TCH 250-150 Manual
Contents
1. SERIES PRODUCT ENHANCEMENTS cont OUTPUT TEMP CONTROL WATLOW OUTPUT TEMPERATURE DELIVERY CONTROL Press and hold the up or down arrow to select desirable temperature output temperature range 70 F 180 F The other buttons are disabled Normal set temperature for Thaw mode is pre set at 180 F 82 2 C Ideal Cure mode set temperature is approximately 85 F 29 4 C Temporary Heat mode can be any set temperature that the environment can endure 21 22 MODEL TCH 150 SPECIFICATIONS AND PERFORMANCE TCH150 PORTABLE HYDRONIC HEATER Fuel Fuel Capacity HTF Capacity HTF Durability HTF Circulation Pump Maximum BTU output Size Weight Electrical service required Hose 3 000 Lineal Feet 918 Lineal Meters Optional Generator Available hitch Safety Codes 1 2 Diesel 102 Gal 390L 56 Gal 2121 80 62 1 Closed Loop Centrifugal 148 000 161 IN X 74 IN X 79 IN 409 cmX 190 cmX 2 00 cm 3 460 LB 1 570 kg 120 v 20 amp 2 x 600 Ft 2 184 7 000 WATT DIESEL FIRED 2 2 5 16 Pintle NHTSA CSA UL IBR TCH150 PORTABLE HYDRONIC HEATER Thaw Area With additional hose Concrete curing area With accessories Frost prevention With accessories Heat buildings Operating Pressure Fuel Consumption full load Run Time Pump Capacity 1 200 SQ FT 2 400 SQ FT 2 400 SQ FT 10 800 SQ FT 2 400 SQ FT 10 800 SQ FT 210 000 CU FT 1 5psi 1 0 GPH2. 48 Page 49 50 Page 51 53 Page 55 57 Page 59 60 Page 61 62 Page 63 Page 65 Operators Manual For model TCH 250 TCH150 Please record the following information from your new Thawzall for future reference This in formation is required for all warranty claims Purchase date Generator make Machine model Generator KW Machine serial number Generator Serial Serial number located on trailer pull tube Thawzall LLC Manufactured by Thawzall LLC P O Box 158 104 Donovan Drive Alexandria MN 56308 Phone 320 759 1588 Fax 320 759 1583 Tech Support 888 757 3545 Website www Thawzall com E Mail Thawzall Thawzall com Older Models similar are H150 H250 and H250SL Maintenance Record for Season See Recommended Maintenance sheet for frequency details DISCONNECTS DATE DATE DATE DATE Clean and lubricate Minimum twice per season HOSE REEL Grease all Zerts Minimum of twice per season Check all Allen screws at gear shaft As needed Check Allen screws at bearing keepers Minimum twice per season BOILER Clean stack As needed Clean flute As needed Clean baffles As needed Clean combustion chamber As needed BECKETT BURNER GENISYS CONTROL Set air band As needed Check nozzle As needed Replace flange gasket As needed Replace fuel filter As needed Check combustion head As needed Lubricate motor As needed Check gap on ignition probe As needed Lubricat
3. ee Lithium Hydrostearate Sebacate Complex E Zinc Alkyldithiophosphate 68649 42 3 22 2011 0550 ee e A Additional Information Part No 120650 0 5 oz tube Part No 107408 4 oz can Part No 197007 5 gallon container May also contain minute amounts of lithium and molybdenum lubricant compounds Section 3 Hazard Identification Acute Health Effects Skin Excessive contact may cause skin irritation and dermatitis Eye Direct contact with eye will cause irritation Inhalation No adverse effects are expected Ingestion Ingestion of product may cause nausea vomiting and diarrhea Chronic Health Effects Existing skin rash or dermatitis may be aggravated by repeated contact OSHA Hazard Classifications None 43 Carcinogenicity Not considered to be a carcinogen by either OSHA NIP 1ARC or ACGIFI Target Organs None known Section 4 First Aid Measures Eye Contact Flush eyes with water for 15 minutes Remove any contact lenses and continue to flush Obtain medical attention if irrita tion develops and persists Skin Contact Remove excess with cloth or paper Wash thoroughly with mild soap and water Obtain medical attention if irritation devel ops and persists Ingestion Contact physician or local poison control center immediately Inhalation Remove patient to fresh air and obtain medical attention if symptoms develop Section 5 Fire Fighting Measures Material
4. Flash Point gt 383 F 195 C Will burn if exposed to flame Extinguishing Media Carbon dioxide dry chemical or foam Special Fire Fighting Procedures None Explosion Hazards None Aluminum powder can react with water to release flammable hydrogen gas In the form of this product this reaction is not expected Section 6 Accidental Release Measures Scrape up and dispose of as solid waste in accordance with state and federal regulations Section 7 Handling and Storage Store in dry place Keep container closed when not in use Section 8 Exposure Controls and Personal Protection Ventilation No special ventilation is required when working with this product Respiratory Protection None required Eye Protection Not normally required However use chemical safety goggles or face shield if potential for eye contact exists especially if mate rial is heated Hand Clothing Protection Not normally required Protective gloves and clothing are recommended as material is difficult to remove from skin and clothing Other Protective Equipment None required Section 9 Physically and Chemical Properties Appearance Odor Aluminum Color Semi solid material pleasant odor Soluble in Water Negligible Specific Gravity 0 86 Section 10 Stability and Reactivity Stability Stable Reactivity Hazardous polymerization will not occur Incompatibilities Strong oxidizing agents and halogens Hazardous Decomposition Products Carbon Dioxid
5. SOIL CONDITION Clay or Silt poor to moderate drainage a qo a de Hose spacing is measured inches on center GROUND THAW SETUP CHARTS cont EMPERATURE 20 F or lower 29 C or lower LAYERS OF BLANKETS TO USE DOUBLE R12 insulation factor SOIL CONDITION Gravel or Sand good drainage Der m Hose spacing is measured inches on center EMPERATURE 20 F to lower 28 C or lower LAYERS OF BLANKETS TO USE DOUBLE R12 insulation factor SOIL CONDITION Clay or Silt poor to moderate drainage fa fe Hose spacing is measured inches on center 27 THAW When moisture freezes in the soil it requires 143 BTU s per pound to thaw the ground Shown are 4 types of soil and their thawing requirements Gravel Sand Clay Silt up to 1 001 BTU s up to 2 574 BTU s up to 3 146 BTU s up to 7 436 BTU s required to melt ice required to required to required to melt ice CURE Concrete cures slowly due to cold temperatures Here s how temperature affects the concrete curing process Curing of Concrete vs Time Bl Time to Initial Set 4 Time to Final Set 77 Time to 500 psi 3 5 MPa 70 F 21 C 60 F 16 C 50 F 10 40 F 4 C 30 F 1 Performance Thaw and Cure performance in the field is affected by a wide range of factors to include soil type density of frozen ice in the soil hose spacing thermal rating of the covering insulati
6. Volume of space to be heated and type of heat exchanger used 11 FAQ Continued Q Can Thawzall operate at high altitudes A Yes but operation at high altitudes may require adjustments see High Altitude section Q What kind of vehicle do I need to tow a Thawzall A A minimum of 3 4 ton truck with a brake controller Please see Specifications section Q What type of fuel does the Thawzall use A 1 fuel oil is preferred and if not available then winter blend with anti gelling additives Q What type of power is required to operate the Thawzall A 120 volt ac 20 amps The burner may not fire with less than 112 volts Q How long can I expect a tank of fuel to last A Depending on ambient temperature work zone insulation and soil conditions the average fuel consumption is roughly 1 GPH without the generator and with the generator is about 1 6 GPH 12 13 IMPORTANT SAFETY RECOMMENDATIONS AND WARNINGS OUTSIDE SAFETY FEATURES Your Thawzall is equipped with DOT Certified outside LED lights reflectors safety chains and elec tronic Break away brakes Make use of these features Before towing the trailer be sure that all the lighting is connected and working Connect the safety chains to the towing vehicle Connect the small cable from the break away switch to the towing vehicle Close the fuel valve at the bottom of the fuel tank on your Thawzall PARKING YOUR THAWZALL Avoid unexpected movement of your T
