OWNER'S MANUALMODEL 18480

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THE ICEBREAKER 480HAS BEEN DESIGNED PRIMARilY FORMUNICIPALITIES AND UTILITY DEPART­MENTs THAT REQUIRE THE USE OF PIPETHAWING EQUIPMENT.

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

FORM WC5283

INSTALLATIONOPERATIONTROUBLESHOOTING

MANUFACTURER'S LIMITED WARRANTY

This equipment is warranted against defects in materi­als 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, ne­glect, 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 CON­SEQUENTIAL, INCLUDING, BUT NOT LIMITED TO,LOSS OF USE, ARISING OUT OF THE USE, OR THEINABILITY TO USE, THE PRODUCT. THE USER AS­SUMES 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 L1MI­TATIONS OR EXCLUSIONS MAY NOT APPLY TO YOU.THIS WARRANTY GIVES YOU SPECIFIC LEGAL

RIGHTS, AND YOU MAY HAVE OTHER RIGHTS WHICHMAY VARY FROM STATE TO STATE.

TABLE OF CONTENTS

INTRODUCTION 1SPECiFiCATIONS 2INSTALLATION 3OPERATION 4TROUBLESHOOTING 11

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

INTRODUCTION

THAWING FROZEN PIPES ELECTRICALLY

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

THE PIPE THAWING PROCESS

When electrically thawing a sec­tion of water pipe, it is onlynecessary to heat the pipe enough tomel t 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 prop­erly, the pipe thawing machine willmelt the ice and cause the water tostart to flow in about 10 minutes(see "APPROXIMATE" thawing times onpage 5) .

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

METHOD REMARKS

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

FIGURE 1. THE THAWING PROCESS

Open flame

Hot Water

Arc Welder

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

Slow.Lack of control.

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

OPENFAUCET

ICEBREAKER

STANDARDWATER

PRESSURE

ElectricPipe Thawer Uses safe low

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

IMPORTANTThe Icebreaker 480 comesequipped with a built-in ther­mal protector. When theIcebreaker's internal tempera­ture reaches a certain point,automatic shut down will occur.

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

CHECK LIST

4.5 - 10V AC480 Amps

19 inches14 inches

27 3/4 inches107 pounds

1 1/4 inch150 feet (max.)

PIPE THAWING CAPACITY:Pipe SizeLength

SPECIAL SAFE TY FEATURE:CLI - Current Leakage Indicator(Special Built-in Safety Circuit)

OUTPUT:VoltageCurrent-(Maximum)

DIMENSIONS:HeightWidthDepthWeight

*Longer cables must also be largerin AWG size.

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

DESCRIPTION

NOTELonger cables must also belarger in AWG size. If smallerdiameter cables are used, cur­rent (amperage) will be lim­ited.

The Systematics Icebreaker 480is a electric pipe thawing machineintended for use by Municipalitiesand Water departments. It is de­signed for use with 1/2 inch to1 1/4 inch copper or iron pipe up to150 feet in length. The unit isprotected by a internal thermalswitch and a 25 amp circuit breaker.It features a six posi tion switch tocontrol heat output. The meter onthe unit informs the operator thatthe selected heat output is; toolow, safe, or too high for each pipethawing operation. Two #2/0 AWGcables of 20, 50 or 100 feet, or two#4/0 AWG cables of 50 or 100 feetshould be used for thawing.

THE SYSTEMATICS ICEBREAKER 480 INCLUDESTHE FOLLOWING:

The Icebreaker 480 comesequipped with our specially de­signed Current Leakage Indicator(CLI). The CLl is a safety circuitbuil t into the I8480 that helpseliminate the possiblity of currentleaking into the electrical ground­ing circuits.

1- 18480Pipe Thawerwithbuilt-inWheel kit

CD CDI!Ir.. 480

WARNINGrfJ -~- -~­~=o 0=

Current leaking into the elec­trical grounding wires canoverheat nearby conbustiblematerials and cause fires.

SPECIFICATIONS

PART NO.

