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RECO 922 Operating Manual

Switch heater control
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OPERATING MANUAL
MODEL 922 SWITCH HEATER CONTROL
230VAC/460VAC
MANUFACTURED
BY
RAILWAY EQUIPMENT COMPANY
th
525 9
STREET SOUTH
DELANO, MINNESOTA 55328
TEL. 763-972-2200
FAX. 763-972-2900
E-Mail:
Sales@rwy.com

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  • Page 1 OPERATING MANUAL MODEL 922 SWITCH HEATER CONTROL 230VAC/460VAC MANUFACTURED RAILWAY EQUIPMENT COMPANY 525 9 STREET SOUTH DELANO, MINNESOTA 55328 TEL. 763-972-2200 FAX. 763-972-2900 E-Mail: Sales@rwy.com...
  • Page 2 (THIS PAGE IS INTENTIONALLY LEFT BLANK)

  • Page 3: Table Of Contents

    Table of Contents Warnings, Cautions, and Notes ....................1 Part Number Description ......................2 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.
  • Page 4 6.2. Control Module Does NOT Turn On ................34 Specifications......................... 35 Drawings ..........................36 Limited Warranty ........................37 P/N R9220-0103D Rev. F © 2021 RAILWAY EQUIPMENT CO. Page ii...

  • Page 5: Warnings, Cautions, And Notes

    NOTE indicates explanatory information that applies to the next step in the procedure. It NOTE 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.

  • Page 6: Part Number Description

    2. Part Number Description P/N R9220-0103D Rev. F © 2021 RAILWAY EQUIPMENT CO. Page 2...

  • Page 7: Customer Connections

    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 Three Phase Wye NOTE: On some models, an adjustable main circuit breaker is...

  • Page 8: Control

    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.

  • Page 9: Heaters

    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.
  • Page 10 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.
  • Page 11 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.
  • Page 12 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. P/N R9220-0103D Rev.

  • Page 13: Fault Indication Light

    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.

  • Page 14: 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.

  • Page 15: Set-Up And Adjustments

    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. Arrow Button Left Pushing the left arrow button will cycle back through the menus.

  • Page 16: Password 0 And 5 Menus

    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).
  • Page 17 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.
  • Page 18 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.
  • Page 19 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.
  • Page 20 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.
  • Page 21 1000mSec. h. Select Run Timer Value The run timer can be set from 0 to 1000 minutes. If 0 is selected, the 922 outputs will operate continuously, until control on is disabled. If another value is selected, the unit will run until the run timer counts down to zero, after which the unit will shut down and drop indication.
  • Page 22 The rail temperature setpoint is selected on this screen. When the rail temperature is above this setpoint, the 922 will be allowed to operate in half power mode. The factory default is 60°F. The range is from 0°F to 280°F.
  • Page 23 Will change the temperature scale to Fahrenheit or Celsius, the default is Fahrenheit. s. Machine S/N (Password 5) Machine serial number is the serial number of the 922 unit. t. Program Rev (Password 5) Shows the current program revision and date it was compiled on.

  • Page 24: Push Buttons And Led Status Indication Lights

    (and the air temperature to be below the setpoint). Another way the 922 can run is through the use of the internet. A message can be sent to the 922 instructing it to run for a given amount of time. b. OFF If the off button is pushed, the 922 cannot be run from remote control, snow detect, or the internet.
  • Page 25 4.4.2. LED Status Indication Lights The LEDs on the front of the control module indicate what state the inputs, and outputs are in. Refer to 5.3 LED Status Indication Lights in section 5. Output Module for more information about the different status lights. a.
  • Page 26 LOCAL, and a contact is closed between TB2-1 and TB2-2, it will be on. It will also be on if the 922 is in fault and remote control is off. When turned on, a dry contact will close between TB2-3 and TB2-4.

