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Tamarack Industries Thawzall HEATZONE TCH250, Operator'S Manual

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Tamarack Industries Thawzall HEATZONE TCH250 Operator'S Manual Download Page 44

43

Burner Maintenance

DO NOT TAMPER WITH THE UNIT OR

CONTROLS - CALL YOUR SERVICE PERSONNEL.

To ensure continued reliable operation, a qualified

service technician must service this burner every 

750 

hours.

More frequent service intervals may be required in

dusty or adverse environments.

Operation and adjustment of the burner requires

technical training and skillful use of combustion test

instruments and other test equipment.

Tools Required

• 

5/16” wrench

• 

3/8” wrench

• 

7/16” wrench

• 

5/8” wrench

• 

3/4” wrench

• 

pliers 

Summary of Contents for Thawzall HEATZONE TCH250

Page 1: ...Operators Manual Part T90099 Date Sept 2019 TCH250 ...

Page 2: ...ular hours are directed to the On call technician After hours support is reserved for issues that cannot wait until the next business day for resolution If no answer please leave a message and we will get back to you as soon as possible By Email support tamarack ind com Feel free to email us at any time with technical questions or parts inquiries Please include the year make and model of your unit...

Page 3: ...del ________________________ Generator KW __________________________________ Machine serial number ________________ Generator Serial _____________________________ Serial number located on trailer tongue Manufactured by Thawzall LLC A DIVISION OF TAMARACK INDUSTRIES 2736 Lakota Lane Unit B Alexandria MN 56308 Phone 320 759 1588 Fax 320 759 1583 Tech Support 888 757 3545 Website www Thawzall com E M...

Page 4: ...ctive harm Some examples of these chemicals are Lead from lead based paints Crystalline silica from bricks Cement and other masonry products Arsenic and chromium from chemically treated lumber Your risk from these exposures varies depending on how often you do this type of work To reduce your exposure to these chemicals ALWAYS work in a well ventilated area and work with approved safety equipment ...

Page 5: ...trouble free operation of your TCH250 requires that you and anyone else who will be operat ing or maintaining the Heater read and understand the Safety Operation Maintenance and Trouble Shooting information contained in the Operator s Manual This manual is applicable to the TCH250 built by Tamarack Industries Use the Table of Contents as a guide when searching for specific information Keep this ma...

Page 6: ...Us 1 Unit Information 2 Warning 3 Introduction 4 Safety 6 11 Warranty 12 13 How It Works 14 Controls 15 19 Operation 20 28 Ground Thaw Set Up 29 33 Troubleshooting 34 37 Alarms 38 40 Maintenance 41 48 Specifications 49 MSDS 50 59 Schematics 60 65 5 ...

Page 7: ...tices Indicates a potentially hazardous situa tion that if not avoided may result in minor or moderate injury It may also be used to alert against unsafe prac tices SIGNAL WORDS Note the use of the signal words DANGER The Safety Alert symbol identifies important safety messages on the Tamarack Heat King and in the manual When you see this symbol be alert to the possibility of personal injury or de...

Page 8: ...s in the manual and to follow these Most accidents can be avoided A person who has not read and understood all operating and safety instructions is not qualified to operate the machine An untrained operator exposes himself and bystanders to possible serious injury or death Do not modify the equipment in any way Unauthorized modification may impair the function and or safety and could affect the li...

Page 9: ...vicinity of open flames sparks or while smoking 14 Explosion Hazard Battery Take care when handling battery if installed TIRE SAFETY 1 Failure to follow proper procedures when mounting a tire on a wheel or rim can produce an explosion which may result in serious injury or death 2 Do not attempt to mount a tire unless you have the proper equipment and experience to do the job 3 Have a qualified tir...

Page 10: ...ning or adjusting the Heater 2 Place all controls in their OFF position disconnect power cords and wait for all moving parts to stop before servicing adjusting or maintaining 3 Do not allow riders in or on machine during transport 4 Clear the area of bystanders especially small children before starting and operating 5 Keep the working area clean and free of de bris to prevent slipping or tripping ...