INPUT:VoltagePhaseFrequencyCurrentInput Cable

IB480

115V ACsingle

50/60 Hz19 Amps20 feet

1- 20CP-14020 footPower InputCable

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

18480 FEATURES INSTAllATION

FIGURE 2. FRONT VIEW

The following features are lo­cated on the front of the IB480.

D. HEAT CONTROL SWITCHA six position switch for con­trolling heat output.

WARNING

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

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

If the wiring is grounded in twoplaces, such as, at a barn anda house, a parallel low vol tagecurrent may be establishedthrough the grounded neutralconductor. If so, the CLI lightshould come on warning theoperator of this possible situ­ation. If left alone, the con­ductor could get hot and starta fire in either building.Disconnect all grounds at ei­ther end of the electricalwiring system.

The Icebreaker 480 is mobile ancan be positioned in any locatioconvenient to the frozen pipe anavailable input power. A 115 volt A'grounded 20 amp circui t is requireor the IB480 can be used on a smalportable generator (4000 watts 0larger). If it is necessary to usan extension cord, it should beheavy-duty 3 prong grounded conductor type.

D.

HEATCONTROLSWITCH

for quickcurrent.

QO. E.

Q=J CURRENT

LEAKAGE

U:OICATORINSULATEDKNOBS

a::::r

.5IiI_---

~ETER I~B. --- •...•1;;1 ­

CIRCUIT [­

BREAKER

C.--OUTPUTLUGS

C. OUTPUT LUGSTerminals allow quick installa­tion and removal of pipe thawingcable assemblies.

A. METERColor coded meterselection of outputWhi te - too lowGreen - safeRed - too high

B. CIRCUIT BREAKERPrimary power switch and over­load protection device.

ICEBREAKERE. CURRENT LEAKAGE INDICATOR (CLI)

Safety circuit light that illu­minates when a low current flowsthrough an unsafe path. The pushbutton switch allows easy test­ing of the CLI operation.

FROZEN AREA

F. INSULATED KNOBSNo wrench required for easycable removal.

PARALLELGROUND WIRE

FIGURE 3. PARALLEL GROUND

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

OPERATION

First, isolate the frozen sec­tion of pipe. Inside a house, thisis done by opening faucets and backtracing the pipes. The frozen sec­tion 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.

The cables get hot during op­eration 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 480 to HEAT #1.

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

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

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.

FROZEN AREA

FIGURE 4. STANDARD HOOKUP

8. Reset the Icebreaker to heat #2.

lO.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.

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

TO 115VAC UNFROZENINPUT \ LINE AT

STANDARDWATER

PRESSURE

15FEET _(MINIMUM)

ICEBREAKER

OPENFAUCET

FIGURE 5. METER LEGEND

NOTEGood connections are neces­sary. Before connecting thecables, clean all pipes bysanding with coarse emerycloth. Make sure all connec­tions 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.

METER

POINTER

HEAT

HEAT CONTROL SWITCH

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

WARNING

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

A small empty pipe in thecircui t may get very hot beforea larger pipe will thaw. Thiscould melt the solder in acopper line or set fire tonearby combustible materials.

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

THAWINGTIME

8 min.10 min.12 min.15 min.20 min.25 min.

3/4 to 1 inchcopper or steel

CURRENT300 Amps270 Amps240 Amps220 Amps200 Amps180 Amps

(2) 50-2/0#2/0 AWG

50 feet (each)"APPROXIMATE"

PIPELENGTH20 feet40 feet50 feet60 feet80 feet100 feet

PIPE TO BE THAWED:Size­Type-

CABLES USED:Size­Length-

NOTICEAfter obtaining the correctmeter reading the CLI red lightshould be "OFF". Test the cir­cuit for operation by pressingthe·push button switch. If thered light comes on, operationis fine (for more informationsee "CURRENT LEAKAGE INDICATOR(CLI) "on page 6).

CAUTION

Always use the Icebreaker480 in the green area - neverin the red area. Make surethe circuit breaker isturned "OFF" before chang­ing the HEAT setting. Moni­tor the equipment during thepipe thawing operation.