7. cell is disregarded This allows the technician to prime the pump without having to jumper the cad cell Terminate the call for heat and the control will exit the pump prime mode and resume normal op eration You can remove the control from the Pump Prime mode by holding the reset button for 1 second The control will return to Standby mode 32 OPERATING STATES cont DISABLE FUNCTION Press and hold red reset button for 1 second at any time to disable the burner e When you release the reset button the burner will return to normal operation e GeniSys control has limited reset e Initial lockouts result in soft lockout Red light flashing click the red reset button to restart e Recurring lockouts without completing a heat cycle will result in Restricted hard lockout Red light on steady hold the red reset button 15 seconds until the yellow light turns on You can NOT reset the control by interrupting line voltage PUMP PRIME MODE e Prepare the burner for priming e Initiate a call for heat e After the burner starts press and hold the reset button until the yellow light turns on 15 sec onds e Release the reset button The yellow light will turn off and the burner will start again e At burner start up click the reset button e Enters 4 minute dedicated pump prime mode with motor and igniter on and oil valve energized The yellow light is on when in the pump prime mode e Terminate the call for heat and t
8. heat or concrete curing product or component thereof if it fails to conform to this warranty In the event a ground defrosting thawing temporary heat or concrete curing product is to be repaired pursuant to this warranty such repair work will be performed by THAWZALL LLC or at its direc tion WARRANTY PERIOD The warranty relating to workmanship materials and labor on THAWZALL ground defrosting temporary heat or concrete cur ing products extends for two 2 years from the date of original invoice WARRANTY POLICY When claiming warranty you must give Thawzall the VIN number of the machine and date of invoice or original invoice number of the machine or part and Thawzall will determine if the affected machine and part is within the warranty period To Start a claim go to our website and complete a warranty claim and e mail to warranty thawzall com Thawzall will issue an RMA for the defective part and provide a pre paid freight return tag or call tag issued through UPS If the part s is not returned within 30 days from the RMA date you will no longer be eligible for any credit towards the replacement part You will need to issue a PO for the replacement part and Thawzall will invoice you for the replacement part and freight Once Thawzall receives the defective part we will inspect and test the part or have our vendor inspect it If the part is determined to be defective a credit will be issued for only the part cost fit is
9. 4 days 30 GPM 1 800 GPH 23 110 m 220 m 220 m 1 000 m 220 m 1 000 m 5 900 m 6895 Pa 34474 Pa 4 54 LPH 3 days 110LPM 6 800 LPH MODEL TCH 250 SPECIFICATIONS AND PERFORMANCE TCH250 PORTABLE HYDRONIC HEATER Fuel Fuel Capacity HTF Capacity HTF Durability HTF Circulation Pump Maximum BTU output Size Weight Electrical service required Hose 3 000 Lineal Feet 918 Lineal Meters Optional Generator Available hitch Safety Codes 1 2 Diesel 160 Gal 608 L 122 Gal 4641 80 F 62 1 Closed Loop Centrifugal 280 000 170 IN X 84 IN X 97 IN 4 318 mm X 2 133 mm X 2 439 mm 5 600 LB 2 522 kg 120 v 20 amp 5 x 600 Ft 5 184 7 000 WATT DIESEL FIRED 2 2 5 16 Pintle NHTSA CSA UL IBR TCH250 PORTABLE HYDRONIC HEATER Thaw Area With additional hose Concrete curing area With accessories Frost prevention With accessories Heat buildings Operating Pressure Fuel Consumption full load Run Time Pump Capacity 3 000 SQ FT 6 000 SQ FT 6 000 SQ FT 18 000 SQ FT 9 000 SQ FT 27 000 SQ FT 400 000 CU FT 1 5psi 1 0 GPH 3 days 30 GPM 1 800 GPH 24 278 m 550 m 550 m 1 670 m 840 m 2 500 m 11 320 m 6895 Pa 34474 Pa 4 54 LPH 3 days 110 PM 6 800 LPH GROUND THAW SETUP CHARTS EMPERATURE 30 F or higher 1 C LAYERS OF BLANKETS TO USE SINGLE R6 insulation factor SOIL CONDITION Gravel or Sand goo
10. 45 Resource Directory e Fuel Filter Kit Item No 1A 30 e Full Synthetic 75 90 Gear Oil made by Valvoline and other oil suppliers e HTF Available 1 and 5 gallon containers or 55 gallon drums from Thawzall LLC Always use Thawzall approved HTF to avoid warranty denial Thawzall LLC 104 Donovan Drive Alexandria MN 56308 O 320 759 1588 F 320 759 1583 T 888 757 3545 www thawzall com FOR TECHNICAL ASSISTANCE CALL THAWZALL TECHNICAL SUPPORT 888 757 3545 57 58 TALL LLC No 00 11 20 08 506 Rev 8 13 Technical Service Bulletin COUPLER REPLACEMENT KIT for Faster Couplers Attention All Service Managers and Service Technicians servicing Thawzall Equipment Subject Coupler Replacement Kit Date Effective November 20 2008 Rev 8 13 Purpose For repair of existing couplers using purchased Thawzall kit Procedure Replace defective coupler parts using parts from the Thawzall replacement kit Follow steps as shown below Place coupler vise Unscrew the body from the adaptor Adaptor after body is removed di an Unscrew the internal body from the The initial disassembly of the cou adaptor pler is now complete Proceed to step 6 to disassemble the valve as sembly Continued on reverse side 59 COUPLER REPLACEMENT KIT for Faster Cou plers Continued from front No 00 11 20 08 506 Rev 8 13 e nl To disassemble the valve assembly Pictured above are all parts fro
11. GNIFICANT INGESTION HAZARD UNDER ANTICI PATED CONDITIONS OF NORMAL USE SECTION VII PRECAUTIONS FOR SAFE HANDLING 4 USE SPILL OR LEAK PROCEDURES DIKE AREA RECOVER AND DISPOSE IN ACCORDANCE TO REGULATORY REQUIREMENTS WASTE DISPOSAL METHOD ACCORDING TO LOCAL STATE amp FEDERAL LAWS SPECIAL PRECAUTIONS HANDLE IN ACCORDANCE WITH GOOD INDUSTRIAL HYGIENE AND SAFETY PRECAUTIONS SECTION VIII CONTROL MEASURES RESPIRATORY PROTECTION specify NONE NEEDED VENTILATION LOCAL EXHAUST PROTECTIVE EQUIPMENT USE IMPERVIOUS GLOVES TO PREVENT SKIN CONTACT USE GOGGLES IF CONTACT IS LIKELY DISCLAIMER THE INFORMATION HEREIN HAS BEEN FROM SOURCES BELIEVED TO BE ACCURATE RELIABLE AND UP TO DATE TO THE BEST OF OUR KNOWLEDGE HOWEVER WE CANNOT GIVE ANY GUARANTEES REGARDING INFORMATION FROM OTHER SOURCES AND EXPRESSLY DO NOT MAKE ANY WARRANTIES NOR ASSUME ANY LIABILITY FROM ITS USE OR MISUSE 42 L4006 7 8 L6006 7 8 AQUASTA TO CONTROLLERS MATERIAL SAFETY DATA SHEET Section 1 Product And Company Identification Product Name Heat Conductive Compound MSDS ID DS9021 Synonyms MS1699 Product Use Heat conductive material used to enhance contact and heat transfer in temperature sensor applications Manufacturer Honeywell Inc 1985 Douglas Drive North Minneapolis MN 55422 Date Released October 8 1999 NFPA Ratings Health 0 Flammability 1 Reactivity 0 Personal Protection B Section 2 Composition Information on Ingredients