Page 11: ...T exceed 55 mph under ideal conditions Reduce speed under adverse weather road or terrain conditions Avoid sudden lane changes U turns etc Sudden maneuvers may cause tipping rollover jackknifing or sliding of the trailer and without warning loss of control of the towing vehicle may result Allow for increased braking distance due to weight of trailer Read the Operator s Manual before towing 4 Cross...

Page 12: ...operate this equipment until such information has been reviewed Annually review this information before the season start up Make these periodic reviews of SAFETY and OPERATION a standard practice for all of your equipment We feel that an untrained operator is unqualified to operate this machine A sign off sheet is provided for your record keeping to show that all personnel who will be working with...

Page 13: ...tructions WARRANTY REGISTRATION please print This form must be filled out by the dealer and signed by both the dealer and the customer at the time of deliv ery Customer s Name Distributor Name Address Address City State Code City State Code Phone Number Check One Contact Name Private THAWZALL Model Contractor Serial Number Other Delivery Date I have thoroughly instructed the buyer on the above des...

Page 14: ...made in writing within ten days from receipt of merchandise 7 RETURN OF GOODS Written permission from Tamarack must be obtained before returning any mer chandise All transportation charges must be borne by the purchaser Credit for returned goods will be based on the original price paid less 20 Special parts or custom built items cannot be returned for credit 8 LIMITATION OF LIABILITY Tamarack s li...

Page 15: ...ound on board The solution in this tank can be used to pressurize the closed loop system in the event of pressure loss A pressure loss can occur from a leak in the system or if the system contained air and it was evacuated through the use of the auto bleeders This pressurization is accomplished through the use of a pump found inline to the reservoir The control panel is located at the right rear s...

Page 16: ...Controls 15 ...

Page 17: ...ent reading of the temperature sensors located in each of the return ports on the manifold The display will automatically cycle through the tmperature readings from each port Day Time Display of real time date and time User Menu This is a menu which provides quick access to settings and informa tion about the unit To navigate the user menu use the up down keys to change the menu items and press th...

Page 18: ... of the controller A login password is required to make changes in this area Escape Key This key will take the operator back one screen In any event it can be pressed repeatedly to return to the main start up screen Up Key The up key is used to change menu selections and ad just values within the various screens Enter Key The enter key is used to select menu items save values and move the cursor b...

Page 19: ... the up down keys to change to the desired target temperature Once completed press the enter key to save Units of Measure Use the enter key to move the cursor to this field and the up down keys to toggle between units Once completed use the enter key to save Settings Screen 18 ...

Page 20: ...tus This screen shows the status of the various switches and sensors of the unit This is stricly for information and no changes can be made on this screen Use the up down arrows to toggle through the different screens 19 ...

Page 21: ...b counter clockwise to remove belt tension Manually spin the drum until the first quick connect is located and start unwinding the hoses one length at time 5 If using the gear box and belt mechanism at the control panel s REEL CONTROL module turn the REEL DIRECTION switch to the OUT position and using the foot switch uncoil the hoses as required one length at a time 6 As hoses are now on the groun...

Page 22: ...mperature Shut Down Procedure 1 At the control HEATER CONTROL module turn the MAIN POWER switch to the OFF position 2 The unit will automatically start a cool down run taking the unit to 130ºF 54ºC to securely stop the boiler preventing it from a hot stop The unit will then automatically shut down the heating loop 3 Place the foot pedal on the ground in a safe location close to the unit to proceed...

Page 23: ... to the passenger s side rear of the machine from an external 120Volt ac power source If the Thawzall machine has a generator package installed the generator can be used to power the ma chine The generator will have a twist lock plug plugged in to the front panel of the machine on the driver s side front panel Below are pictures of the 2 methods for powering the machine Using Power Source switch s...

Page 24: ...dicator is to the left as you look in the door and down by the floor of the trailer The impeller wheel should spin when flow is established Also there are two automatic air bleeders that need to be opened The automatic air bleeders are made out of brass One automatic air bleeder is located on the return manifoldan the other automatic air bleeder is inside the passenger s side door on top of the fu...