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.

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

(continued on following page)

Systematics, Inc. 1025 Saunders Ln. West Chester, Pa. 19380 5

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CURRENT LEAKAGE INDICATOR (CLI)

1. Under proper thawing conditionsthe CLI red light will be off.The red light will come on onlywhen a low current flows throughan·unsafe path such as electri­cal ground lines.

WARNING

A unsafe condition is apossibility when one of thethawing leads is connectedto a fire plug instead of thecurb service valve when thaw­ing the street to houseservice pipe. This condi­tion only developes if thepipe line sections in thestreet have not been prop­erly bonded- electricallytogether. When the bondshave been accidently brokenor missed, thawing currentcan not go through the streetpipe directly to the house.Instead it goes to someother nearby house, throughthe ground wire , up theelectrical power lines, (frompole to pole), down thepower lines through the groundwire to the pipe in thedesired house and otherhouses. This condition cancause fires.

2. If an unsafe condition shouldoccur, the CLI light will come onimmediately. The machine thenshould be turned "OFF". Underthis condition the thawing cur­rent would be too low to thaw thepipe but may be high enough tooverheat the ground wires.

3. During every thawing operation,the CLI should be tested forproper operation.

a. Following the directions out­line under "THAWING DIRECTLINES" on page 4.

RED--:r INDICATOR

~- L1GIH~EINDfCATOR

-. - CURRENTOl 0-- ~~~ONTESTSWITCH

FIGURE 6. CURRENT LEAKAGE INDICATOR

b. With the pointer of the meterlocated well into the greenarea. The red indicator lightof the CLI circuit will be"OFF".

c. Activate the push button testswitch. The red light shouldilluminate (see Figure 6).

d. If the test results arepositive, continue with thethawing process.

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 adj ustable groundlevel cover probably does not makea good connection to the valve.

ICEBREAKER

CURB KEY

FROZEN AREA

FIGURE 7. HOUSE SERVICE PIPE

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

NOTICEThe curb key must make a excel­lent 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 fau­cet. It may be used on hot waterheating systems. However, the de­sign of these systems presentsproblems which may make theIcebreaker's use ineffective.

FROZEN AREA (ZONE 1)

NON·FROZEN (ZONE 2)

PUMP

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

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

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

1. SEPARATE AND CAP ALL UNFRO­ZEN ZONES.

2. SEPARATE FROZEN ZONE.3. PUT CARDBOARD INSULATION

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

ICEBREAKER. COLLECT THAW­ING WATER IN A CONTAINER.

5. SHUT OFF EVERYTHING.QUICKLY CONNECT PIPES.

6. CHECK HEAT IN ALL ZONES.

FIGURE 8. HEATING SYSTEMS

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 8.

Systematics, Inc. 1025 Saunders Ln. West Chester, Pa. 19380 7

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.

ICEBREAKER

FIGURE 9. BASEBOARD SYSTEM

PREVENT REFREEZING OF PIPES

Prevent refreezing by takingsteps to prevent the pipe fromcooling below 32 degrees F. Insu­late all cracks and openings, wrappipes with thermostatically con­trolled 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 "Amprobell>" meter, thistest instrument is highly recom­mended for best results. Currentshould be between 200 and 400 amps.If the current is less than 200amps, a second Icebreaker 480 can beused to increase the current.

The second Icebreaker 480 willrequire a second 20 amp 115 volt ACcircuit. The proper methods ofconnection are shown below. In setup #1, both uni ts 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 polar­ity must be correct for the secondunit to operate properly.

WARNING

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

DETERMINING THE POLARITY

Since these units have an alter­nating current output, the instan­taneous polarity can not be ob­served. A test procedure must befollowed to determine if the polar­ity is correct.

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

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 polari ty is correctand the clamps may be attached tothe pipe. If there is a strongspark, the polarity is wrong. Cor­rect 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.