12. HEMATICS Page 1 7 12 awg SJO Cable L From Outlet Power N LG From Generator Power NG A ro he 09022110021 uonnquisig IVA skeidsiq eimesadwia 9 06201 08291 08 91 UONGUISIG OCA 08221 108 91 weJBerg alnjejadua NA eupuexe v 38 05221 06 21 40 MATERIAL SAFETY DATA SHEET PRODUCT NAME THAWZALL HEAT TRANSFER FLUID VERSION 1 PG 1 PRODUCT CODE AFPGBK DATE 8 29 2012 CHEMICAL FAMILY GLYCOL SECTION I MANUFACTURES NAME Thawzall LLC ADDRESS 104 Donovan Drive Alexandria MN PHONE 320 759 1588 EMERGENCY COC INFO TRAC 1 800 468 1263 SECTION II HAZARDOUS COMPONENTS CHEMICAL by wt CAS OSHA PEL ACGIH TLV All Ingredients Are Non Hazardous According To OSHA 29 Part 1910 1200 Subpart Z SECTION III PHYSICAL CHEMICAL CHARACTERISTICS BOILING POINT gt 200 F pH 9 10 FREEZING POINT 68 F SPECIFIC GRAVITY 1 05 VAPOR PRESSURE mm Hg N A PERCENT VOLATILE 36 VAPOR DENSITY AIR 1 N A APPEARANCE reddish pink SOLUBILITY IN WATER COMPLETE ODOR none EVAPORATION RATE BUTYL ACE TATE 1 SECTION IV FIRE amp EXPLOSION DATA FLASH POINT N A EXTINGUISHING MEDIA Co2 ALCOHOL RESISTANT FOAM DRY CHEMICAL SPECIAL PROCEDURES HEAT FROM FIRE CAN GENERATE FLAMMABLE VAPOR WHEN MIXED WITH AIR AND EXPOSED TO IGNITION SOURCE VAPORS CAN BURN IN O
13. ITUDE OPERATION Continued from page 1 ELEVATION ABOVE SEA NOZZLE SIZE COMBUS AIR INTAKE SETTING LEVEL TION HEAD 2 000 5 000 FT 1 75 F 22 2 5 000 7 5000 FT 1 5 F 22 3 6 6 000 10 000 FT 1 5 F 22 5 2 1 35 F 6 5 8 10 000 12 000 FT Nozzle and air intake changes affect burner BTU output only slightly at 1 4896 for every 1 000 FT above sea level Beckett Burner with GeniSys Contr EXPLODED PARTS BREAKDOWN 50 THAWZALL LLC No 00 06 08 502 rev 8 13 Technical Service Bulletin HEAT TRANSFER FLUID CHECK Attention Service Managers and Service Technicians Subject Testing of Heat Transfer Fluid HTF for freeze protection Date Effective June 1 2008 rev 8 13 Models Affected TCH 250 H2505L H150 2M 6A 12HU 12F XH and all new HEATZONE Series machines Purpose To ensure that the heat transfer fluid in the Thawzall system is concentrated enough to re sist freezing in cold weather all Thawzall model systems are now shipped with full strength not diluted with water Thawzall Heat Transfer Fluid Full strength HTF provides freeze protection down to 70 F or 56 C is not automotive antifreeze Automotive antifreeze MUST NOT be used in your Thawzall Please follow this three step procedure Please follow this three step procedure Step 1 From the fluid reservoir remove a small sample of HTF Test it with a refractometer according to the instructions sup plied with th
14. PEN OR EXPLODE IF CONFINED VAPORS CAN TRAVEL LONG DISTANCES ALONG THE GROUND BEFORE IGNITING AND FLASHING BACK TO VAPOR SOURCE FINE SPRAYS MISTS MAY BE COMBUSTIBLE AT TEMPERATURES BELOW NORMAL FLASH POINT AQUEOUS SOLUTIONS CONTAINING LESS THAN 95 PROPYLENE GLYCOL BE WEIGHT HAVE NO FLASH POINT AS OBTAINED BY STANDARD TEST METHODS HOWEVER AQUEOUS SOLUTIONS OF PROPYLENE GLYCOL GREATER THAN 22 BY WEIGHT IF HEATED SUFFICIENTLY WILL PRODUCE FLAMMABLE VAPORS ONLY AQUEOUS SOLUTIONS OF PROPYLENE GLYCOL LESS THAN 22 SHOULD BE USED IN SPRINKLER SYS TEMS OR OTHER FIRE FIGHTING EQUIPMENT ALWAYS DRAIN AND FLUSH SYSTEMS CONTAINING PROPYLENE GLYCOL WITH WATER BEFORE WELDING OR OTHER MAINTENANCE 41 PRODUCT NAME THAWZALL HEAT TRANSFER FLUID VERSION 1 PG 2 PRODUCT CODE AFPGBK DATE 8 29 2012 CHEMICAL FAMILY GLYCOL SECTION V REACTIVITY DATA STABILITY STABLE HAZARDOUS POLYMERIZATION WILL NOT OCCUR INCOMPATIBILITY HEAT SPARKS amp OPEN FLAME amp CONDITIONS TO AVOID STRONG OXIDIZING AGENTS HAZARDOUS DECOMPOSITION CARBON MONOXIDE OR BY PRODUCTS SECTION VI HEALTH HAZARD DATA ROUTES OF ENTRY SKIN EYES INGESTION HEALTH HAZARDS acute amp chronic EYE CONTACT CAUSES IRRITATION AND EYE TISSUE INJURY SKIN CONTACT MAY IRRITATE AND CAUSE DERMATITIS CARCINOGENICITY NOT LISTED BY OSHA IARC OR NTP EMERGENCY amp FIRST AID PROCEDURES IF CONTACT WITH EYES OR SKIN IMMEDIATELY FLUSH WITH WATER INGESTION NOT EXPECTED TO PRESENT A SI
15. ZONE aes T em D O WEATHER occ M a FAST amp EFFICIENT GROUND FROST REMOVAL amp THAWZALL TCH250 and TCH150 Manufactured by Thawzall LLC 104 Donovan Drive PO Box 158 Alexandria MN 56308 USA T 320 759 1588 24 7 Tech Support 888 757 3545 F 320 759 1583 www thawzall com E mail thawzall thawzall com Table of Contents Cover Page Table of Contents Registration Sheet Maintenance Record Company General Information History Frequently Asked Questions Important Safety Recommendations and Warnings HeatZone Series Product Enhancements TCH150 Specifications and Performance TCH250 Specifications and Performance Ground Thawing Setup Charts Altitude Adjustments Hose fill capacity Connector Maintenance General Maintenance Chart Beckett Burner GeniSys Controller Features TCH250 Wiring Schematics MSDS HTF MSDS AquaStast Tech Service Bulletin Hydronic System Leak Check Tech Service Bulletin High Altitude Operation Technical Service Bulletin Heat Transfer Fluid Check Technical Service Bulletin Preventive Maintenance Procedures Technical Service Bulletin Coupler Replacement Kit Thawzall Limited Warranty How to File a Warranty Claim Warranty Claim Form Page 1 Page 3 Page 5 Page 7 Page 9 10 Page 11 12 Page 13 18 Page 18 21 Page 23 Page 24 Page 25 28 Page 29 Page 30 Page 31 34 Page 35 39 Page 41 42 Page 43 45 Page 47
16. ble hydronic heat system using a low pressure closed loop system The first of hundreds of machines to come was produced that first win ter Because Jakobson felt that he and a better idea than a competing model he applied for and re ceived patent 5 964 402 for his portable hydronic heater in 1999 This patented system uses a mani fold fluid distribution system that features quick disconnects and multiple heat zones Jakobson an avid hunter and fisherman decided to sell his company known then as T H E Machine Company to a group of five local investors from the Alexandria Minnesota area in order to pursue his passions On July 1 2007 the company was formed with new ownership and management and be came known as Thawzall LLC The new management team is committed to listening to its customers for their ideas regarding prod uct innovation and simplicity By listening carefully to our customers we are confident that in the next generation Thawzall heat units will exceed our customers expectations and set new standards for quality and innovation in the industry for portable hydronic and flameless heater technology All Thawzall employees are committed to excellence in manufacture and customer satisfaction We take great pride with every machine we build Thank you for investing in a Thawzall portable heater David Reller General Manager Steve Knisley Sales Neil Beilke Technical Service Manager Jeremy Guhlke Operations Manage
17. ctivity Dripless quick connect couplers No loss of fluid from the system Shut off ball valves above couplers For maintenance safety and zone control 14 Gallon reservoir tank Prevents fluid spill if relief valve opens Dual temperature heat controls on boiler Prevents boiler from overheating Aquastats and high limit control FACTORY PRE SET DO NOT ADJUST Electronic Mixing valve OPERATIONAL THRU THE CONTROL PANEL WATLOW CON TROL THE ACTUAL VALVE IS PRE SET AT FACTORY DO NOT ADJUST Hydraulically crimped hose connections Strongest possible crimp on hoses Covered foot control for hose reel Prevents accidental activation of hose reel from falling objects Interior Light for Enclosure Provides visibility for machine operations or setup during early morning or evening hours Gages at all vital points Help to maintain proper operation levels All hoses and electrical components are UL approved Low Water Cut Off control Automatically shuts down the furnace if fluid level becomes too low for safe operation 17 SAFETY FEATURES OF THE THAWZALL HEAT MACHINE cont Trailer axles with electric brakes and breakaway stop system meet safety codes to include NHTSA CSA Transport Canada UL and IBR TCH HEATZONE SERIES PRODUCT ENHANCEMENTS Performance Improvements Improved heat distribution Improved circulation performance Full Strength HTF heat transfer fluid Simplified Configuration Quality Improvements Stee