Page 25: ...ond delay the furnace will attemp to light 6 The TCH250 uses a mixing valve to control the output temperature to the supply manifold The valve is electronically controlled by the PLC The temperature setpoint is adjustable by the user from 70 F to 180 F The PLC display screen will display the setpoint and current temperatures of each of the return ports Valve shown in open position ...

Page 26: ... touch but still pliable enough for winding up the hose for storage Once the temperature on the temperature pressure gauge on the face of the fur nace has reached at least 140 F you can turn off the generator or disconnect from shore power Close the fuel valve on the fuel tank Closing the fuel valve on the fuel tank will help prevent air from getting in to the fuel supply to the burner If air get ...

Page 27: ...ent stress on the ends of the hoses Once all hoses are reeled up engage the reel lock pin to prevent the reel from turning during transport 26 Reel Lock Pin Unspooling To spool out the hose release the lock pin as shown in the picture below Loosen the belt tension knob to allow the hose reel to free wheel out Start pulling the hose off the reel if you find that the reel is free wheeling too fast i...

Page 28: ...valve on the discharge side of the fill pump 2 Loosen the bleeder valve cap half a turn located on the passenger side of the boiler 3 Press and hold the momentary switch until the pressure temperature gauge located on the boiler shows between 5 10 PSI NEVER EXCEED 10PSI 4 Release the momentary switch and tighten up the bleeder cap 5 Press the reset button on the low level switch located on top of ...

Page 29: ...the fuel system warm and put extra load on the generator to prevent wet stacking a condition caused in diesel engines when there isnt enough load and the engine doesnt get hot enough to burn off carbon deposits When the TCH250 is powered by an onboard generator this heater will automati cally run 28 ...

Page 30: ... 36 48 60 Hose Spacing 16 16 16 16 16 Hours to run 24 48 72 96 120 Hose spacing is measured inches on center TEMPERATURE 15 F to 30 F 9 C to 1 C LAYERS OF BLANKETS TO USE SINGLE R6 insulation factor SOIL CONDITION Gravel or Sand good drainage Frost Depth 12 24 36 48 60 Hose Spacing 24 24 24 24 24 Hours to run 24 48 72 96 120 Hose spacing is measured inches on center TEMPERATURE 15 F to 30 F 9 C to...

Page 31: ...22 30 ...

Page 32: ...24 36 48 60 Hose Spacing 16 16 16 16 16 Hours to run 24 48 72 96 120 Hose spacing is measured inches on center TEMPERATURE 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 Frost Depth 12 24 36 48 60 Hose Spacing 16 16 16 16 16 Hours to run 24 48 72 96 120 Hose spacing is measured inches on center 31 ...

Page 33: ... 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 HIGH ALTITUDE ADJUSTMENTS If your Thawzall is to be used at altitudes above 5 000 feet 1 530 ...

Page 34: ...tain any penetrating 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 t...

Page 35: ... t start No fuel Fill the fuel tank No power Plug machine in and turn on Breaker tripped Reset breaker Low glycol Fill glycol reservoir pressurize system Switch off Pull out Emergency Stop switch NOTE For the burners to be able to fire three conditions must be met 1 The Pressure switch on the circulation loop must see pressure gray plastic box on circ pump 2 The low glycol sensor must sense glycol...

Page 36: ... Operation 1 Standby 2 Valve on delay 3 Trial for ignition 4 Lockout 5 Ignition carryover 6 Run 7 Recycle 8 Motor off delay 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 The igniter and motor are on while the fuel solenoid valve rema...

Page 37: ...ailure 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 Lockou...

Page 38: ...set button 15 seconds until the yellow light turns on You can NOT reset the control by interrupting line voltage PUMP PRIME MODE Prepare the burner for priming Initiate a call for heat After the burner starts press and hold the reset button until the yellow light turns on 15 seconds Release the reset button The yellow light will turn off and the burner will start again At burner start up click the...

