owner's manual - systematics inc.owner's manual the icebreaker 450 thaws frozen metal...

FOR TECH. SERVICE, CALL 1-610-696-9040

INSTALLATIONOPERATIONTROUBLESHOOTING

OWNER'S MANUAL

THE ICEBREAKER 450THAWS FROZEN METAL WATER PIPESELECTRICALLY IN MINUTES. SAVE TIME,LABOR AND MONEY!

MODEL IB450

FORM WC5282

MANUFACTURER’S LIMITED WARRANTY

This equipment is warranted against defects in materi-als and workmanship for a period of 2 YEARS from the dateof purchase.

Should it become defective for such reason, the Manu-facturer will repair it without charge, if it is returned to theManufacturer’s factory, freight prepaid. This warrantydoes not cover: (1) failure due to normal wear and tear; (2)damage by accident, force majeure, improper use, ne-glect, unauthorized repair or alteration; (3) anyone otherthan the original purchaser.

THIS LIMITED WARRANTY IS IN LIEU OF ALLOTHER WARRANTIES, EXPRESS OR IMPLIED. THEMANUFACTURER SHALL NOT BE LIABLE FOR ANYINJURY TO PERSONS, INCLUDING DEATH; OR LOSSOR DAMAGE TO ANY PROPERTY, DIRECT OR CON-SEQUENTIAL, INCLUDING, BUT NOT LIMITED TO,LOSS OF USE, ARISING OUT OF THE USE, OR THEINABILITY TO USE, THE PRODUCT. THE USER AS-SUMES ALL RISK AND LIABILITY WHATSOEVER INCONNECTION WITH THE USE OF THE PRODUCT,AND BEFORE DOING SO, SHALL DETERMINE ITSSUITABILITY FOR HIS INTENDED USE, AND SHALLASCERTAIN THE PROPER METHOD OF USING IT.

SOME STATES DO NOT ALLOW LIMITATIONS ONHOW LONG AN IMPLIED WARRANTY LASTS, OR THEEXCLUSIONS OR LIMITATIONS OF INCIDENTAL ORCONSEQUENTIAL DAMAGES. SO THE ABOVE LIMI-TATIONS OR EXCLUSIONS MAY NOT APPLY TO YOU.THIS WARRANTY GIVES YOU SPECIFIC LEGALRIGHTS, AND YOU MAY HAVE OTHER RIGHTS WHICHMAY VARY FROM STATE TO STATE.

TABLE OF CONTENTSINTRODUCTION .................................................... 1SPECIFICATIONS .................................................. 2INSTALLATION ...................................................... 3OPERATION .......................................................... 3TROUBLESHOOTING ........................................... 9

Systematics, Inc. 1025 Saunders Ln. West Chester, Pa. 19380

Systematics, Inc. 1025 Saunders Ln. West Chester, Pa. 19380 1

THE PIPE THAWING PROCESS

When electrically thawing a sec-tion of water pipe, it is onlynecessary to heat the pipe enough tomelt a thin film of ice on the insideof the pipe. The warmer water, understandard pressure, on the one sideof the ice will seep through themelted film and very quickly meltthe rest of the ice, causing a flowout of the open faucet on thedownstream side. If operated prop-erly, the pipe thawing machine willmelt the ice and cause the water tostart to flow in about 10 minutes(see "APPROXIMATE" thawing times onpage 5).

NOTICESince copper pipe will not heatup as fast as iron pipe, allowabout 30 percent longer thawingtime.

INTRODUCTIONTHAWING FROZEN PIPES ELECTRICALLY

A frozen water pipe can be thawedvery quickly by passing low volt-age, high current AC electricitythrough it. This method works onsteel or copper pipes even when theyare buried in the ground or con-cealed in the walls of buildings.This method DOES NOT work on plasticpipes because they will not conductelectricity. The method requiresthat there be unfrozen water, understandard pressure, on one side ofthe frozen section of pipe and anopen faucet on the other side.

Thawing pipes electrically hasbeen shown to be more convenient andsafer than other methods of thawingpipes including the following:

METHOD REMARKS

Open flame Lack of control.Uses dangerous gasor other flammableliquids.Risk of fire.

Hot Water Slow.Lack of control.