18. d drainage poor RR o Hose spacing is measured inches on center EMPERATURE 30 F or higher 1 C LAYERS OF BLANKETS TO USE SINGLE R6 insulation factor SOIL CONDITION Clay or Silt poor o moderate drainage a i a Hose spacing is measured SENE TEM on center EMPERATURE 15 F to 30 9 to 1 C LAYERS OF BLANKETS TO USE SINGLE R6 insulation factor SOIL CONDITION Gravel or Sand good drainage EMPERATURE 15 to 30 9 C to 1 LAYERS OF BLANKETS TO USE SINGLE R6 insulation factor SOIL CONDITION Clay or Silt poor o moderate drainage eem Hose spacing is measured inches on center GROUND THAW SETUP CHARTS cont EMPERATURE 0 to 15 F 18 C to 9 LAYERS OF BLANKETS TO USE DOUBLE R12 insulation factor SOIL CONDITION Gravel or Sand good drainage _ Hose spacing is measured inches on center EMPERATURE 0 to 15 F 18 to 9 LAYERS OF BLANKETS TO USE DOUBLE R12 insulation factor SOIL CONDITION Clay or Silt poor to moderate drainage Hose spacing is measured inches on center EMPERATURE 20 to 0 F 28 to 18 LAYERS OF BLANKETS TO USE DOUBLE R12 insulation factor SOIL CONDITION Gravel or Sand good drainage ar o3 o3 o9 9 5 Hose spacing is measured inches on center EMPERATURE 20 to 0 F 28 Cto 18 LAYERS OF BLANKETS TO USE DOUBLE R12 insulation factor
19. determined that the part is NOT defective you will be a charged for the time it took to inspect and test the part Labor rate of 100 00 per hour WARRANTY PROCEDURE RMA Return Material Authorization To ensure processing of warranty claim a Return Merchandise Authorization RA must be obtained at the time of claim and prominently shown on correspondence and packages To obtain warranty and an RMA call 888 757 3545 U S Central Time or E mail warranty thawzall com Parts must be returned within 30 days of an RMA being is sued to receive credit 61 WARRANTY LIMITATIONS Thawzall Ground Defrosting Thawing Temporary Heat or Concrete Curing products must be installed where appli cable operated and maintained in accordance with all instructions provided by Thawzall LLC Failure to follow our installation where applicable operating or maintenance procedures and or use of unauthorized parts may void this warranty Purchasers and Users are responsible for the suitability of the products for their application This warranty does not apply to Repairs or replacements necessitated by any cause beyond the control of THAWZALL LLC including but not limited to any malfunction defect or failure caused by or resulting from unauthorized service or parts installation where applicable operating or maintenance contrary to furnished instruc tions local water conditions handling shipping or transit accidents m
20. e Carbon Monoxide 44 Section 11 Toxicology Information No date available Section 12 Ecological Information Chemical Fate Information Hydrocarbon components will biodegrade in soil relatively persistent in water Section 13 Disposal Consideration Dispose of as a solid waste in accordance with Local State and Federal regulations Section 14 Transportation Information DOT Classification Not classified as hazardous Section 15 Regulatory Information SARA Title III Supplier Notification Include in Section 311 312 inventory reports if amounts exceed 10 000 pounds Aluminum compounds are subject to the reporting requirements under Section 313 of Emergency Planning and community Right To Know Act of 1986 40 CFR 372 Ingredients listed in TSCA Inventory Section 16 Other Information This information is furnished without warranty expressed or implied except that is accurate to the best of our knowledge Prepared by PROSAR 1295 Bandana Boulevard Suite 335 St Paul MN 55108 651 917 6100 45 46 TECHNICAL SERVICE BULLETIN no 00 05 14 08 500 Rev 8 13 HYDRONIC SYSTEM LEAK CHECK Attention All Service Managers and Service Technicians servicing Thaw zall equipment Subject Hydronic system leak check for hose installed on Thawzall equipment Date Effective June 1 2008 For Models TCH250 H250SL H150 Purpose A system leak test procedure that will enable service employ Photos ees to quickly find in
21. e circulator As needed PRESSURE RELIEF Inspect to ensure working properly As needed MISCELLANEIOUS Check pH level of heat transfer fluid As needed HEAT ZONE Registered trademarks of Thawzall LLC COMPANY GENERAL INFORMATION Mission Statement Itis the mission for Thawzall to continue to derive quality and innovate while securing a larger market share and become the brand of choice recognized by all major rental companies and their contractor and oil field service customers for providing the most fuel efficient rental store friendly glycol and flameless heaters VISION STATEMENT Thawzall s vision is fairly simple As a team we want to provide the very best equipment to our valued customers Our relationships within our team and with our customers are faith based and predicated on honesty trust fidelity and respect Balance sheet growth and employee personal growth are tandem precepts Thawzall intertwines as it prepares for the future At the end of the day Thawzall wants a bet ter world for its customers and its employees History of Thawzall LLC The idea of a portable hydronic heating system was conceived and named Thawzall in an Alexandria Minnesota workshop in 1996 by a Norwegian plumber who had a contractor friend who was behind schedule on a construction site when the winter freeze up caught him off guard History of Thawzall LLC cont The plumber Jerome Jakobson developed his version of a porta
22. e refractometer THAWZALL LLC 104 Donovan Drive Alexandria MN 56308 Your Thawzall may have either style O 320 759 1588 F 320 759 1583 T 888 757 3545 www thawzall com See photo at right to identify reservoir Continued on page 2 FOR ASSISTANCE CALL THAWZALL TECHNICAL SUPPORT 888 757 3545 51 HEAT TRANSFER FLUID CHECK No 00 06 08 502 rev 8 13 continued from Page 1 Thawzall HTF has additives that provide lower freeze protection than standard Propylene Glycol The re fractometer reading must therefore be converted to a real protection reading using the following chart Fahrenheit to Celsius Conversion Chart Pumpable Burst Pro tection Down To 1 o 1 ul o N Ww N o Step 2 Using the chart above locate the refractometer reading in the left column and read across to the right to find the Freeze Protection Down To degree reading This is the temperature at which the Thawzall Heat Transfer Fluid will begin to freeze If this degree reading is at or below the coldest temperature that you can expect in your climate no further action is necessary If this reading is above the coldest temperature that you can expect in your climate go to step 3 THAWZALL LLC The temperature readings in the third column Pumpable Down To 3 hich a f lush mixture of HTF may still 104 Donovan Drive indicate a temperature at which a frozen slush mixture o ays Ale