Page 39: ...ssible alarm conditions see Alarm list section of the manual Alarm Description In addition to the alarm code each alarm condition has a unique descriptor For a complete list of possible alarm conditions see Alarm list section of the manual Alarm Number This indicates where you are in the list of active alarms starting with the most recent Total Active Alarms Indicates how many alarms are currently...

Page 40: ...l Warning Alarm message generated no action take 8 AUTO Supply Temp Probe Fail Temperature Sensor Reading Error 9 AUTO Return Temp Probe Fail Temperature Sensor Reading Error 10 AUTO Return Temp Probe Fail Temperature Sensor Reading Error 11 AUTO Return Temp Probe Fail Temperature Sensor Reading Error 12 AUTO Return Temp Probe Fail Temperature Sensor Reading Error 13 AUTO Return Temp Probe Fail Te...

Page 41: ...ssing and holding the Alarm for 3 seconds ALARM LOGGER The alarm logger contains a list of historical alarm events for the purpose of troubleshooting The log ger can be accessed through the alarm screen by pressing the Enter key The records can be scrolled through using the up and down keys 40 ...

Page 42: ...d clean thoroughly Also clean lubricant passage Re place fitting if necessary 1 Review the Operator s Manual and all safety items before working with maintaining or operating the Heater 2 Place all controls in their OFF position dis connect power cords and wait for all moving parts to stop before servicing adjusting or maintaining 3 Have a first aid kit available for use should the need arise and ...

Page 43: ... Burner Fuel filter Change X Grease Axle Hubs Service X Grease Reel Bear ings Service X Reel Gear Box Check X Item Part Burner 1 75 80 A GPH Nozzle T10628 Fuel pump T10465 Electrode Kit T10390 Cad cell T10525 transformer T10405 Primary Control T10660 Fuel filter 445157 Circulation Pump 1 2 HP Mechanical Seal Kit 449063 Pump Assembly 441185 ...

Page 44: ...technician must service this burner every 750 hours More frequent service intervals may be required in dusty or adverse environments Operation and adjustment of the burner requires technical training and skillful use of combustion test instruments and other test equipment Tools Required 5 16 wrench 3 8 wrench 7 16 wrench 5 8 wrench 3 4 wrench pliers ...

Page 45: ...nozzles and elecrodes should be changed To change follow this procedure Check adjust electrodes Check the electrode tip settings Adjust if necessary to comply with the dimensions shown To adjust loosen the electrode clamp screw and slide rotate electrodes as necessary Securely tighten the clamp screw when finished ...

Page 46: ...bly 2 Disconnect oil connector tube from nozzle line 1 Turn off power before servicing 3 Loosen the two screws securing igniter retaining clips and rotate both clips to release igniter baseplate Then tilt igniter back on its hinge ...

Page 47: ...y from burner being careful not to damage the elec trodes or insulators while handling To ease removal of the assembly rotate assembly 180 from installed position after pulling partially out of tube To replace the nozzle assembly reverse the above steps ...

Page 48: ...47 Complete Drawer Assembly Removed Nozzle and Electrodes Removed ...

Page 49: ...clean Change more frequently if contaminants are introduced into the system during re fuelling In the bottom of each of the filter is a knob that can be loosened to drain water out that gathers in the bottom of the filter Note Put a pan under the fuel filter when changing them to capture any fuel that may leak or drip Dispose all fuel related items responsibly Filters ...

Page 50: ...2 in Weight w glycol 5600 lbs Weight w fuel and glycol 6580 lbs Fuel Capacity 138 US gal Glycol water capacity 83 US gal 50 50 Mix Hoses 5 x 600 ft 3 4 ID Circulation manifold 5 X 3 4 quick disconnects 1 X 1 quick disconnect Burner 250 000 BTUH Oil Fired Burner Pumps 1 1 2 HP Centrifugal Circulating Pump Reel motor 1 1 2 HP Motor Axles 1 7000 lb rated w Electric Brakes Tires 235 80R 16 Tire inflat...

