Railway Equipment 955 Operating Manual

Gas fired hot air blower / track switch snow melter

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OPERATING MANUAL

MODEL NO. 955 STANDARD

MODEL NO. 954 LOW PROFILE

3 HP

230V 1 PHASE

230V 1 PHASE AC DRIVE

460V/575V 3 PHASE

GAS FIRED HOT AIR BLOWER

TRACK SWITCH SNOW MELTER

WITH STEEL TIE DUCT

MANUFACTURED

RAILWAY EQUIPMENT COMPANY

15400 MEDINA ROAD

PLYMOUTH, MINNESOTA 55447

TEL. 763-972-2200

FAX. 763-972-2900

E-Mail:

Technical Support: Techsupport@rwy.com

Sales: Sales@rwy.com

P/N R9550-0100

REV I

11/18

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Summary of Contents for Railway Equipment 955

Page 1 OPERATING MANUAL MODEL NO. 955 STANDARD & MODEL NO. 954 LOW PROFILE 3 HP 230V 1 PHASE 230V 1 PHASE AC DRIVE 460V/575V 3 PHASE GAS FIRED HOT AIR BLOWER TRACK SWITCH SNOW MELTER WITH STEEL TIE DUCT MANUFACTURED RAILWAY EQUIPMENT COMPANY...
Page 2 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. P/N R9550-0100 © 2018 RAILWAY EQUIPMENT CO. REV I 11/18...
Page 3 CHECK WITH LOCAL FIRE SAFETY AUTHORITY IF YOU HAVE QUESTIONS ABOUT APPLICATIONS. Other standards govern the use of fuel gases and heat producing products in specific applications. Your local authority can advise you about these. P/N R9550-0100 © 2018 RAILWAY EQUIPMENT CO. REV I 11/18...
Page 4 THIS SYSTEM OPERATES WITH NATURAL GAS OR PROPANE. BOTH ARE GASES WHICH ARE FLAMMABLE AND EXPLOSIVE. USE EXTREME CAUTION WHEN WORKING IN THE AREA. AVOID ANY OPEN FLAME, CAUTION SPARKS OR OTHER SOURCE OF IGNITION. P/N R9550-0100 © 2018 RAILWAY EQUIPMENT CO. REV I 11/18...
Page 5 A HIGH TEMPERATURE LIMIT SYSTEM HAS BEEN INCORPORATED INTO ALL RAILWAY EQUIPMENT COMPANY GAS SNOW MELTER SYSTEMS BEGINNING IN 1999. RAILWAY EQUIPMENT COMPANY ALSO HAS A HIGH TEMPERATURE LIMIT MODIFICATION KIT THAT CAN BE ADDED TO GAS SNOW MELTER SYSTEMS MANUFACTURED PRIOR TO 1999.
Page 6: Table Of Contents
LOW PRESSURE REGULATOR ADJUSTMENT VII. TROUBLESHOOTING UNIT DOES NOT START UNIT DOES NOT MAINTAIN OPERATIONS LOW HEAT LEVEL LOW AIRFLOW GAS VALVE HIGH HEAT LEVEL VIII. SNOW DETECTOR INSTALLATION OPERATION MAINTENANCE TROUBLESHOOTING P/N R9550-0100 © 2018 RAILWAY EQUIPMENT CO. REV I 11/18...
Page 8: General Information
10X10 ADAPTOR FLANGE 954 3HP Low Profile 3 = DUAL STAGE WITH SENSORS 4 = 480VAC 3PH 955 3HP High Profile 4 = DUAL STAGE WITH SENSORS AND NOZZLES (NO TIE DUCT) 5 = 575VAC 3PH 960 2HP Bungalow Enclosed...
Page 9 Tank "pigtail" with POL/POL fittings (P/N 45038-12” or 60127-36”) High pressure regulator (P/N 45103) Gas line strainer (P/N 45040) Remote solenoid valve (P/N 45036) OR Complete Propane Package (P/N 9458-0100) P/N R9550-0100 © 2018 RAILWAY EQUIPMENT CO. REV I 11/18...
Page 10: Component Description
AIR TEMPERATURE SENSOR: This is a thermocouple sensor for monitoring the ambient air temperature. The flexible magnetic end of the sensor should be placed so it is shaded by the GHAB unit, generally on the north side. P/N R9550-0100 © 2018 RAILWAY EQUIPMENT CO. REV I 11/18...
Page 11: Main Hab Unit
TRACK DUCT NOZZLE ISOLATING KIT: This is an electrically insulating gasket with insulating washers and hardware to provide isolation between the nozzles and the outlet duct. Refer to drawing 9278-0027 for proper installation. P/N R9550-0100 © 2018 RAILWAY EQUIPMENT CO. REV I 11/18...
