Tamarack Industries Thawzall HEATZONE TCH250 User manual

Operators Manual
Part #T90099
Date: Sept 2019
TCH250

As a new customer of Thawzall we would like to welcome you! We are looking for-
ward to providing you with technical support for your Thawzall unit. Whatever you need
we are here to help.
Ways to contact us for support
By Phone : [phone]
The main Technical support phone line is staffed monday-friday 7:00 AM to 3:30 PM
excluding holidays.
After hours support
Calls received outside of regular 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 : [email protected]
Feel free to email us at any time with technical questions or parts inquiries. Please
include the year make and model of your unit if you have a specic question about your
machine so we can better help you. If it is an emergency please call 1-888-757-3545
For more information please visit our website
www.thawzall.com
1

For model:
TCH 250
Please record the following information from your new Thawzall
for future reference. This information is required for all warranty
claims.
Purchase date: ______/______/_______
Generator make: _____________________________
Machine model:________________________
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 [phone]
Fax: [phone]
Tech Support 888.757.3545
Website: www.Thawzall.com
E-Mail: [email protected]
Operators Manual
2

WARNING
CALIFORNIA - Proposition 65 Warning
Engine exhaust and some of its constituents and some dust
created by power sanding, sawing, grinding, drilling and
other construction activities contains chemicals known to the
State of California to cause cancer, birth defects and other
reproductive 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, such as dust masks that are
specially designed to lter out microscopic particles.
3

INTRODUCTION
Congratulations on your choice of a Tamarack Industries Thawzall TCH250 to complement your construction
operation. This equipment has been designed and manufactured to meet the needs of the buyer for the efcient
heating of construction sites.
Safe, efcient and 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 specic information.
Keep this manual handy for frequent reference and to pass on to new operators or owners.
4

Table of contents
Title Pages
Ways to contact 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
Specications 49
MSDS 50-59
Schematics 60-65
5

6
Accidents Disable and Kill
Accidents Cost
Accidents Can Be Avoided
Why is SAFETY important to you?
3 Big Reasons
ous situation that, if not avoided, will
result in death or serious injury. This
signal word is to be limited to the most
extreme situations, typically for ma-
chine components that, for functional
purposes, cannot be guarded.
Indicates a potentially hazardous situa-
tion that, if not avoided, could result in
death or serious injury, and includes
hazards that are exposed when guards
are removed. It may also be used to
alert against unsafe practices.
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 identies
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 death. Follow the instruc-
tions in the safety message.
This Safety Alert symbol means
ATTENTION! BECOME ALERT!
YOUR SAFETY IS INVOLVED!
WARNING and CAUTION with the safety
messages. The appropriate signal word for
each message has been selected using the
following guide-lines:
SAFETY
SAFETY ALERT SYMBOL
DANGER - Indicates an imminently hazard-
WARNING -
CAUTION -

7
Safety, Installation & Operation
SAFETY
YOU are responsible for the SAFE operation and
maintenance of your Tamarack Industries Heat
King. YOU must ensure that you and anyone else
who is going to operate, maintain or work around
the Heat King be familiar with the operating and
maintenance procedures and related SAFETY
information contained in this manual. This manual
will take you step-by-step through your working
day and alerts you to all good safety practices that
should be adhered to while operating the Heater.
Remember, YOU are the key to safety. Good
safety practices not only protect you but also
the people around you. Make these practices a
working part of your safety program. Be certain
that EVERYONE operating this equipment is
familiar with the recommended operating and
maintenance procedures and follows all the safety
precautions. Most accidents can be prevented.
Do not risk injury or death by ignoring good safety
practices.
• Heater owners must give operating instruc-
tions to operators or employees before allow-
ing them to operate the machine, and at least
annually thereafter.
• The most important safety device on this
equipment is a SAFE operator. It is the opera-
tor’s responsibility to read and understand
ALL Safety and Operating instructions 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
qualied 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 modication may impair the
function and/or safety and could affect the life
of the equipment.
• Think SAFETY! Work SAFELY!
GENERAL SAFETY
Only trained competent persons shall operate
the Heater. An untrained operator is not qualied
to operate the machine.
Have a rst-aid kit available for
use, should the need arise and
know how to use it.
Do not allow riders.
Have a re extinguisher available for use
should the need arise and know how to
use it.
Wear appropriate protective gear. This
list includes, but is not
limited to:
- A hard hat
- Protective boots with
slip resistant soles
- Protective goggles
- Heavy gloves
- Hearing protection
Place all controls in their OFF position,
disconnect power cords and wait for all moving
parts to stop before servicing, adjusting or
maintaining
Wear appropriate hearing protection
when operating for long periods of
time.
Wear protective gloves
Ventilation ~ Never operate in a poorly
ventilated or enclose area. Avoid
prolonged breathing of exhaust
gases.
2.
3.
4.
5.
6.
7.
8.
9.
10.
1. Read and understand the
Operator's manual and all
safety signs before
operating, maintaining,
adjusting, servicing or
cleaning the Heater.