  • Page 27: Master Connections

    Here are all the different connections you could have, starting in the upper left-hand corner: a. Earth Ground (J14) Required for use of earth ground by the 922. b. Control Module Transformer (J21) Required for incoming power to the control module and output modules.
  • Page 28 e. Heater (J17) Power output (230VAC) for panel heater. f. Fan (J26) Power output (230VAC) for panel heater fan. g. A.R.R Post (J6) Required for the use of the A.R.R posts. h. Output Comm (J4) This is for communication between the control module and the outputs. i.

  • Page 29: Operation

    NET Cycle (Optional internet connection must be established) • To Start o The website sends a message to the 922, instructing it to turn on for a period of time • To End o The net timer elapses P/N R9220-0103D Rev.

  • Page 30: Wave Mode Operation

    The output module(s) will switch to full power once the unit is called for. Some faults can cause the 922 output modules to halt their operation cycles. For a list of these faults and their effects on operation, see the next section (4.7 Fault Conditions).

  • Page 31: Fault Conditions

    All faults can be cleared by resetting the output module that is in fault. 4.7.1. Master Faults These relate to faults occurring on the 922 control module: a. Fuse #1 24VDC 24VDC fuse open indicates that fuse F1 is open.
  • Page 32 4.7.2. Output Faults These relate to faults occurring in the output module(s): a. Open Heater Fault This fault will only be checked while the output is running in full wave mode. This will tell you which breaker on an output is drawing less current than when the Auto Heater Setup was run.
  • Page 33 d. Comm. Loss Fault This indicates that the output shown is failing to communicate to the control module. • The interconnect between the master and output 1 may not be connected properly • Interconnects between the individual outputs may not be connected properly •...

  • Page 34: Output Module

    5. Output Module 5.1. Description The 922 output module contains all of the functions necessary to control rail heaters. Some of the features of the output module are: Power contactor control Communications with control modules Output voltage and current, measuring...

  • Page 35: Led Status Indication Lights

    5.3. LED Status Indication Lights The following status lights exist on the output module depict what state the output module is in. Refer to 4.4. LED Status Indication Lights in section 4. Control Module for more information about the status lights. a.

  • Page 36: Output Circuit Board Connections

    5.4. Output Circuit Board Connections a. Output Location (J6) This is required for the control module to be able to communicate with this output module. These are numbered plugs that give the output module a unique identification. The output modules must be incrementally numbered, starting at 1 for the leftmost module (the one connected directly to the control module).

  • Page 37: Operation

    5.5. Operation The output module operates dependent on instructions passed onto it by the control module. For detailed instructions on how to run the outputs, see 4.6 Operation in section 4. Control Module. There are no user-serviceable parts on the output module. When an output module is instructed (by the control module) to turn on, it will always follow these steps: •...

  • Page 38: Troubleshooting

    6. Troubleshooting Before looking through this section make sure no faults exist and if any do, first refer to 4.7 Fault Conditions. After going through this section and you cannot fix the problem, please call Railway Equipment Co. to resolve the problem. 6.1.

  • Page 39: Specifications

    7. Specifications Input: 230VAC or 460VAC, 1 or 3 phase, 60Hz Heater Fault to Ground Range: Minimum 20mA (user settable) Open Heater Range: Minimum 5A loss on any output (user settable) Indication: 115VAC (2A max) signal on TB2-3 and TB2-6, or 24 VDC (2A max) signal on TB2-4 and TB2-9, or Dry Contact (2A @ 28VDC or 2A @ 230VAC) on TB2-3 and TB2-4 Air Temperature Setpoint Range: 0°F to 100°F.

  • Page 40: Drawings

    ELECTRIC HEATER CONTROL 480V 1PH 2 OUTPUT 922-41C0212-110A 922 CONTROL MODULE 9228-0320 ASSY, OUTPUT SECTION NO HALF POWER 9228-4010 ASSY, OUTPUT SECTION WITH HALF POWER 9228-4009 922 MENU FLOW CHART P/N R9220-0103D Rev. F © 2021 RAILWAY EQUIPMENT CO. Page 36...

  • Page 41: Limited Warranty

    9. Limited Warranty 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. This warranty is expressly in lieu of and excludes all other expressed or implied warranties, including but not limited to warranties of merchantability and fitness for a particular purpose.

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