background image

8

installation

 & 

operation

 

manual

 | 

ola

 

heating

 

system

 

 OOE:

 

  The specified power source must be within 

plus or minus 10% of the rated voltage.

 OOE:

 

  The circuit breaker must be near the 

heating system and easily accessible. 

HOTSTART recommends connecting the 

heating system to a circuit breaker rated for 

125% of the system’s maximum load.

 OOE:

 

  The main power supply operates the 

heating elements and the circulating 

pumps. A transformer is used to operate 

the control circuit. The transformer and 

control circuits are overload-protected.

 

h

For 

three-phase applications

, the terminal 

blocks are labeled 

L1

,

 L2 

and 

L3

 

(A)

.

 

h

For 

single-phase applications

, use the terminal 

blocks labeled 

L1

 and

 L2

 or 

and 

  (A)

2. 

Connect the main power ground wire to the ground 

block 

(B)

.

2.5.2  CUSTOMER INTERFACE 

CONNECTIONS

The following customer interface connections are 

available for remote control and monitoring 

(See Fig. 5)

:

 

OB2:1/OB2:2  
Remote On/Off 24 V DC shutdown (C)

 

When activated, the remote on/off 

connection shuts down the heating system. 

When deactivated, normal heating will 

resume. Use this connection for remote 

operation of the heater when the 

local

/

off

/

remote

 switch is turned to 

remote

.

 OOE:

 

 The 

24 V DC shutdown

 connection is 

wired 

 C (normally closed)

 from the 

factory; see system wiring schematic for 

directions to switch to NO (normally open) 

operation.

 

OB2:3/OB2:4 
Fault Signal (D)

 

The fault signal will indicate a heating system 

shutdown, triggered by either the high-

limit temperature control relay or the motor 

protection switch (

see 

SECOIO  4.1.1

).

 

OB2:5/OB2:6 
Motor Run Signal (E)

 

A motor run signal indicates the pump motor 

is running. If no signal is present, the pump 

motor is not running.

L1

L2

TB1

L3

L1

L2

L3

13

T1

T2

T3

13

MPS1

TB2

X1

2 4 6

1 3 5

7 8 9

1011121314

A1 A3

T1 T2 T3

13 14 A2-

11 12

TCR1

CONTROL

0

100

A1 A3

T1 T2 T3

13 14 A2-

11 12

TCR1

HIGH
LIMIT

0

100

L1

L2

TB1

L3

L1

L2

L3

13

T1

T2

T3

13

MPS1

TB2

X1

2 4 6

1 3 5

7 8 9 1011121314

A1 A3

T1 T2 T3

13 14 A2-

11 12

TCR1

CONTROL

0

100

A1 A3

T1 T2 T3

13 14 A2-

11 12

TCR1

HIGH
LIMIT

0

100

A

B

L1

L2

TB1

L3

L1

L2

L3

13

T1

T2

T3

13

MPS1

TB2

X1

2 4 6

1 3 5

7 8 9 1011121314

A1 A3

T1 T2 T3

13 14 A2-

11 12

TCR1

CONTROL

0

100

A1 A3

T1 T2 T3

13 14 A2-

11 12

TCR1

HIGH
LIMIT

0

100

E

D

C

Figure 5.  Main power supply and customer interface connections 
as shown in the OLA control box. Reference electrical schematic 
drawing for proper wiring locations; the following illustrations are 
typical customer interface locations.

A. 

Main power terminal block

B. 

Main power ground 
terminal block

C. 

Remote On/Off 

24 V DC shutdown

D. 

Fault signal

E. 