8
ELECTRICAL SAFETY
1. Place all controls in their OFF position, discon-
nect power cords and wait for all moving parts to
stop before servicing, adjusting or maintaining.
2. Place all controls in their OFF position before
plugging in power cords.
3. Keep all electrical components in good repair
before starting.
4. Do not lay power lines or connectors in water
or on a wet surface. Dry connectors and raise
power lines out of the water before and during
operation.
5. Do not operate machine if there are electrical
malfunctions. Correct problem before resuming
work.
11. Hot surface ~ Avoid contact with
hot exhaust and glycol system.
Allow to cool before performing repairs
or service.
12. Electrocution Hazard ~ Always use proper size
grounded extension cord. Inspect all extension
cords for cuts, frayed wires and broken connectors.
Do not use cords if not in good condition.
13. Fire Hazard ~ Do not operate
machine in the vicinity of open
ames, 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 qualied tire dealer or repair service
perform required tire maintenance.
4. Torque wheel nuts to 120 ft-lbs
STORAGE SAFETY
1. Store unit in an area away from human
activity.
2. Do not permit children to play on or around the
stored Heater.
FUEL SAFETY
Danger: To avoid possible injury, re, or explo-
sion, please read and follow these instruc-
tions.
1. Handle fuel with care. It is highly ammable.
2. Allow burners to cool for 5 minutes before
refueling. Clean up spilled fuel before restarting
engine.
3. Do not refuel the machine while smoking or
when near open ame or sparks.
4. Always use an approved fuel container.
5. Fill fuel tank outdoors.
6. Prevent res by keeping machine clean of ac
cumulated trash, grease and debris.

9
MAINTENANCE SAFETY
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. Follow good shop practices:
4. Keep hands, feet, clothing and hair away from
all moving and/or rotating parts.
5. Always wear heavy gloves to prevent burns
when handling hot components. Wait until burn-
ers, coils and glycol system components have
cooled before working on them.
6. Do not attempt any adjustment or maintenance
to any system of the Heater unless the power
wires are disconnected from the battery.
7. Make sure that all guards, shields and hoods
are properly installed and secured before oper-
ating the Heater.
8. Securely support the machine using blocks
or safety stands before working beneath it or
changing tires.
9. Store and transfer diesel fuel, solvents, cleaners
or any ammable liquids only in safety standard
approved containers.
- Keep service
area clean and dry.
- Be sure electri-
cal outlets and tools
are properly ground-
ed.
- Use adequate
light for the job at
hand.
OPERATING SAFETY
1. Read and understand the Operator’s Manual
and all safety signs before operating, servic-
ing, maintaining 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. Clean up
fuel spills immediately if they occur.
6. Slow down. Use care when working around
unit - the steps, frame or oor may be wet
and/or slippery.
7. Do not allow personnel that are taking drugs,
alcohol or any medications that impair the
senses or when excessively tired or stressed
to operate the Heater.
8. Do not operate unit in a poorly ventilated or
enclosed area to prevent asphyxiation when
the heaters are operating.
9. Do not smoke when connecting fuel source or
when working around machine.
10. Always wear heavy gloves when working on
the machine to prevent burns when touching
hot components.
11. Use the foot pedal switch to engage the hose
reel take up or extend function and guide the
hose by hand.
12. Keep all electrical lines and components in
good working order. Do not operate in wet
conditions or when standing in water. Damp
or wet conditions can cause shocks or trip the
breakers.
13. Keep all components in good condition.
14.Do Not plug or block access doors or vents.
Keep 1 foot of clearance around unit.
15. Review safety instructions with operators
annually.