23. e setting for operation above 5 000 ft Date Effective June 1 2008 and August 2013 Models Affected H150 TCH150 H250SL TCH250 2M 6A 12F 12HU Purpose To re rate the burner nozzle and air intake setting based on altitude above sea level Other Pertinent Information All models affected are shipped with nozzle numbered 1 75 and air intake is set a 2 If your Thawzall is to be used at altitudes above 5 000 feet above sea level the burner nozzle and air in take setting must be changed to accommodate lower oxygen levels at higher altitudes Use the table at the top of back page to find the nozzle size and air intake settings for your altitude To change the burner nozzle e Turn power off e Referring to the burner diagram on the back page locate oil line and disconnect the nut from the top end of the line e Open the hinged cover by loosening two clips to access the nozzle assembly e Loosen and remove the splined nut from the outside end of the nozzle assembly Do not loosen es cutcheon Plate 4 Nozzle assembly will fall free e Turn and remove burner nozzle unit 24 e With 5 8 and 3 4 open ended wrenches loosen and replace the nozzle at front end of the assembly with one of the proper size being careful not to bend the THAWZALL LLC two electrodes 104 Donovan Drive O 320 759 1588 Alexandria MN 56308 FOR ALL TECHNICAL QUESTIONS PLEASE CALL THAWZALL USA F 320 759 1583 TECHNICAL SUPPORT 888 757 3545 49 HIGH ALT
24. g Avoid heating near pressurized pipes and hoses and near a fuel tank Dispose of waste properly Improperly disposing of waste including HTF Heat transfer flu id grease and plastics filters and batteries threaten the ecology of the environment Do not pour HTF on the ground down a drain or into any water source Inquire about the proper way to dispose of wastes in your area at your recycling center HANDLING BATTERIES SAFELY Battery gas can explode Keep sparks and flames away from the battery on the generator on your Thawzall Never place a metal object across the battery posts Always disconnect the grounded battery clamp first and re connectit last Battery acid is poisonous and can burn skin and eat holes in clothing and cause blindness if splashed into the eyes Flush contaminated skin with water and baking soda If acid is swal lowed drink water or milk and get medical attention immediately OR CONTACT YOUR LOCAL POISON CONTROL CENTER IMMEDIATELY 16 STORING YOUR THAWZALL To store your Thawzall for the summer months Park on level ground and block wheels to prevent accidental movement Close the fuel tank valve See applicable service bulletins at the back of this manual for annual maintenance items SAFETY FEATURES OF THE THAWZALL HEAT MACHINE The following safety features have been built into your Thawzall Heat Machine to ensure the safest possible use of the machine and convenience that enhances your produ
25. hawzall Avoid parking on hills Use blocks or wheel chucks to prevent movement Always use the jack to support the hitch TOWING YOUR THAWZALL Tow safely 3 4 ton truck with a brake controller is recommended for towing the TCH 250 150 Thawzall axles wheels and tires are rated to travel at legal posted speeds on the highway Connect safety chains lights and brake cable to towing vehicle Thawzall trailers are equipped with electronic break away brakes in case the trailer should be come disconnected from the towing vehicle Trailer brakes will apply automatically Failure to connect trailer in a safe manner could result in a serious accident or death Always verify that the hitch ball size on the towing vehicle matches the size of the coupler on the Thawzall trailer GENERAL OPERATING INSTRUCTIONS Do not operate your Thawzall without instruction and understanding the startup and shut down procedures thoroughly If you do not understand these instructions call Thawzall Technical Support 888 757 3545 14 GENERAL OPERATING INSTRUCTIONS cont Keep your machine in proper working condition Unauthorized modifications to the machine may impair the function and or the safety and affect the life of the machine Wear hand protection while handling hot hoses and disconnects HOSE REEL DANGER Be very careful to keep hands and gloves clear from the hose reel when rewinding the hose A glove can get caught between hoses which may cause
26. he control will exit the pump prime mode and resume normal op eration 33 Instruction Manual Model AF Oil Burner Beckett Service amp maintain burner The Air Band Assembly is pre set to 2 The Air Shut ter is pre set to 10 DO NOT ADJUST UNLESS ALTI Replacement parts TUDE CONDITIONS WARRANT DIFFERENT AIR IN TAKE Cim Description Partnumber tem Description Part Number Fi Bumer housing assemby 98248 13 Blower wheel we only RWB replacement 2690 2 Air band assembly 8 so a po AN Note 1 Screw 10 24 x 74 4198 Primary R7184A interrupted ignition 7455 Nut 10 24 square 4150 Control R7184B valve on delay 7456 Note 1 Screws 10 24 x 5 16 4292 R7184P with alarm contacts 7458 A A Noe 1 Screw 1032 x 5 16 4292 A 9 a e Note 1 Flange universal adjustable incl gasket X 720 Ai tube combination seo Table 1 page2 Smely ee 24600 zi Heat shield kit ceramic or ber Speo caricia een 22 Electrode kit F head air tubes up to 9 57 iT 08 3 edm E _ LEE c NENNT ES eee UR SN PD Timer delay cordset for 21844 pump 21887U These items are included in the 5624B burner housing assembl Note 1 Note 2 Factory installed Please do not remove from burner LE Solenoid valve kit non delay 2182602U Solenoid valve kit includes PD Timer cordset 2182604U 11 Connector tube assembly 8 5 12 ZE A 34 TCH 250 WIRING SC
27. he failed parts with the RMA form to Thawzall within 30 days e When the failed parts are returned to Thawzall you will receive the remaining credit 63 64 WARRANTY CLAIM FORM Thawzall warranties hydronic equipment for two years and flameless heaters for one year from the original invoice date RMA Return Material Authorization number is required for parts re turn RMA must be clearly marked on the outside of the returned pack THAWZALL LLC age Parts must be returned within 30 days after RMA is issued TODAY S DATE YOUR NAME YOUR TITLE COMPANY E MAIL PHONE FAX CELL MODEL NUMBER VIN NUMBER DATE OF ORIGINAL PURCHASE Describe problem in detail How was the problem resolved 104 Donovan Drive Alexandria MN 56308 USA O 320 759 1588 F 320 759 1583 T 888 757 3545 www thawzall com LABOR HOURS HOURLY LABOR RATE IF PARTS WERE ORDERED FROM THAWZALL RECORD SALES ORDER OR INVOICE HERE 65
28. imited Reset e Recurring lockouts without a complete heat cycle puts control in restricted hard lockout mode Limited Recycle e If flame is established and then lost the control will recycle until the cumulative time trial for igni tion budget is exhausted and will then go into hard lockout This prevents excessive oil accumula tion in the appliance Valve on delay 15 seconds Motor off delay None Sequence of Operation 1 Standby 2 Valve on delay 3 Trial for ignition 4 Lockout 5 Ignition carryover 6 Run 7 Recycle 8 Motor offdelay 9 Pump prime OPERATING STATES STANDBY The burner is idle waiting for a call for heat When a call for heat is initiated there is a second delay while the control performs a safe start check VALVE ON DELAY pre time e igniter and motor on while the oil solenoid valve remains de energized typically 15 sec onds Allows the burner to establish air flow and brings the pump to full speed helping to keep ig nitions smooth and clean TRIAL FOR IGNITION The oil solenoid valve is energized A flame should be established within the factory set trial for igni tion time also known as lockout time 15 seconds on the GeniSys control 31 OPERATING STATES cont IGNITION CARRYOVER Once flame is established the igniter remains on for 10 additional seconds to ensure flame stability before shutting off RUN The flame is sustained until the call for heat is sati