Arc Welder Large power sourceis required tosupply needed highvoltage.Arc can meltpipes.Hazard of highvoltage shock tooperator.Damage to welder.Risk of fire.

ElectricPipe Thawer Uses safe low

voltage.Easy to use.No flame or arcwhen usedproperly.

STANDARDWATER

PRESSUREOPENFAUCET

ICEBREAKER

FROZEN AREA

WATER UNDERSTANDARD PRESSURE

SEEPS THROUGHMELTED FILM

FROZENAREA

FIGURE 1. THE THAWING PROCESS

IMPORTANTThe Icebreaker 450 comesequipped with a built-in ther-mal protector. When theIcebreaker's internal tempera-ture reaches a certain point,automatic shut down will occur.

2 Systematics, Inc. 1025 Saunders Ln. West Chester, Pa. 19380

DESCRIPTIONThe Systematics Icebreaker 450

is a compact electric pipe thawingmachine intended for use by profes-sional plumbers and for light in-dustrial use. It is designed for usewith 1/2 inch to 1 inch copper oriron pipe up to 150 feet in length.The unit is protected by a internalthermal switch and a 20 amp circuitbreaker. It features a six positionswitch to control heat output. Themeter on the unit informs theoperator that the selected heatoutput is; too low, safe, or toohigh for each pipe thawing opera-tion. Two #2/0 AWG cables of 20, 50or 100 feet, or two #4/0 AWG cablesof 50 or 100 feet should be used forthawing.

NOTELonger cables must also belarger in AWG size. If smallerdiameter cables are used, cur-rent (amperage) will be lim-ited.

SPECIFICATIONSPART NO. IB450

INPUT:Voltage 115V ACPhase singleFrequency 50/60 HzCurrent 17 AmpsInput Cable 9 feet

OUTPUT:Voltage 4.5 - 10V ACCurrent-(Maximum) 450 Amps

PIPE THAWING CAPACITY:Pipe Size 1 inchLength 150 feet (max.)

DIMENSIONS:Height 12 inchesWidth 13 inchesDepth 12 inchesWeight 58 pounds

RECOMMENDED CABLES:two 50 ft. #2/0 AWG* (2)50-2/0two 100 ft. #4/0 AWG* (2)100-4/0

*Longer cables must also be largerin AWG size.

A. CARRYING HANDLEHeavy-duty constructed handlefor easy lifting of the IB450.

B. METERColor coded meter for quickselection of output current.White - too lowGreen - safeRed - too high

C. OUTPUT LUGSTerminals allow quick installa-tion and removal of pipe thawingcable assemblies.

D. INSULATED KNOBSNo wrench required for easycable removal.

E. HEAT CONTROL SWITCHA six position switch for con-trolling heat output.

F. CIRCUIT BREAKERPrimary power switch and over-load protection device.

G. INPUT CORDNine foot heavy-duty cord withgrounded plug.

E.HEATCONTROLSWITCH

F.CIRCUITBREAKER

G.INPUTCORD

A.CARRYINGHANDLE

B.METER

C.OUTPUTLUGS

D.INSULATEDKNOBS

IB450 FEATURESThe following features are lo-

cated on the front of the IB450.

FIGURE 2. FRONT VIEW


INSTALLATIONThe Icebreaker 450 is portable

and can be positioned in any loca-tion convenient to the frozen pipeand available input power. A 115volt AC grounded 20 amp circuit isrequired. If it is necessary to usean extension cord, it should be aheavy-duty 3 prong grounded conduc-tor type.

WARNINGIf the wiring is grounded in twoplaces, such as, at a barn anda house, a parallel low voltagecurrent may be establishedthrough the grounded neutralconductor. If so, it could gethot and could start a fire ineither building. Disconnectall grounds at either end of theelectrical wiring system.

Disconnect all appliances toprevent blowing house fuses oroverheating the house wiring.

Do not connect the Icebreakerto the 115 volt power until allpipe connections have beenmade. See "Operation" section.

OPERATIONFirst, isolate the frozen sec-

tion of pipe. Inside a house, thisis done by opening faucets and backtracing the pipes. The frozen sec-tion will usually be in the outsidewalls, near doors or windows, or incrawl spaces under floors. If allwater outlets in the house fail tooperate, the line from the curbvalve to the house could befrozen(see "THAWING HOUSE SERVICEPIPES" on page 5).

