Hotstart OLA Installation & Operation Manual Download

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IDENTIFYING YOUR SYSTEM

The HOTSTART heating system is designed to heat fluids for use in marine propulsion, diesel-powered generator sets,

locomotives, gas compression or any large-engine applications. The system is pre-wired, pre-plumbed and assembled on

steel plate. Each heating system has an identification plate which includes the part number and serial number.
When ordering replacement parts, be sure to reference your heating system’s

model

number

and

serial

number

found on the identification plate and following label:

WARRANTY INFORMATION

Warranty information can be found at

www.hotstart.com

or by contacting our customer service department at

(

509)536-8660

. Have your

model

number

and

serial

number

ready when contacting the warranty department.

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 &
Manufacturing
Headquarters

5723 E. Alki Ave.
Spokane, WA 99212 USA

509.536.8660

sales@hotstart.com

Oil & Gas Office

21732 Provincial Blvd.
Suite 170
Katy, TX 77450 USA

281.600.3700

oil.gas@hotstart.com

Railroad Office

8915 Broadway
Merrillville, IN 46410 USA

219.648.2448

railroad@hotstart.com

Europe Office

HOTSTART Europe GmbH
Hansestraße 79
51149 Köln, Germany

+49.2203.98137.30

europe@hotstart.com

Asia Pacific Office

HOTSTART Asia Pacific Ltd.
2-27-15-4F Honkomagome
Bunkyo-ku, Tokyo
113-0021, Japan

+81.3.6902.0551

apac@hotstart.com

IOM216348-000

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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