29. ish REEL OPERATION The TCH 250 150 reel has a switch control mounted on the right hand side of the back enclosure The reel can be powered both to take up and release hose thru the manually switch There are two operating speeds Low and High The reel unit uses a brake coupler that can be released for optional free wheeling for manual hose deployment BRAKE COUPLER OPERATION The unit should always be transported with the brake engaged to prevent hose un spooling Note The motor should not be run with the brake in the manual release position to avoid over heating of friction disks Reel direction switch HOSE IN HOSE OUT Two speed reel HIGH SPEED Brake disengage PISENGAGE button green SERIES PRODUCT ENHANCEMENTS cont TCH250 TCH150 SERIES TCH150 TCH250 CONTROL BOX features On Cool Down Off switch Panel Light on off Enclosure Light on off Strobe Light on off Voltmeter Fuel Gage Hour Meter Temperature Delivery Set Switch CONAN P WNP TCH150 has three zone return temperature displays two displays for the individual Thaw Cure zones and one display for the Auxiliary Zone TCH250 has six zone temperature displays five displays for the individual Thaw Cure zones and one display for the Auxiliary Zone The Auxiliary Zone display is used for monitoring temperature return for a remote manifold or heat exchanger in temporary heat situations 20
30. l manifold and non copper piping DOT certified LED lights Industrial door struts Control System Improvements Centralized controls Rooftop mounted message beacon Digital display for individual heat zones Hour Meter voltmeter fuel gage Digital control for heat delivery by zone Electronic mixing valve Operational Improvements Automatic Fuel Bleed System Fork Picksfor ease of placement on job site Back flow check valve Lockable cover over temp controls Furnace Troubleshooting guide For faster THAW more uniform CURE For greater head pressure and GPM flow For pump ability down to 80 F Easy to operate and understand For improved durability and reparability For operational reliability To secure door open or closed Convenience for startup and monitoring For visual assurance of proper operation To monitor critical return temperatures To monitor hours volts fuel Ideal for precise curing mode Precise temperature delivery no fuel line bleeding required to eliminate HTF fill tank overflow to prevent unauthorized tampering to reduce non revenue service calls 18 SERIES PRODUCT ENHANCEMENTS cont Built in Features for Quality Reinforced Fiber Combustion Chamber For rugged use and durability Fuel Oil Furnace Unit is totally self contained Bell and Gosset Pumps Quality pump nationally available Closed Loop Fluid System No calcium buildup ensures warranty Powder Coat Finish Attractive high quality fin
31. m the disas press exterior springs down to re sembled coupler move the semi guides A Using parts from rg the re build kit 4 C y reassemble the valve group and Black o ring A White o ring B coupler in reverse Shown above is the complete Thawzall Re Build Kit Remove and replace black o ring A order and white o ring B inside internal body Remove and replace exterior black o ring on adaptor Resource Directory Thawzall Coupler Replacement Kit available from Thawzall LLC Call 888 757 3545 Thawzall LLC 104 Donovan Drive 1 www thawzall com Alexandria MN 56308 O 320 759 1588 F 320 759 1583 FOR ALL TECHNICAL ASSISTANCE CALL TECHNICAL SUPPORT 888 757 3545 T 888 757 3545 60 LIMITED WARRANTY GENERAL THAWZALL LLC hereby extends to the original purchaser of its THAWZALL Ground Defrosting Thawing Temporary Heat or Concrete Curing Products a warranty against defects in materials and workmanship for a two year time period as indicated below The warranty is only valid on Ground Defrosting Thawing Temporary Heat or Concrete Curing Products purchased and used in accordance with placards and instructions e g Operators Manuals provided by Thawzall LLC This warranty applies only to the original purchaser and is subject to the terms and conditions set forth below THAWZALL LLC will repair or replace at its discretion a ground defrosting thawing temporary
32. m the top end of the line Open the hinged cover 18 by loosening two clips to access the nozzle assembly Do not loosen escutcheon Plate 4 The nozzle assembly will fall free Beckett Burner GenySis Control Inspect the nozzle for wear or damage To replace the nozzle with 5 8 and 3 4 open end wrenches loosen and replace the nozzle with a new on being careful not to bend the two electrodes Reverse the procedure for re assembly The copper tube on the burner is 12 in the diagram HTF Heat Transfer Fluid Check e From the fluid reservoir using a refractometer remove a small sample of HTF See Service Bulletin No 502 Rev 8 13 e Full strength HTF provides pumpability down to 80 F 62 C Continued on page 3 FOR TECHNICAL ASSISTANCE CALL THAWZALL TECHNICAL SUPPORT 888 757 3545 56 PREVENTIVE MAINTENANCE No 00 07 20 08 503 Rev 8 13 Continued from page 3 Visual Inspection of Burner Boiler and Chimney e Visually inspect the chimney for signs of soot or damage to the chimney and cap Excessive soot means that the burner is not combusting cleanly and may not be properly adjusted see Tech nical Service Bulletin 00 06 01 08 501 Rev 8 13 for proper settings e Open the Columbia burner inspection door and inspect the inside of the boiler with a flashlight Note evidence of excessive sooting or any apparent cracks If any evidence is found call Thaw zall Technical Support at 888 757 35
33. ng blankets and ambient temperatures Heat performance in interior spaces is also affected by several factors to include outside am bient temperatures heat loss through walls and ceiling and the volume of the space to be heated In general with proper hose spacing and adequate insulation the operator should be able to THAW about one foot of soil per day Consult our Thawzall Technical Support personnel with questions regarding proper hose spacing 888 757 3545 28 HIGH ALTITUDE ADJUSTMENTS Ifyour Thawzall is to be used at altitudes above 5 000 feet 1 530 meters the burner nozzle and air intake settings must be changed to accommodate lower oxygen levels at higher altitudes Please see service bulletin 501 HOSE CAPACITY FILL CHART HOSE SIZE GALLONS PER FOOT Inside dia 1 2 0 016 5 8 0 019 3 4 0 023 1 00 0 04 11 4 0 063 DISCONNECT MAINTENANCE 1 Water and dirt may get into a disconnect piece and cause it to corrode or to work improperly It is vital that dis connects be cleaned and lubricated at least once per season or when they get dirty Failure to maintain discon nects properly will void the warranty To clean disconnects e Use a mild soap and water or all purpose cleaner like dish soap or Windex e Use a nylon bristle brush to scrub the couplers Do not use metal brush e Rinse and wipe parts dry e Allow parts to dry To lubricate disconnects Use only Silicon based products that do not contain any pene