Page 51: ...lity of incidental food contact and as a product for use in the immersion or spray freezing of wrapped meat and packaged poultry products We recommend that you use this product in a manner consistent with the listed use If your intended use is not consistent with the stated use please contact your sales or technical service representative COMPANY IDENTIFICATION THE DOW CHEMICAL COMPANY 2030 WILLAR...

Page 52: ...itional important symptoms and effects are described in Section 11 Toxicology Information Indication of any immediate medical attention and special treatment needed Notes to physician No specific antidote Treatment of exposure should be directed at the control of symptoms and the clinical condition of the patient 5 FIREFIGHTING MEASURES Suitable extinguishing media Water fog or fine spray Dry chem...

Page 53: ...e appropriate safety equipment For additional information refer to Section 8 Exposure Controls and Personal Protection Environmental precautions Prevent from entering into soil ditches sewers waterways and or groundwater See Section 12 Ecological Information Methods and materials for containment and cleaning up Small spills Absorb with materials such as Cat litter Sawdust Vermiculite Zorb all Coll...

Page 54: ... potential body reactions to glove materials as well as the instructions specifications provided by the glove supplier Other protection Wear clean body covering clothing Respiratory protection Respiratory protection should be worn when there is a potential to exceed the exposure limit requirements or guidelines If there are no applicable exposure limit requirements or guidelines wear respiratory p...

Page 55: ...mended storage conditions See Storage Section 7 Hygroscopic Possibility of hazardous reactions Polymerization will not occur Conditions to avoid Exposure to elevated temperatures can cause product to decompose Generation of gas during decomposition can cause pressure in closed systems Avoid direct sunlight or ultraviolet sources Incompatible materials Avoid contact with Strong acids Strong bases S...

Page 56: ...ly Sensitization For the major component s Did not cause allergic skin reactions when tested in humans For respiratory sensitization No relevant data found Specific Target Organ Systemic Toxicity Single Exposure Evaluation of available data suggests that this material is not an STOT SE toxicant Specific Target Organ Systemic Toxicity Repeated Exposure In rare cases repeated excessive exposure to p...

Page 57: ... 96 Hour Growth rate inhibition 19 000 mg l OECD Test Guideline 201 Toxicity to bacteria NOEC Pseudomonas putida 18 Hour 20 000 mg l Chronic toxicity to aquatic invertebrates NOEC Ceriodaphnia dubia water flea semi static test 7 d number of offspring 13 020 mg l Dipotassium hydrogen phosphate Acute toxicity to fish Material is practically non toxic to aquatic organisms on an acute basis LC50 EC50 ...

Page 58: ...in soil Propylene glycol Given its very low Henry s constant volatilization from natural bodies of water or moist soil is not expected to be an important fate process Potential for mobility in soil is very high Koc between 0 and 50 Partition coefficient Koc 1 Estimated Dipotassium hydrogen phosphate No relevant data found 13 DISPOSAL CONSIDERATIONS Disposal methods DO NOT DUMP INTO ANY SEWERS ON T...

Page 59: ... information can be obtained through an authorized sales or customer service representative It is the responsibility of the transporting organization to follow all applicable laws regulations and rules relating to the transportation of the material 15 REGULATORY INFORMATION OSHA Hazard Communication Standard This product is not a Hazardous Chemical as defined by the OSHA Hazard Communication Stand...

Page 60: ...eferences within our company THE DOW CHEMICAL COMPANY urges each customer or recipient of this M SDS to study it carefully and consult appropriate expertise as necessary or appropriate to become aware of and understand the data contained in this M SDS and any hazards associated with the product The information herein is provided in good faith and believed to be accurate as of the effective date sh...

Page 61: ... ID1 U9 ID1 ID1 Burner Flame LED 5 N Circ Pump LED R3_11 Breaker B1 VDC VDC VDC ID2 NO3 ID2 System Off Switch 8 6 4 2 Breaker B3 R2_4 8 6 2 4 5 E Stop Switch 92 93 90 91 91 91 94 Hose Reel Direc ꡌon Switch 1A E Stop Switch Breaker B4 1A 1C 1C E Stop Switch 1C Breaker B1 1C Breaker B2 N N N N N N B1_14 R4_A1 R6_A1 5 5 NO1 NO2 1 1 0 0 N 1 Shore Gen Switch 0 0 0 GND Green N1 White L1 Black Shore Power...

