Mine has the same exact issue. What year is yours? Do you drive with it on? Shane told me 1 week ago everyone drives with them on, after they towed it back and he called me this week, he changed his tone and says I can't drive with it on. Unreal... I know 4 guys with this same trailer and they all drive with it on...
Like you, I ran mine for 45-1hr and the only area that was blowing warm air was in the box below the boots. The in floor heat didn't feel warm ever. I couldn't ever get my thermostat above 55degrees. The one day I ran the furnace for 4 hours and it still never got above 55degrees. I truly believe trails west failed on this new design. Everyone I know with a 2013 doesn't have these problems and the in floor heat system isn't necessary. All the ducting and air passages actually don't move air. Traps it
They said on Wednesday it was 7 degrees and they ran the trailer for 10 min and rose to 82 degrees inside. They even opened the side door and ran it to make sure it continuously run and nake sure the furnace didn't fail. Sounds like you have a faulty unit yourself.
Mine is a 2014 also. Yeah the in floor heat is pretty much worthless. I've only used my trailer three times and have had the heat on each time while traveling, so far no problems.
While yours is back at the factory, are they going to just fix the dependability issues you're having, or are they also going to try and get it to produce more heat? I have a 35 foot fifth wheel with a 35,000 btu furnace, it heats the trailer much better than the furnace in the Trails West trailer.