THAWING DIRECT LINES

1. Uncoil the pipe thawing cables.

2. Connect them to the Icebreakerand the pipe to be thawed, at thenearest convenient spots thatwill place the frozen sectionBETWEEN the clamps.

(continued on following page)

FIGURE 4. STANDARD HOOKUP

NOTEGood connections are neces-sary. Before connecting thecables, clean all pipes bysanding with coarse emerycloth. Make sure all connec-tions are tight to preventoverheating or arcing at theclamps. When the connectionsare good, the pipe and cableswill vibrate to the touch. Donot use cables coiled up orplaced on steel objects asheating in the pipe will bereduced.

15 FEET(MINIMUM)

OPENFAUCET

ICEBREAKER UNFROZENLINE AT

STANDARDWATER

PRESSURE

TO 115VACINPUT

FROZEN AREA

FIGURE 3. PARALLEL GROUND

FROZEN AREA

PARALLELGROUND WIRE

ICEBREAKER

BAR

N

HO

USE


11.If the pointer is in the redarea, turn the circuit breaker"OFF" and reset the Icebreakerto the next lower HEAT setting.

12.If the meter will not go into thegreen zone, larger diametercables are required for maximumthawing results.

CAUTION

Always use the Icebreaker450 in the green area - neverin the red area. Make surethe circuit breaker isturned "OFF" before chang-ing the HEAT setting. Moni-tor the equipment during thepipe thawing operation.

13.Pipes may be thawed with themeter in the white zone, butthawing times will be longer.

WARNINGA small empty pipe in thecircuit may get very hotbefore a larger pipe willthaw. This could melt thesolder in a copper line orset fire to nearby combus-tible materials.

The following chart indicatesthe "APPROXIMATE" thawing timesunder "ideal" condition.

PIPE TO BE THAWED:Size- 3/4 to 1 inchType- copper or steel

NOTICEThe Icebreaker relies upon aconductive material, (i.e.bronze, copper, iron), for op-eration. So plastic or PVC pipecan not be thawed using thistype of equipment.

THAWING DIRECT LINES (Cont.)

WARNINGThe cables get hot during op-eration so keep them off rugsand finished floors that may bedamaged by the heat.

3. Place the clamps at least 15 feetapart to prevent overheating themachine and cables.

4. Set the Heat Control Switch onthe Icebreaker 450 to HEAT #1.

5. Plug the power input cord into a115 volt AC receptacle.

6. Turn "ON" the circuit breakerand observe the meter.

7. If the pointer of the meter is inthe white or lower green area,turn "OFF" the circuit breaker.

8. Reset the Icebreaker to heat #2.

9. Turn the circuit breaker "ON"and observe the meter.

10.If the pointer is still in thewhite or lower green area, tryHEAT #3 setting and so on untilthe pointer is well into thegreen area but not in the redarea.

FIGURE 5. METER LEGEND

WHITE GREEN RED

POINTER

HEAT CONTROL SWITCHMETER


CABLES USED: (2)50-2/0Size- #2/0 AWGLength- 50 feet (each)

"APPROXIMATE"PIPE THAWING

LENGTH CURRENT TIME20 feet 300 Amps 8 min.40 feet 270 Amps 10 min.50 feet 240 Amps 12 min.60 feet 220 Amps 15 min.80 feet 200 Amps 20 min.100 feet 180 Amps 25 min.

THAWING HOUSE SERVICE PIPES

House service pipes usually canbe thawed by connecting one cable tothe exposed pipe in the kitchen orbasement and the other cable to thecurb service. At the curb, make theconnection to the valve at thebottom of the service riser using acurb key. The adjustable groundlevel cover probably does not makea good connection to the valve.

MAINFROZEN AREA VALVE

SERVICERISER

ICEBREAKER

CURB KEY

HO

USE

NOTICEThe curb key must make a excel-lent connection or heating ofthe key will be the only result.