34. ng without proper venting of the exhaust to the outside Carbon monoxide poisoning and asphyxiation may occur if exhaust is inhaled HANDLE FUEL SAFELY Avoid fires by handling fuel with care Both diesel fuel used in the generator and 1 fuel oil or a winter blend of fuel oil used in the furnace are extremely flammable Do not refuel the machine while smoking or while an open flame or sparks are near the re fueling point Do not refuel while the generator or furnace is running A clean machine is a safe machine Prevent fires by keeping your Thawzall clean of accumulated trash grease and debris Clean up spilled fuel properly 15 HANDLE CHEMICAL PRODUCTS SAFELY Direct exposure to hazardous chemicals can cause injury Potentially haz ardous chemicals used in your Thawzall include grease paint and adhe sives Grease paint and adhesives are espe cially toxic when heated Please read with care the Material Safety Data Sheets MSDS provided in this manual They pro vide specific details on the products used in you Thawzall physical and health hazards safety procedures and emergency response techniques Check the MSDS sheets before operating your Thawzall so you will know the risks and first aid techniques in case of an accident Keep emergency phone numbers for doctors ambulance service hospital and fire department near your phone SAFETY INCLUDES PREVENTITIVE MAINTENANCE Remove paint and adhesives before welding or heatin
35. ntion Service Managers and Service technicians Subject Preventive Maintenance Date Effective 8 1 2008 Thawzall Models affected All Purpose A recommendation for annual checks and maintenance for all Thawzall machines Fuel Filter Replacement e Replace the fuel filter annually before putting your Thawzall into service in the fall e Shut off the fuel valve at the base of the fuel tank e Loosen and remove the bolt at the top center of the fuel filter base and catch Fuel Filter the cup from the bottom e Remove the old filter from the cup Clean the cup and install a new filter dis posing the old one properly e Replace two O rings one between the cup and the filter base and the other on the bolt Both O rings come with the filter in Kit 1A 30 e Assemble the filter cup and base tightening the bolt just snug Union Inspections and Leak Repair e Inspect the unions for leaks e Tighten all unions Do Not over tighten Thawzall LLC 104 Donovan Drive Alexandria MN 56308 Continued on page 2 O 320 759 1588 Inspect union for leaks F 320 759 1583 T 888 757 3545 FOR TECHNICAL ASSISTANCE CALL THAWZALL TECHNICAL SUPPORT 888 757 3545 www thawzall com 55 Burner Nozzle Inspection To inspect the burner nozzle PREVENTIVE MAINTENANCE No 00 07 20 08 503 Rev 8 13 Continued from page 1 Turn the power off Referring to the burner diagram below locate oil line 12 and disconnect the nut fro
36. odifications or repair by the user abuse misuse neglect accident incorrect power line voltage power line surge lightning damage or fire flood or other Acts of God Repair or replacement in the ordinary course of expendable ground defrosting thawing temporary heat or concrete curing product part Elements and controls whose damage or failure is attributable to corrosion scale or dirt accumulations or to low water conditions Thawzall LLC is not liable for labor and other costs incurred in removal reinstallation or unauthorized repair of the Ground Defrosting Thawing Temporary Heat or Concrete Curing product or for damages of any type whatsoever including incidental or consequential damages There are no warranties which extend beyond the description contained herein and specifically liability for any breach of any implied warranty of merchantability or fitness for a purpose is excluded The duration of any warranties which may be implied by law notwithstanding the previous sentence including the warranties of merchantability and fitness is limited to the term of this warranty In no event shall Thawzall LLC be liable for special incidental or consequential damages arising from ownership or use of any Ground Defrosting Thawing Temporary Heat or Concrete Curing product or for any delay in the performance of it obligations under this warranty due to causes beyond its control Some states do not allow limitations on how long an im
37. otection reading in the Freeze Protection Down To col umn If the new test is satisfactory no further action is required If the test is not satisfactory drain the boiler again Refill the reservoir again with full strength HTF and run the circulating pump again for a few minutes to fill the boiler and mix the HTF in the system Remember that the boiler must be filled from the reservoir each time the boiler is drained before circu lating the fluid for another test Test a sample again from the boiler with a refractometer and consult the chart on page 2 for a real protection reading in the Freeze Protection Down To column Repeat the above procedure as often as necessary to bring the freezing temperature of the HTF in the system down to the temperature required in your climate Your Thawzall can now be safely put back into service Consult your Thawzall owners manual for other regular service procedures THAWZALL LLC Resource Directory 104 Donovan Drive Alexandria MN 56308 O 320 759 1588 F 320 759 1583 T 888 757 3545 www thawzall com Heat Transfer Fluid HTF can be purchased from Thawzall in increments of one and five gallon containers and 55 gallon barrels Refractometer can also be purchased through Thawzall FOR ASSISTANCE CALL THAWZALL TECHNICAL SUPPORT 888 757 3545 53 54 THAWZALL LLC No 00 07 20 08 503 Rev 8 13 Technical Service Bulletin PREVENTIVE MAINTENANCE PROCEDURES Atte
38. plied warranty lasts and or do not allow the exclusion or limita tion of consequential damages so the above limitations and exclusion may not apply to you This warranty gives you specific legal rights You may have other rights which vary from state to state This warranty set forth herein is in lieu of all other expressed or implied warranties THAWZALL LLC does not as sume or authorize any party to assume for it any other obligation or liability THAWZALL LLC 104 Donovan Drive PO Box 158 Alexandria MN 56308 USA TF 888 757 3545 T 320 759 1588 F 320 634 4563 Email warranty thawzall com Website www thawzall com 62 How to File a Warranty Claim The warranty on your Thawzall covers parts and labor for two years from the date of purchase In the event of a failure which is covered in the Warranty Statement on the preced ing pages e Access the warranty claim form online at http www thawzall com warranty asp p 1 1 9 Or fill out claim form on the next page fill it out completely and send it to Thaw zall via USPS Mail Fax or E mail Thawzall will determine the validity of the claim and issue 50 credit to you for all valid claims within 5 days Please call 888 757 3545 or e mail us at warranty Thawzall com to request Return Material Authorization RMA number e Thawzall will issue you RMA number for the failed parts To collect the balance of the credit owed you MUST return t
39. r Helen Berner Purchasing and Inventory Manager Karen Weis Office Manager 10 FREQUENTLY ASKED QUESTIONS Q What can I do with a Thawzall Hydronic heater A 1 Remove ground frost 2 Prevent ground frost 3 Use as a temporary heat source 4 Cold weather concreting Q How does it work A TCH 250 150 utilizes a top draft high efficiency oil fired furnace which heats water propylene glycol HTF and distributes the HTF through the patented multi zone manifold system thru a series of 600 foot industrial hydronic hoses in a low pressure closed loop system Thawzall us es an automatic tempering valve to cover the various temperatures needed for Thaw Cure and Heat modes Under no circumstances will the furnace ever need to be adjusted down as the electronic tempering valve can adjust the temperature delivery needed for the specific applica tions How long does it take to remove frost Up to 12 inches of frost can be removed in a 24 hour period depending on layout of hose insu lation used ambient outside temperature and soil conditions PERFORMANCE THAW AND CURE performance in the field is affected by a wide range of factors which include Soil type Moisture content in the soil Hose spacing Thermal rating of the covering construction blankets Outside ambient temperatures HEAT performance in interior work spaces is also affected by several factors which include Outside ambient temperature Heat loss