WARNING

Due to the chance of a dischargeof an electrical spark duringthe polari ty test. Extreme cau­tion should be exercised.Please remove all flammablematerials, gases, etc. , fromthe immediate area. Wear heavygloves and eye protection.

ICEBREAKER #1

ICEBREAKER #2

FROZEN AREA

~ 20 FEET (MIN.) --)j

FIGURE 10. #1 PARALLEL CONNECTIONS

(BEST FOR LARGE DIAMETER PIPE)

(continued on following page)

Systematics, Inc. 1025 Saunders Ln. West Chester, Pa. 19380 9

TEST FOR POLARITY - SET UP #2(Series) IMPORTANT REVIEW

FROZEN AREA

40 FEET (MIN.)

00- use short cables.00- unwind the cables.00- connect clamps to unfrozen

pipe on either side offrozen section.

00- clean pipe and make goodconnections.

00- make connections to pipebefore plugging in the Ice­breaker.

00- open faucets so moving wa­ter can help thaw pipe.

00- use only heavy duty exten­sion cords.

00- disconnect other appli­ances while using the Ice­breaker.

00- disconnect all electricalgrounds attached to thaw­ing area(i.e. telephone,cable TV, etc.).

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

00- attach clamps to pipe cor­rectly.

00- watch for overheating andfires.

00- prevent refreezing.00 NOT- lay cables across

floors or carpeting.00 NOT- leave cables wound up.00 NOT- make quick connections

to dirty pipe.00 NOT- move clamps while cur­

rent is flowing.00 NOT- leave machine unat­

tended.00 NOT- leave machine "ON"

over night.

ICEBREAKER #2ICEBREAKER #1

Make all connections except theclamp on one end of the pipe.Momentarily touch the clamp to thepipe a·ndobserve the spark. If thereis a strong spark, the polarity iscorrect and the clamp can be con­nected to the pipe. If there isIittle 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.

FIGURE 11. #2 SERIES CONNECTIONS(BEST FOR LONG LENGTHS OF PIPE)

Two Icebreakers, properly con­nected, will double the thawingaction.

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

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

Cables stay cold-pipe does notthaw (no currentflow) .

Cables get warmbut not hot-pipe does notthaw.

Cables get hot-pipe does notthaw.

POSSIBLE CAUSE

Line fuse is blown.Machine circuit breaker

is "OFF".Poor connection by

cable clamps.Both clamps are not on

same pipe.Thermal protector is

tripped.Some pipe in line is

connected with rubberinsulated couplings.(not a complete circuit)

There is some plasticpipe in the line (nota complete circuit)

Solder joint has beenpushed apart by ice.(not a complete circuit)

Clamps attached to metalcover and not directlyto pipe.

Poor connection by cableclamp.

Use of longer thanstandard cables whichare not larger inAWG size.

No water pressure-source is frozen.

No water pressure-pump is not operating.

Clamps do not cover allof frozen area.

Pipes interconnectedelectrically-notenough heat isconcentrated in thefrozen section.

Thawing hot water systemswith several zones-not enough heat isconcentrated in frozensection.

REMEDY

Replace fuse.Turn on circuit breaker.

Clean pipe where clampare attached.

Put clamps on same pipe.

Allow unit to cool andretry.

Need a complete circuitfor electric current.

Need a complete circuitfor electric current.

Need a complete circuitfor electric current.

Attach clamps directlyto pipe.

Clean pipe where clampsare attached.

Use larger AWG cables-longer cables mustalso be larger.

Thaw water pressuresource.

Turn on pump-waterpressure is required.

Reposition clamps so allof frozen area isbetween them.

Separate frozen pipefrom non-frozen pipe.

Separate frozen zonefrom non-frozen zone.

THE ICEBREAKER 480 RELIES ON CURRENT FLOW FOR PROPER OPERATION.PLEASE EQUIP YOURSELF WITH AN AC CLAMP-ON "AMPROBE~' METER FOR CUR­RENT MONITORING PURPOSES.

Systematics, Inc. 1025 Saunders Ln. West Chester, Pa. 19380 11

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