Page 12: Optional Ductwork
A kit is available (P/N 9278-0270) that includes a 7’ track duct, a track duct nozzle and a track duct isolation kit. OTHER DUCTWORK ASSEMBLIES ARE AVAILABLE. CONSULT THE FACTORY FOR SPECIAL DUCTWORK NEEDS. P/N R9550-0100 © 2018 RAILWAY EQUIPMENT CO. REV I 11/18...
Page 14: Installation
Remove the end flange plate nearest the HAB by loosening the six retainer bolts. Install the two-foot heavy duty offset duct (P/N 9278-3403) to the tie duct using hardware and gasket supplied with the offset duct. P/N R9550-0100 © 2018 RAILWAY EQUIPMENT CO. REV I 11/18...
Page 15: Main Hab Unit
Connect the other end of the flex duct to the HD offset duct. With all components in the proper position, the foundation nuts may now be tightened. The fill can now be replaced around the mounting foundations. P/N R9550-0100 © 2018 RAILWAY EQUIPMENT CO. REV I 11/18...
Page 16 Push in the square knockouts in the track ducts where airflow is desired. The knockout should be pushed in and bent completely so that no portion of the knockout obstructs the airflow in the duct. Knockout tabs that are not bent back P/N R9550-0100 © 2018 RAILWAY EQUIPMENT CO. REV I 11/18...
Page 17: Gas Connection
Install the "Y" strainer downstream (but near) the high pressure regulator, or natural gas source. *Install the remote gas valve downstream (but near) the "Y" strainer. Electrical connections from the remote gas valve are made to terminal posts TS1-10 P/N R9550-0100 © 2018 RAILWAY EQUIPMENT CO. REV I 11/18...
Page 18 7” water column for natural gas. NOTE: Clockwise to increase pressure, counter- clockwise to decrease pressure. Let the GHAB run for a 10 minute period. After the 10 minute period, take temperature readings at P/N R9550-0100 © 2018 RAILWAY EQUIPMENT CO. REV I 11/18...
Page 19 If the temperature is above 250˚F, adjust the gas pressure at the low pressure regulator down (1” w.c. at a time) until you reach the desired temperature. Replace the top plug. * OPTIONAL ITEMS AVAILABLE FROM RAILWAY EQUIPMENT CO. P/N R9550-0100 © 2018 RAILWAY EQUIPMENT CO. REV I...
Page 21: Changing The Gas Orifice
Replace the bolts on the inlet bracket (outside of GHAB), and tighten the U-bolt hardware. Re-install the lower intake cover. Turn on power and manual gas valve. Test unit and check regulator adjustment and output temp. P/N R9550-0100 © 2018 RAILWAY EQUIPMENT CO. REV I 11/18...
Page 22: Electrical Connection
+24 VDC: Place a jumper between terminal posts TS1-2 and TS1-4. +24 VDC indication is now present on post TS1-3 with common at terminal post TS1-6. P/N R9550-0100 © 2018 RAILWAY EQUIPMENT CO. REV I 11/18...
Page 23 Attach the sensor to the bottom of the stock rail in front of the point nozzle. Attach conduit to ties using the provided clamps. Run wires from sensor into enclosure and plug connector into THERMOCOUPLE CONNECTIONS RAIL TEMP (YELLOW) located on the control module. P/N R9550-0100 © 2018 RAILWAY EQUIPMENT CO. REV I 11/18...
Page 24: Control Module
30 second pre-purge before ignition Direct spark ignition 10 second maximum ignition period before lock-out Rectification type flame rod sensor Automatic retry on flame loss 4 minute post-purge period after gas valve turn-off P/N R9550-0100 © 2018 RAILWAY EQUIPMENT CO. REV I 11/18...
Page 25: Set-Up And Adjustments