THAWING HOT WATER HEATING SYSTEMS(WINTER/SUMMER HOOKUP)

This unit is intended for use insituations where there is a directpipeline from an unfrozen, highpressure pipeline to an open fau-cet. It may be used on hot waterheating systems. However, the de-sign of these systems presentsproblems which may make theIcebreaker’s use ineffective.

1. Because these systems use lowpressure pumps, more heating isrequired before the warmer watercan seep past the ice and con-tinue the thawing process.

2. Because the pipes in the systemare interconnected electri-cally, the resistance heatingfrom the Icebreaker current cantake several paths through thepipes and will not be concen-trated in the frozen section.The heat developed in the frozensection will be only 1/2 to 1/3of the heat developed by theIcebreaker. There may or may notbe enough heat to thaw the pipe.

(continued on following page)FIGURE 6. HOUSE SERVICE PIPE


THAWING HOT WATER HEATING SYSTEMS(Cont.)

3. There is little hope of thawingpipes in systems using cast ironradiators, large iron pipes orgravity circulation.

FROZEN AREA (ZONE 1)

NON-FROZEN (ZONE 2)

HEATER

PUMP

CARDBOARDINSULATION

ICEBREAKER

THAWING COPPER BASEBOARD SYSTEMS

To thaw copper pipe baseboardsystems, attach the clamps directlyto the pipe and not to the sheetmetal pipe covers. Covers should beremoved or lifted up so they willnot touch the heating pipe. Thecopper pipe should be insulatedfrom any metal hangers or supports.

PREVENT REFREEZING OF PIPES

Prevent refreezing by takingsteps to prevent the pipe fromcooling below 32 degrees F. Insu-late all cracks and openings, wrappipes with thermostatically con-trolled heating tape and let watertrickle on cold nights (usually aflow of one gallon per hour isenough to prevent freezing).

THAWING PIPES WITH TWO ICEBREAKERS

The heating current in the pipemay be checked with a standard ACclamp-on "Amprobe®" meter, thistest instrument is highly recom-mended for best results. Currentshould be between 200 and 400 amps.If the current is less than 200amps, a second Icebreaker 450 can beused to increase the current.

If the setup is correct and thereis no thaw, the final solution is toopen the pipes so all the heat andpressure is concentrated in onefrozen zone at a time, as shown inFigure 7.

ICEBREAKER

INSULATION

FROZEN AREA

FIGURE 8. BASEBOARD SYSTEM

FIGURE 7. HEATING SYSTEMS

1. SEPARATE AND CAP ALL UNFRO-ZEN ZONES.

2. SEPARATE FROZEN ZONE.3. PUT CARDBOARD INSULATION

BETWEEN PIPE ENDS.4. TURN ON HEATER, PUMP AND

ICEBREAKER. COLLECT THAW-ING WATER IN A CONTAINER.

5. SHUT OFF EVERYTHING.QUICKLY CONNECT PIPES.

6. CHECK HEAT IN ALL ZONES.


The second Icebreaker 450 willrequire a second 20 amp 115 volt ACcircuit. The proper methods ofconnection are shown below. In setup #1, both units MUST be set on thesame heat setting. In set up #2, theunits are not required to be set onthe same heat setting. Just as withjumping auto batteries, the polar-ity must be correct for the secondunit to operate properly.

WARNINGOperation of a second unit withthe polarity incorrect willburn up the machines and willnot heat the pipe.

DETERMINING THE POLARITY

Since these units have an alter-nating current output, the instan-taneous polarity can not be ob-served. A test procedure must befollowed to determine if the polar-ity is correct.

TEST FOR POLARITY - SET UP #1(Parallel)

Make the two pipe connections onone side of the pipe and plug in bothunits. Momentarily touch the othertwo clamps together and notice theamount of spark. If there is littleor no spark, the polarity is correctand the clamps may be attached tothe pipe. If there is a strongspark, the polarity is wrong. Cor-rect the polarity by (A) turningover one of the 115V plugs OR (B)interchanging the cable leads onone of the Icebreaker units. Testagain for the amount of spark.

TEST FOR POLARITY - SET UP #2(Series)

Make all connections except theclamp on one end of the pipe.Momentarily touch the clamp to thepipe and observe the spark. If thereis a strong spark, the polarity iscorrect and the clamp can be con-nected to the pipe. If there islittle or no spark, the polarity iswrong. Correct the polarity by (A)turning over one of the 115V plugsOR (B) interchanging the cableleads on one of the Icebreakerunits. Retest the spark strength.