Page 62: ...14 1C R3_11 BLACK 14 B3 B1 N WHITE 18 VDC NO1 VDC GREY 18 ID2 GREY 18 BLACK 14 BLACK 14 0 1 VDC NO3 3 3 3 4 4 4 3 4 1A B4 16 BLACK 14 4 5 7 BLACK 14 0 GREY 18 ORANGE 18 BLACK 14 GREY 18 ORANGE 18 N WHITE 18 6 8 WHITE 14 N 1 2 3 4 5 7 6 8 BLACK 12 L1 WHITE 12 N1 BLACK 12 L2 WHITE 12 N2 RED 14 E STOP BLACK 14 1C BLACK 12 1 BLACK 14 93 BLACK 14 92 BLACK 14 94 BLACK 14 90 BLACK 14 17 15A 5A LED 24 INT...

Page 63: ...e PURPLE WHITE BLUE BLACK BURNER BOILER LOCKOUT SWITCH R6_A1 R3_14 RED R3_14A BLACK N WHITE GND GREEN 14AWG 4C Cable R3_14 WHITE BLACK GREEN GROUND RED ORANGE 14AWG 5C Cable BLACK WHITE 14AWG 3C Cable WHITE BLACK RED BLACK WHITE ORANGE GREEN GREEN GREEN 14AWG 4C Cable RED BLACK RED WHITE WHITE WHITE WHITE ORANGE ORANGE RED GREEN GREEN GREEN BLACK BLACK ...

Page 64: ...K 14 R4 Low Level Relay P N Relay A2 A1 R4 CAD CELL VALVE L2 VLV LIMIT L2 MOTOR L2 MTR IGNITER L2 IGN ORANGE BLACK Igniter Motor Valve PURPLE WHITE BLUE BLACK N 15A B2 15A Breaker P N 462134 Breaker P2 Fill Pump P N T23690 Pump 1C BLK 14 SW3 Momentary Switch P N 446090 Switch P2 Fill Pump P N T23690 Pump 5 M M N LED 1 LED 3 LED 2 Indicator P N 462139 LED 1 1 1 To Electrical E1 WHITE 12 BLACK 12 1 ...

Page 65: ...J10 3 1 NO1 BLUE NO2 BLACK From Electrical E1 NO5 NO4 NO3 c pCO J11 NO3 ORG NO4 ORG GRY 18 GRY 18 GRY 18 C3 4 5 ORG 18 R3 A2 A1 R2 A2 A1 R1 A2 A1 BLOILER ENABLE CIRC PUMP SYSTEM OFF DELAY NO6 C6 c pCO J12 NO5 ORG Tw TR THERMOSTAT TERMINALS ON TOP OF BURNER ASSEMBLY ORG 18 INTERIOR LED LIGHT GRY 18 ORG 18 GRY 18 EXTERIOR LED LIGHT ORG 18 COOL DOWN LED 4 From Secondary contacts on Main Power Switch ...

Page 66: ... ON OFF Relay Contact R4 c pCO U10 Fuel Tank Level Fuel Sender 240 30 Ohm c pCO ID1 Emergency Stop ON OFF c pCO ID2 System Off Request ON OFF OUTPUTS Board Point Description Notes c pCO NO1 Strobe Red PLC switches common of DC power supply C1 2 c pCO NO2 Boiler Enable Strobe Green PLC switches common of DC power supply C1 2 c pCO NO3 Cool Down LED Blue LED Flash during cool down c pCO NO4 Circulat...

Page 67: ...1 888 757 3545 support tamarack ind com 1 320 759 1583 WWW THAWZALL COM 2736 Latoka Lane SW Unit B Alexandria MN 56308 USA 66 ...

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