10
SAFE TRANSPORTATION AND STORAGE
When transporting the machine, review and follow
these instructions:
1. Be sure all bystanders are clear of the machine.
2. Back the truck up to the hitch and lower hitch
over the ball.
3. Secure with a mechanical retainer.
1. Attach to towing vehicle and secure with a me-
chanical retainer. Cross the safety chains under
the hitch and anchor to truck frame.
2. Connect the brake anchor cable to the truck
frame to activate the trailer brakes if the trailer
unexpectedly unhooks. Provide sufcient slack
for turning.
3. Check that all lights and reectors required by
the DOT are clean and functioning.
4. Do not exceed 55 mph under ideal conditions.
5. Do not allow riders on machine.
6. Do not drink and drive.
TRANSPORTING SAFETY
TRAILER TOWING CAN
BE HAZARDOUS
WARNING
* DO NOT 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, jackkning 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 the safety chains under the hitch and at-
tach to truck frame.
5. Attach the brake line to the truck frame. Be sure
to leave sufcient slack for turning.
6. Connect electrical harness to truck plug-in.
7. Raise and secure the hitch jack.
8. Reverse the Heat King set-up procedure t
9. Check and be sure that all lights are working.
10. Do not allow riders on machine.
11. Never exceed a safe travel speed.
12. Do not drink and drive.
13. Check with local highway authorities on the
specic requirements for transporting fuel oil
through their jurisdiction. Always comply with the
requirements before transporting.

11
SIGN-OFF FORM
Tamarack Industries follows the general Safety Standards specied by the Society of Automotive Engi-
neers (SAE) and the Occupational Safety and Health Administration (OSHA). Anyone who will be operat-
ing and/or maintaining the Heat King must read and clearly understand ALL Safety, Operating and Mainte-
nance information presented in this manual.
Do not operate or allow anyone else to 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 unqualied to operate this machine.
A sign-off sheet is provided for your record keeping to show that all personnel who will be working with the
equipment have read and understand the information in the Operator’s Manual and have been instructed
in the operation of the equipment.
DATE EMPLOYEES SIGNATURE EMPLOYERS SIGNATURE
SIGN-OFF FORM

12
Date Dealer’s Rep. Signature
The above equipment and Operator’s Manual have been received by me and I have been thoroughly
instructed as to care, adjustments, safe operation and applicable warranty policy.
Date Owner's Signature
TAMARACK INDUSTRIES
THAWZALL
WARRANTY REGISTRATION FORM & INSPECTION REPORT
DISTRIBUTOR INSPECTION REPORT
SAFETY
Emergency Stop Switch Works
All Decals Installed and Legible
Lights and Reectors Installed,
Clean and Working
Review Operating And
Safety Instructions
WARRANTY REGISTRATION (please print)
This form must be lled 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 described equipment which review included the Op-
erator’s Manual content, equipment care, adjustments, safe operation and applicable warranty policy.
Tire Pressure Checked
Wheel Bolts Torqued
Brakes Work
Check Fluid Levels (Fuel and Glycol)
Lubricate Machine
Check That All Controls Function

