X R E X I √ Calculated Circuit Nominal Test Readings Individual Heaters - Common Sizes All Heaters At 300 Watts Per Foot Nominal 240 VOLT 480 VOLT 600 VOLT...

  • Page 55: Control Panel General Equipment Procedures

    (either full or 25% power maintenance cycle) if new snow falls and the ambient temperature falls below 38°F, the automatic control is re-initiated and full heating operation starts over. Figure I.1.1 - FDC-6/FDC-7 Integrated Control & Sensor System CCI Thermal Technologies Inc.

  • Page 56: Stand Alone Control Panel (Manual Operation)

    STAND ALONE CONTROL PANEL (MANUAL ADDITIONAL FEATURES STAND ALONE OPERATION) CONTROL PANEL Manual start operation is a momentary push button REMOTE ANNUNCIATION: on the inner door that initiates the same timed heating cycles as explained in the preceding ‘Automatic • For single and multiple switch stand-alone panels, Operation’...

  • Page 57: Master/Extension Control Panels (Automatic Operation)

    Once the time this period. period is up the system will then shut off. d) To interrupt the over-ride heat cycle press the red “Manual Stop” push button. CCI Thermal Technologies Inc.

  • Page 58: Additional Features Master/Extension Control Panel

    STROBE LIGHT CIRCUIT: If positive shut down of the Master system is desired turn the circuit breaker CB1 (located in the Master • Strobe light output (terminals 38 & 39 in the Master panel) to the off position. panel) is a dry contact, which closes if the circuit a) Automatic control will not operate again until CB1 breakers for the transformer are manually turned off is returned to the on position.

  • Page 59: Switchblade Heating

    Primary Pwr. Dist. Block Secondary Note: If frog does not have proper heater clearance Heater And Control or is not a size listed contact engineering or Fastrax ® Circuit Breakers 17.7 Loads for optional installation methods. CCI Thermal Technologies Inc.

  • Page 60: Movable Point Frog Heating

    I.12 MOVABLE POINT FROG HEATING J.2 INSTALLATION PROCEDURE Note: Do not operate heaters at voltages in excess Contact Fastrax or review the bill of material for proper mov- of that stamped on the heater. Excess voltage will able point frog heater selection. shorten heater life.

  • Page 61: Maintenance Procedure

    Only qualified personnel trained in electrical equipment service should perform maintenance WARNING on switch heating and control equipment. • Periodically (minimum annual) check connection of the electrical terminals and tighten if necessary to torque specification guides. CCI Thermal Technologies Inc.
  • Page 62 NOTES...
  • Page 63 As a leader in advanced heating and filtration solutions with facilities across North America, CCI Thermal Technologies Inc. manufactures six of the top brands in industrial heating in addition to a comprehensive line of engineered industrial filtration products including: Cata-Dyne™ is the industry standard in infrared gas catalytic heaters, enclosures, pipeline systems and accessories.

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