Decrease Value button to select the appropriate menu. Once the appropriate menu is selected, use the Mode Up or Down buttons to view the contents of the menu. NOTE: Use the Increase or Decrease Values button to change setpoint values. P/N R9550-0100 © 2018 RAILWAY EQUIPMENT CO. REV I 11/18...
Page 26 Tank level displays the actual level of propane tank in percent full (optional tank level monitor must be installed). Bat displays the battery level of the tank monitor. Temp displays the temperature in the battery monitor. P/N R9550-0100 © 2018 RAILWAY EQUIPMENT CO. REV I 11/18...
Page 27 OVER TEMPS WARNING COUNTER Counts the total number of Over Temp warnings. AUTO OVERTEMP RESET COUNTER Counts the total number of times the Over Temp was reset. P/N R9550-0100 © 2018 RAILWAY EQUIPMENT CO. REV I 11/18...
Page 28 Snow sense speed sets the delay time after the moisture detector sees moisture and starts the snow cycle. The delay time can be set from 1 to 60 seconds. The moisture sensor must see moisture for entire time to start cycle. P/N R9550-0100 © 2018 RAILWAY EQUIPMENT CO. REV I 11/18...
Page 29 2 HP 230V 3PH, 3 HP 230V 3PH, 5 HP 230V 3PH. RAIL TEMP SETPOINT This can be set from 0 F to 280 F (-18 C to 138º C). P/N R9550-0100 © 2018 RAILWAY EQUIPMENT CO. REV I 11/18...
Page 30 This feature is only for use on units that have a two wire overtemp sensor. Current production units are equipped with a four wire overtemp sensor. NOTE: BYPASSING THE OVERTEMP SENSOR MAY CAUSE HARMFUL OPERATING CONDITIONS. P/N R9550-0100 © 2018 RAILWAY EQUIPMENT CO. REV I 11/18...
Page 31 Shows the MAC address for the unit. AMBIENT OFFSET Used to calibrate the ambient temperature sensor. RAIL OFFSET Used to calibrate the rail temperature sensor. DUCT OFFSET Used to calibrate the duct temperature sensor. P/N R9550-0100 © 2018 RAILWAY EQUIPMENT CO. REV I 11/18...
Page 32 LOCAL: If LOCAL without air temp parameter is enabled, placing SS1 in the LOCAL position enables the snow melter regardless of outside air temperature. The snow melter will remain on until LOCAL is turned off. This is useful for hot weather testing. P/N R9550-0100 © 2018 RAILWAY EQUIPMENT CO. REV I 11/18...
Page 33: Led Status Indicating Lights
Also may be on when there is a fault condition under snow detector. FAIL: This LED is on when ever a fault is present. P/N R9550-0100 © 2018 RAILWAY EQUIPMENT CO. REV I 11/18...
Page 34: Operation
100% capacity. If the duct temp sensor sees a temperature above 325 F (163º C) both gas valves will be disabled. This prevents over temps. P/N R9550-0100 © 2018 RAILWAY EQUIPMENT CO. REV I 11/18...
Page 35: Fault Conditions
Check to see if the flame rod is shorted to ground, the flame rod is loose, the flame rod is dirty or if the insulators is fully installed so that no moisture can short out the flame rod. 4. FLAME DETECTED ON FAULT: P/N R9550-0100 © 2018 RAILWAY EQUIPMENT CO. REV I 11/18...
Page 36 After problem is corrected, leave power off for 30 seconds and fuse will reset. 10. CHECK FUSE # 6 SNOW HEAD # 1: Fuse # 6 is tripped. Check the following circuits: P/N R9550-0100 © 2018 RAILWAY EQUIPMENT CO. REV I 11/18...
Page 37 If the temperature is close to overtemp value, the unit will restart in a certain time period. 17. OVERTEMP MISSING INSTALL OVERTEMP: Caused my missing overtemp sensor. 18. MOTOR VOLTAGE LOW: P/N R9550-0100 © 2018 RAILWAY EQUIPMENT CO. REV I 11/18...