Motor run signal

1

2

3

4

SW1-B

X1:8

P1:8

X1:9

P1:9

P1:7

X1:7

X1:7

X1:8

X1:9

TB2:3

TB2:4

TB2:5

TB2:6

TB2:1

TB2:2

14

13

K2

K1

A1

A2

12

11

K4

LOCAL SIGNAL

REMOTE SIGNAL

REMOTE ON/OFF 24 V DC

FAULT WHEN CLOSED

MOTOR ON WHEN CLOSED

Summary of Contents for OLA

Page 1: ...216348 000 rev1 INSTALLATION OPERATION MANUAL MODEL OLA OIL CIRCULATING HEATING SYSTEM FOR HAZARDOUS LOCATIONS ...

Page 2: ......

Page 3: ...r and serial number ready when contacting the warranty department COPYRIGHT Hotstart Manufacturing Inc is the owner of all trademarks and copyrightable material contained herein all rights are reserved no form of reproduction is authorized without prior written consent from Hotstart Manufacturing Inc NOTE Typical heating system identification plate Your identification plate may vary Corporate Manu...

Page 4: ...ble overcurrent limiting device Power disconnection A means to disconnect the heating system from the power supply is required HOTSTART recommends that a power switch or circuit breaker be located near the heating system for safety and ease of use Flameproof joints Flameproof joints are not intended to be repaired in the field Do not attempt to repair any flameproof joints that become damaged Bend...

Page 5: ... Prime Button 9 3 1 3 Reset Button 9 3 1 4 Pressure Temperature Gauge 9 3 1 5 Pressure Relief Valve 9 3 2 SYSTEM COMPONENTS 10 3 2 1 Motor Protection Switch 10 3 2 2 Control TCR Temperature Control Relay 10 3 2 3 High Limit TCR Temperature Control Relay 10 3 3 HEATING SYSTEM START UP 10 3 3 1 First Run Procedure 11 4 MAINTENANCE AND TROUBLESHOOTING 11 4 1 SYSTEM FAULTS 11 4 1 1 Oil Faults 11 4 2 S...

Page 6: ...iv installation operation manual ola heating system this page intentionally left blank ...

Page 7: ...ions are for reference only and are not to scale See part drawings for dimensions and specifications A local off remote switch B prime button C reset button D Heating element E Oil outlet 1 NPT F High limit resistance temperature device RTD G Heating tank H Identification plate I Control resistance temperature device RTD J Pressure Temperature gauge K Pump motor L Oil pump M Oil inlet 0 5 1 0 1 5 ...

Page 8: ... line The oil pump will continuously circulate fluid throughout the engine or compressor To maintain consistent fluid temperature the heating element will cycle on and off at the user selected temperature control point An oil check valve user supplied and installed near the oil suction port prevents backflow while the engine or compressor is operating When the engine or compressor is shut down the...

Page 9: ...ure it is completely full of fluid while in operation Pump priming Fill supply line with fluid Pump is not self priming Fluid must be present in the pump before start up Trapped air inside the pump will cause pump and seal damage Pump seal damage Do not reduce the oil supply line to an inner diameter smaller than the pump inlet pump seal damage could occur Check valve HOTSTART recommends installin...

Page 10: ...eters To minimize flow restriction HOTSTART recommends using sweeping bends or 45 fittings At a minimum size the oil supply line per the pump inlet NOTICE Do not reduce the supply line inner diameter pump seal damage will occur NOTE To maximize flow and allow the longest possible supply line install the largest practical inner diameter hose for most installations HOTSTART recommends using a hose w...

Page 11: ...CTION PORT SECTION 2 1 1 CHECK VALVE SECTION 2 1 1 ISOLATION VALVE ISOLATION VALVE OIL SUPPLY SECTION 2 1 1 OIL RETURN SECTION 2 1 2 E 2 E 1 V 2 V 3 V 1 COMPONENT DESCRIPTION V 1 USER SUPPLIED CHECK VALVE V 2 USER SUPPLIED FULL FLOW ISOLATION VALVE E 1 OIL PUMP E 2 OIL HEATING ELEMENT V 3 USER SUPPLIED FULL FLOW ISOLATION VALVE ...