(continued on following page)

FIGURE 9. #1 PARALLEL CONNECTIONS(BEST FOR LARGE DIAMETER PIPE)

WARNINGDue to the chance of a dischargeof an electrical spark duringthe polarity test. Extreme cau-tion should be exercised.Please remove all flammablematerials, gases, etc., fromthe immediate area. Wear heavygloves and eye protection.

20 FEET (MIN.)

FROZEN AREA

ICEBREAKER #2

ICEBREAKER #1


IMPORTANT REVIEWDO- use short cables.DO- unwind the cables.DO- connect clamps to unfrozen

pipe on either side offrozen section.

DO- clean pipe and make goodconnections.

DO- make connections to pipebefore plugging in the Ice-breaker.

DO- open faucets so moving wa-ter can help thaw pipe.

DO- use only heavy duty exten-sion cords.

DO- disconnect other appli-ances while using the Ice-breaker.

DO- disconnect all electricalgrounds attached to thaw-ing area(i.e. telephone,cable TV, etc.).

DO- make sure there is waterpressure at one side offrozen section.

DO- attach clamps to pipe cor-rectly.

DO- watch for overheating andfires.

DO- prevent refreezing.DO NOT- lay cables across

floors or carpeting.DO NOT- leave cables wound up.DO NOT- make quick connections

to dirty pipe.DO NOT- move clamps while cur-

rent is flowing.DO NOT- leave machine unat-

tended.DO NOT- leave machine "ON"

over night.

Two Icebreakers, properly con-nected, will double the thawingaction. If more heat is required, alarger Icebreaker unit and quali-fied operator will be necessary.

40 FEET (MIN.)

ICEBREAKER #1 ICEBREAKER #2

FROZEN AREA

FIGURE 10. #2 SERIES CONNECTIONS(BEST FOR LONG LENGTHS OF PIPE)


TROUBLE SHOOTINGFOR TECH. SERVICE, CALL 1-610-696-9040

The Trouble Shooting Chart is a guide in identifying and correctingpossible troubles which may occur when operating this equipment.

FAULT POSSIBLE CAUSE REMEDY

Cables stay cold Line fuse is blown. Replace fuse.-pipe does not Machine circuit breaker Turn on circuit breaker.thaw (no current is "OFF".flow). Poor connection by Clean pipe where clamp

cable clamps. are attached.Both clamps are not on Put clamps on same pipe.

same pipe.Thermal protector is Allow unit to cool and

tripped. retry.Some pipe in line is Need a complete circuit

connected with rubber for electric current.insulated couplings.(not a complete circuit)

There is some plastic Need a complete circuitpipe in the line (not for electric current.a complete circuit)

Solder joint has been Need a complete circuitpushed apart by ice. for electric current.(not a complete circuit)

Cables get warm Clamps attached to metal Attach clamps directlybut not hot cover and not directly to pipe.-pipe does not to pipe.thaw. Poor connection by cable Clean pipe where clamps

clamp. are attached.Use of longer than Use larger AWG cables

standard cables which -longer cables mustare not larger in also be larger.AWG size.

Cables get hot No water pressure Thaw water pressure-pipe does not -source is frozen. source.thaw. No water pressure Turn on pump-water

-pump is not operating. pressure is required.Clamps do not cover all Reposition clamps so all

of frozen area. of frozen area isbetween them.

Pipes interconnected Separate frozen pipeelectrically-not from non-frozen pipe.enough heat isconcentrated in thefrozen section.

Thawing hot water systems Separate frozen zonewith several zones from non-frozen zone.-not enough heat isconcentrated in frozensection.

THE ICEBREAKER 450 RELIES ON CURRENT FLOW FOR PROPER OPERATION.PLEASE EQUIP YOURSELF WITH AN AC CLAMP-ON "AMPROBE®" METER FOR CUR-RENT MONITORING PURPOSES.

Systematics, Inc. 1025 Saunders Ln. West Chester, Pa. 19380

owner's manual - systematics inc.owner's manual the icebreaker 450 thaws frozen metal...

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