13
Tamarack Industries CONDITIONS OF SALES & LIMITED WARRANTY
All sales made by Tamarack Industries, here after ref-
ered to as Tamarack, a Division of ELJO Industries Inc.
are subject to these conditions unless otherwise agreed
in writing with a duly authorized ofcer of Tamarack. In
all cases of conict between these conditions and the
requirements of the purchase order, these conditions
shall prevail.
(1) SALES POLICY: Nothing herein shall be construed
as abridging the right of Tamarack to sell directly or indi-
rectly to: (a) Federal, State or Provincial Governments
or Agencies thereof, or to Agencies employing Federal,
State or Provincial Government aid; (b) Purchasers
who buy Tamarack's products for sale as integral or as-
sembled parts of their products; (c) Firms operating on a
national scale; (d) Any other class of purchaser to whom
Tamarack may from time to time, elect to sell.
(2) PRICES: All prices are F.O.B. our warehouses,
freight allowance as specied on Distributor Net Price
Lists. The suggested list prices and discounts schedules
are established by Tamarack and are intended to act as
a guide for our distributors. Unless otherwise stated in
writing, prices are subject to change without notice and
will be applied as in effect at time of shipment.
(3) TERMS: Unless otherwise agreed upon in writing by
an ofcer of Tamarack, all invoices become due and pay-
able net 30 days following the date in invoice. Interest
at the maximum legal rate will be charged on all overdue
accounts. Minimum net charge per invoice is $75.00
(4) CANCELLATION AND CHANGES: No orders or
sales may be cancelled or changed without the consent
of Tamarack. At Tamarack's option cancelled/changed
orders are subject to payment of cancellation charges
equal to all costs incurred by Tamarack up to the date
of cancellation/change.
(5) DELAYED DELIVERIES: Tamarack shall not be
liable for any delay of merchandise for any cause what-
soever.
(6) CLAIMS: All goods shall be deemed delivered to pur-
chaser at the time they are placed in the hands of carrier
and consigned to purchaser: loss, damage or destruc-
tion of any said merchandise is assumed by purchaser.
No claims may be made for shortages unless 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 liability on
any claim of any kind, including negligence, for any loss
or damage arising out of, connected with, or resulting
from contract, or the performance or breach thereof, or
the design, manufacture, sale, delivery, resale, installa-
tion, technical direction of installation, inspection, repair,
operation or use of any equipment covered by or fur-
nished under contract shall in no case exceed the price
paid by the purchaser for the equipment. Tamarack also
disclaims all purchaser for the equipment. Tamarack
also disclaims all liability, whether in contract, tort, war-
ranty, or otherwise, to any party other than purchaser.
(9) All Price Lists, Catalogues and other material shall re-
main the property of Tamarack and are subject to return
on demand. The Suggested List Prices are established
by Tamarack and are intended to act as a guide. All
shipping weights shown are approximate.
LIMITED TAMARACK WARRANTY
For two years from date of purchase, Tamarack will
replace or repair for the original purchaser, free of
charge, any part or parts, found upon examination by any
Tamarack Authorized Service Depot or by the Tamarack
factory, to be defective in material or workmanship or
both. Equipment and accessories not manufactured
by Tamarack are warranted only to the extent of the
original manufacturer's warranty. All transportation
charges on parts submitted for replacement or repair
under this warranty must be borne by the purchaser.
For warranty service contact your nearest Tamarack
Authorized Service Depot.
THERE IS NO OTHER EXPRESS WARRANTY,
IMPLIED WARRANTIES, INCLUDING THOSE OF
MERCHANTABILITY AND FITNESS FOR A PARTICU-
LAR PURPOSE ARE LIMITED TO ONE YEAR FROM
PURCHASE AND TO THE EXTENT PERMITTED BY
LAW. LIABILITY FOR CONSEQUENTIAL DAMAGES
UNDER ANY AND ALL WARRANTIES ARE EXCLUD-
ED TO THE EXTENT EXCLUSION IS PERMITTED BY
LAW. (THIS WARRANTY IS AN ADDITION TO ANY
STATUTORY WARRANTY.)
P.O. Box 234, Station "L"
Winnipeg, Manitoba
Canada R3H 0Z5
WARRANTY VOID IF NOT REGISTERED

14
How It Works
Boiler
Level
switch
Supply
manifold
Return
manifold
On-board
Diesel Tank
Flue
exhaust
TCH 250 –DIESEL
Supply
Temp
sensor
Thermostat Safety
Thermostat
Circulating
pump
The Thawzall TCH250 is designed to heat a propylene glycol water solution which is then used for
ground thawing, concrete curing or space heating. The glycol solution is pumped into the onboard
boiler by use of a 1/2hp centrifugal pump, where it is heated and sent out to a distribution manifold
for use in the eld. This solution is returned from the eld into the return manifold and back into the
boiler for reheating. An electronically controlled three way valve adjusts the amount of return cool-
ant being directed into the, boiler depending on the set temperature requested at the controller.
(Operator selected)
The TCH250 is a closed loop system where the glycol/water solution is always stored within the
boiler and the eld hoses.
A reservoir tank which contains about 12 gallons of the glycol/water solution is also found 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 side of the unit. All operations are controlled from here
including selection of input power preference as well as burner and reel control. The operator can
set the required temperature via the HMI (Human Machine Interface). The HMI will also display all
the return temperature being read at the manifold so all 5 zone temperatures can be monitored.
Safeties
The unit has a PRV valve which will release excess pressure back into the reservoir in the event of
over pressurization. Also found on the top of the water jacket on the boiler is a low glycol shutdown
safety. This safety will shut down the boiler is the case of low glycol in the system or excess air in
the system. The TCH250 comes with a shutdown thermostat located directly on the boiler in the
event of an over temperature condition within the boiler

Controls
15

Main Status Screen
16
Fuel Level - Current reading of the fuel level sender located in the fuel tank
Supply Temperature- Current reading of the temperature sensor located in the
supply line feeding the manifold.
Return Temperature- Current 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 the enter key to select a menu item.

Navigating the controller
17
Alarm] Key - Pressing this key will display any active alarms and
provide read access to historical alarm data. When the key is
ashing red, an active unacknowledged alarm is present. Solid red
indicates an active acknowledged alarm.
[Program] Key - This key provides access to the various advanced
settings 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 between elds on the screen.
[Down] Key - The Down key is used to change menu selections
and adjust values within the various screens.

Target Condition- Use the enter key to move the cursor to this eld and
use 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 eld and the
up/down keys to toggle between units. Once completed use the enter key to
save.
Settings Screen
18

I/O Screen
I/O Status- 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