40. serious bodi ly injury Close ball valves on manifold when coupling or uncoupling the hoses to avoid accidental flu id loss and spillage or possible injury from hot liquid No loose clothing Do not wear loose clothing that can get caught in the hose reel or on lev ers or latches on your Thawzall Do not use gasoline or kerosene to fire the furnace on your Thawzall This may cause explo sion which may result in serious injury or death Only 1 fuel oil or a winter blend of fuel oil is recommended for the furnace GFI Outlet Always plug the electrical cord from your Thawzall into a GFI protected outlet Failure to do so could cause shock or electrocution Safety glasses Always wear safety glasses when operating your Thawzall especially when connecting and disconnecting hoses fueling or maintaining the battery on the optional genera tor Caution and Warning decals Carefully observe and maintain all of the caution and warning decals placed on your Thawzall machine They are there to ensure proper operation of the Thawzall and your safety Never hot wire of the electrical wiring on your Thawzall or optional generator Wiring circuits are carefully designed to provide for safe Startup and operation of the furnace pumps and hose reel Any alteration may cause an unsafe condition and could cause any or all compo nents to malfunction or operate out of sequence Operate only OUTDOORS Never operate and engine or furnace inside a buildi
41. sfied or safety limit shuts down burner MOTOR OFF DELAY post time If applicable the oil solenoid valve is de energized and the motor continues to run for the preset motor off delay time Cools the nozzle to prevent after drip and expels fumes and combustion If the cad cell detects flame in the Motor Off Delay mode the control goes into the standby mode This is to prevent a failed fuel valve from keeping the flame burning LOCKOUT the control has shut down the burner for one of the following safety reasons Trial for ignition lockout time expires without flame being established Cad cell detects flame at the end of valve on delay Recycle time budget expires Relay check failure You can NOT reset the control by interrupting line voltage RECYCLE If the flame is lost while the burner is firing the control shuts down the burner enters a 60 second recycle delay and repeats the ignition sequence The control will continue to recycle each time the flame is lost until it reaches a preset cumulative trial for ignition time allotment The control will then go into Hard Lockout instead of recycle This feature prevents excessive accumulation of oil in the appliance firing chamber PUMP PRIME Enter Pump Prime mode by holding down the reset button while in the trial for ignition until the control powers down the equipment Then oppress the reset button again to enter Pump Prime mode The igniter and motor are on 4 minutes and the cad
42. spect and repair system leakage and or dam aged hose on Thawzall equipment Photo 1 Attach jumper hose 1 Turn boiler on and circulating pump let system oper ate for 10 minutes 2 Visually inspect connections photos 2 3 and 4 looking for leaks 3 Ifanyleaksare located snuggly re tighten the union without over tightening 4 Continue to operate the system while looking for additional leaks 5 other leaks are spotted proceed to 6 on next page Photo 3 47 TECHNICAL SERVICE BULLETIN no 00 05 14 08 500 Rev 8 13 HYDRONIC SYSTEM LEAK CH ECK Continued from page 1 Photo 4 m Deploy all hoses from reel and connect each to the supply and return 7 Follow each loop from supply to return to determine if there are any leaks 8 If leaks are located at Faster connectors use Thawzal Coupler Repair Kit call 888 757 3545 9 f hose leaks are found use Thawzall Hose Repair Kit call 888 757 3545 10 After all leaks are detected the system may need HTF added to ensure proper system psi and to avoid a low water shut off situation THAWZALL LLC 104 Donovan Drive Alexandria MN 56308 O 320 759 1588 F 320 759 1583 T 888 757 3545 FOR ALL THAWZALL TECHNICAL QUESTIONS CALL TECHNICAL SUPPORT 888 757 3545 48 Technical Service Bulletin no 00 06 01 08 501 Rev 8 13 HIGH ALTITUDE OPERATION Attention All Service Managers and Service Technicians Subject Selection of burner nozzle and air intak
43. trating oils like LPS or Lubrimatic Silicone based lubricants are available at automotive parts stores or farm equipment dealerships Apply silicone lubricant liberally DO NOT USE WD 40 OR SIMILAR PRODUCTS THAT CONTAIN PENETRATING OIL Silicone based lubricants will displace water trapped in the disconnects and will not damage the seals inside For repair of the male coupler please use the following 6 step proce dure 1 Place the male coupler in a vise with the valve end up 2 Using a drift punch or other dull or flat tool push the valve into the coupler body 3 Wedge a steel pick in between the valve and the body to hold the valve down 4 Remove the damaged O ring and back up ring with another pick 5 Clean the O ring seat and install the back up ring 6 Lubricate the O ring seal and install it Then release the valve by removing the pick 29 GENERAL MAINTENANCE CHART PART MAINTENANCE FREQUENCY Fuel Filter Replace once per year Furnace Maintenance annually by qualified technician Hose Reel Grease all fittings twice per year Hoses Inspect for damage after each use Quick Disconnects Clean thoroughly at least twice per year For further information about general maintenance items see Service Bulletin 503 in the service bulletin section at the back of this manual 30 BECKETT BURNER GENISYS CONTROL Basic Features Three indicator lights e Red reset button lockout light e Pump Prime e Green flame recycle light L
44. xandria MN 56308 O 320 759 1588 F 320 759 1583 Down To column will severely damage the pump and other compo T 888 757 3545 nents of your Thawzall www thawzall com Continued on page 3 be pumpable in the system Running the circulating pump and the burner will thaw the slush and make the Thawzall usable until it is shut off again Frozen HTF a temperature below the Burst Protection FOR ASSISTANCE CALL THAWZALL TECHNICAL SUPPORT 888 757 3545 52 HEAT TRANSFER FLUID CHECK Continued from page 2 Step 3 No 00 06 08 502 Rev 8 13 Completely drain the boiler of HTF The boiler holds about 16 gallons or 23 of the total sys tem The boiler can be drained with a garden hose attached to the valve on the side of the boil er housing Boiler Drain valve Then fill the plastic reservoir with full strength HTF refer to the start up procedure card that comes with your Thawzall to learn how to fill the boiler reservoir Run the circulating pump for a few minutes to fill the boiler and mix the system Un reel all of the hoses from the hose reel and connect them to the supply and return sides of the liquid manifold at the back of the reel area so Rear Manifold Hose Connections that all of the fluid can be circulated through eve ry component of the Thawzall Using a refractometer test a sample of HTF from the boiler valve this time not from the reservoir Consult the table on Page 2 for the real pr
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