Page 12: ... SECTION 2 1 1 ISOLATION VALVE OIL SUPPLY SECTION 2 1 1 OIL RETURN SECTION 2 1 2 ISOLATION VALVE CHECK VALVE SECTION 2 1 1 E 2 E 1 V 2 V 3 V 1 V 4 COMPONENT DESCRIPTION V 1 USER SUPPLIED CHECK VALVE V 2 USER SUPPLIED FULL FLOW ISOLATION VALVE E 1 OIL PUMP E 2 OIL HEATING ELEMENT V 3 USER SUPPLIED FULL FLOW ISOLATION VALVE V 4 OPTIONAL USER SUPPLIED PRV ...

Page 13: ...n Electrical hazard The heating system must be connected to a suitable protective earthing conductor The heating system s power supply must be connected to a suitable overcurrent limiting device A means of disconnection from power supply is required HOTSTART recommends that a power switch or circuit breaker be located near the heating system for safety and ease of use Reference markings on heating...

Page 14: ...utdown connection is wired NC normally closed from the factory see system wiring schematic for directions to switch to NO normally open operation TB2 3 TB2 4 Fault Signal D The fault signal will indicate a heating system shutdown triggered by either the high limit temperature control relay or the motor protection switch see SECTION 4 1 1 TB2 5 TB2 6 Motor Run Signal E A motor run signal indicates ...

Page 15: ...e than five seconds at a time NOTE The prime function is intended for use during the first run procedure see SECTION 3 3 1 or after performing maintenance on the heating system or plumbing see SECTION 4 2 3 1 3 RESET BUTTON Press the reset button to reset the pump motor protection switch without opening the control box The reset function is intended for use immediately following resolving and repa...

Page 16: ...erheating The high limit TCR uses a resistance temperature device RTD located near the tank outlet The default setting for the high limit TCR is 194 F 90 C and should always be at least 18 F 10 C higher than the control TCR set point The high limit TCR hysteresis is not used in the high limit control See Fig 7 Figure 7 OLA motor protection switch left showing stop off A and reset on B buttons To r...

Page 17: ...n the control dial on the temperature control relay TCR1 to the desired temperature setting for engine oil HOTSTART recommends a control temperature on TCR1 of 104 F 40 C The high limit temperature setting on TCR2 should be set at 194 F 90 C See SECTION 3 2 2 and SECTION 3 2 3 7 Turn the local off remote switch to remote to verify the 24 V DC remote signal connection if installed 4 MAINTENANCE AND...

Page 18: ...d contactor coil The contacts on the magnetic contactor should be inspected periodically for welding arc erosion and mechanical wear If any of these conditions exist replace the magnetic contactor HOTSTART recommends contactors be replaced every five years 4 2 5 PUMP SEAL If seal becomes worn replacement pump seals are available To ensure pump seal longevity ensure the supply lines do not restrict...

Page 19: ... below high limit preset temperature Perform system start up see SECTION 4 If fault or temperature problems persist after start up contact HOTSTART for further assistance h h If there is no continuity between TCR terminals T2 and T3 locate connected RTD on the heating tank Unscrew the RTD plug from RTD See Table 3 5 Using the ohmmeter touch the probes to RTD lead TS2 WHT A and lead TS2 RED B See F...

Page 20: ...en to ensure that the heating system is operational for start up Steps must be taken to ensure that water ingress is mitigated at all locations All plugs and caps must remain tight and a suitable cover must be provided for the system The cover must shield the system from direct rain and protect from any directed spray that may occur For any storage longer than three months desiccant bags must be p...

Page 21: ... tripped Check and reset switch If problem occurs again check motor Restart system RTD failure Check TCR and RTD See SECTION 4 2 9 RTD cable failure Check TCR and RTD See SECTION 4 2 9 Oil temperature too low Motor failure Check motor Replace if necessary Heater has been turned off and fluid is cold Allow time for the heating system to heat fluid Heating element failed Check elements for continuit...

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