Page 38 28. TANK VAPORIZATION PRESSURE LOW WARNING: Tank vaporization pressure low warning is caused by low tank temperatures. 29. UTILITY POWER LOST: P/N R9550-0100 © 2018 RAILWAY EQUIPMENT CO. REV I 11/18...
Page 39: Seasonal Maintenance
Check the flame current. Refer to Section IV, Control Module (B), SET- UP AND ADJUSTMENT 19. Check the air temperature for proper setting. P/N R9550-0100 © 2018 RAILWAY EQUIPMENT CO. REV I 11/18...
Page 40: Low Pressure Regulator Adjustment
If the temperature is above 250˚F, adjust the gas pressure at the low pressure regulator down (1” w.c. at a time) until you reach the desired temperature. Replace the top plug. Return all switches to their normal operating position. P/N R9550-0100 © 2018 RAILWAY EQUIPMENT CO. REV I 11/18...
Page 41: Troubleshooting
Check the low pressure regulator. Check to see if the burner control is on low only or if it is in auto and the Rail Temp Sensor setting is forcing it to low output. P/N R9550-0100 © 2018 RAILWAY EQUIPMENT CO. REV I 11/18...
Page 42: Low Airflow
Check the gas valve for obstructions. Check the gas valve for proper operation. HIGH HEAT LEVEL Check for proper orifice installation. Perform the low pressure regulator and Temp Test found in Section VI. P/N R9550-0100 © 2018 RAILWAY EQUIPMENT CO. REV I 11/18...
Page 43 A second sensing head is then placed away from the switch area, such as on a bungalow or pole. P/N R9550-0100 © 2018 RAILWAY EQUIPMENT CO. REV I 11/18...
Page 44 Use a clean, dry cloth to wipe the grid. Make sure there is no residue left on the surface. P/N R9550-0100 © 2018 RAILWAY EQUIPMENT CO. REV I 11/18...
Page 45 Clean the snow detector heads as described in section C, Snow Detector Maintenance. Remove white lead(s) from terminal post 9. If moisture indication is still on, the control module is defective and should be replaced. P/N R9550-0100 © 2018 RAILWAY EQUIPMENT CO. REV I 11/18...
Page 46 600,000 BTU/HR 300,000 BTU/HR FUEL : Propane or Natural Gas FLOW RATE: Natural Gas: 600 CFH/300 CFH Propane: 240 CFH/120 CFH 6.6 GPH/3.3 GPH INDICATION CONTACTS: 30VDC 1A or 125VAC 300mA P/N R9550-0100 © 2018 RAILWAY EQUIPMENT CO. REV I 11/18...
Page 47 GHAB ELECT. PANEL LAYOUT 230V AC DRIVE 9558-0154 GHAB ELECT. SCHEMATIC 230V AC DRIVE 9554-0133 GAS PIPING, 2 STAGE 9558-0237 AIR TEMP SENSOR, 4’ MAGNETIC 9508-0404 BURNER ASSEMBLY 9528-0135 PRESSURE SWITCH CALIBRATION P/N R9550-0100 © 2018 RAILWAY EQUIPMENT CO. REV I 11/18...
Page 48 LIMITED WARRANTY Railway Equipment Co., Inc. (“Railway”) warrants all of its products to be free from defects in material and workmanship when used under specified operating conditions and within specified limits. Railway’s warranty shall extend for a period of two (2) years from the date of shipment to the original purchaser.
Page 81 Pressure Switch Calibration These steps describe how to calibrate the pressure switch to turn off when 90% of the air intake is blocked. 1. The Pressure Switch comes pre calibrated based on the horsepower of the Gas Hot Air Blower. If adjustment is needed they can be adjusted between 0.12”wc to 5.0”wc.
Page 82 4. Turn the Pressure Switch adjustment screw Clockwise (CW) until the Air Flow LED on the control module turns off. It is now calibrated.

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