Hotstart OGM, Installation & Operation Manual

Page 1: ...216311 000 rev1 INSTALLATION OPERATION MANUAL OIL CIRCULATING HEATING SYSTEM MODEL OXM OGM ...

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Page 3: ...se in marine propulsion diesel powered generator sets locomotives gas compression or any large engine applications The system is pre wired and pre plumbed 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 foll...

Page 4: ...t must be thoroughly familiar with the instructions in this manual before commencing work Hot surfaces Avoid contact with the system while it is in service Some surfaces may remain hot even if the system is not energized Proper lifting Proper rigging and safety equipment must be used to move this equipment Do not lift the heating system by any cords electrical conduit or cabling Create a plan befo...

Page 5: ...RATURE GAUGE 8 3 5 PRESSURE RELIEF VALVE 8 3 6 MOTOR PROTECTION SWITCH MPS 8 3 7 HIGH LIMIT TCR TEMPERATURE CONTROL RELAY 9 3 8 CONTROL TCR TEMPERATURE CONTROL RELAY 9 4 HEATING SYSTEM START UP 10 5 MAINTENANCE REPAIR AND TROUBLESHOOTING 10 5 1 FAULTS 10 5 2 SYSTEM MAINTENANCE 11 5 2 1 Plumbing Connections 11 5 2 2 Electrical Connections 11 5 2 3 System Mounting 11 5 2 4 Magnetic Contactors 11 5 2...

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

Page 7: ...n OXM model incorporates two heater circuits 50 100 switch and heater lights not available Figure 1 OXM OGM heating system components H I J L K G F D E C B A O M N A Element assembly B Pressure temperature gauge C Oil outlet 1 25 NPT D prime button E local off remote switch F 50 100 switch G remote light H Lift points I local light J fault light K Oil pump inlet OXM 1 5 NPT OGM 2 5 NPT L Pump moto...

Page 8: ...g elements will cycle on and off at the user selected temperature control point A return line check non return valve included with the OXM OGM unit and installed at the outlet and a supply line check non return valve user supplied installed near the oil suction port prevent backflow while the engine is operating When the engine is shut down the heating system should be activated locally or remotel...

Page 9: ...pped 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 will occur Check valve HOTSTART recommends installing a user supplied swing type or full flow check valve non return valve to prevent oil from flowing back into the oil sump If the pump is installed above the minimum oil level...

Page 10: ...il flowing into the sump Install the check valve as close to the oil supply port as possible 2 1 2 OIL RETURN When installing the OXM OGM oil return line refer to the following HOTSTART guidelines At a minimum size the oil return line per the heating system outlet NOTICE Do not reduce the return line inner diameter Install the oil discharge port near the engine oil pump or to the opposite end of t...

Page 11: ... Installation illustrations are for reference only and are not to scale See part drawings for dimensions and specifications OIL RETURN SECTION 2 1 2 OIL SUPPLY SECTION 2 1 1 OIL DISCHARGE PORT SECTION 2 1 2 OIL SUCTION PORT SECTION 2 1 1 ISOLATION VALVES CHECK VALVE NON RETURN SECTION 2 1 1 ...

Page 12: ...g system turn off the power and follow your organization s lockout and tagout procedure Failure to do so could allow others to turn on the power unexpectedly resulting in harmful or fatal electrical shock Electrical hazard All wiring shall be done by qualified personnel in accordance with national state and local codes Each system shall be grounded in accordance with the National Electrical Code F...

Page 13: ...Fault Signal C 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 5 1 TB2 3 TB2 4 Motor Run Signal D A motor run signal indicates the pump motor is running If no signal is present the pump motor is not running TB2 5 TB2 6 Remote On Off 24 V DC shutdown E When activated the remote on off co...

Page 14: ... vary depending on the configuration of the engine 3 5 PRESSURE RELIEF VALVE CAUTION Pressure relief valve If the OXM OGM heating system is for use with a pressurized fluid system additional user supplied pressure relief must be installed along the heating system outlet plumbing User supplied pressure relief valve plumbing must be routed back to oil sump or to atmospheric pressure Do not route pre...

Page 15: ...ONTROL RELAY The control TCR TCR1 is used to control the temperature of the oil The control TCR uses a resistance temperature device RTD to sense the temperature of the fluid as it enters the heater and will deactivate the element when the set temperature is reached The standard setting for the control temperature relay TCR1 set point is 104 F 40 C at 10 hysteresis See Fig 7 Figure 7 OXM OGM motor...

Page 16: ...the lines NOTE When priming the pump the pressure gauge should indicate an increase in pressure Your system s operating pressure may vary depending on the configuration of the engine 5 Turn the local off remote switch to local or remote to energize the heating system 6 Once operation is satisfactory turn the control dial on the temperature control relay TCR1 to the desired temperature setting for ...

Page 17: ...ally 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 5 2 5 PUMP SEAL Pump mechanical seals are controlled leakage devices and are not intended to create a zero leak seal Some leaking from the seal is expected during normal operation If seal becomes worn replacement pump seals are...

Page 18: ...een TCR terminals T2 and T3 h h If there is continuity between TCR terminals T2 and T3 the TCR RTD and RTD cable are functioning correctly Close control panel Allow fluid to cool 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...

Page 19: ...TION 5 2 10 1 De energize the heating system Allow fluid to cool 2 Close isolation valves Drain fluid from the oil heating tank Locate the RTD that requires replacement See Fig 11 3 Unscrew RTD plug Remove plug See Fig 12 4 Unscrew RTD from tank 5 Screw replacement RTD to tank When tightening ensure plug is aligned with notch toward top of tank See Fig 13 6 Fit RTD plug to RTD Ensure plug is align...

Page 20: ...urations shown on the following page Note your unit s phase configuration See Fig 17 NOTE Replacement elements may be a different phase configuration 6 Disconnect the ground green yellow and power electrical wires from the posts inside the cap 7 Unscrew cable gland G from heating element assembly B See Fig 16 Remove electrical cable and wires from the heating element 8 Unscrew heating element asse...

Page 21: ...ts F Heating tank G Cable gland Figure 15 Removing and replacing the heating tank element The heating system should be drained cleaned and flushed annually See SECTION 5 3 Figure 16 The cable gland as shown connected to the element assembly Unscrew to remove element wiring Figure 17 Heating tank element phase configurations Replacement elements may be a different phase configuration ...

Page 22: ...ons 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 placed next to the system if it is still in the original packaging and inside the control box If the storage duration will be one year or lon...

Page 23: ...if needed Restart system Motor protection switch tripped Check and reset switch If problem occurs again check motor Restart system RTD failure Check TCR and RTD See SECTION 5 2 10 RTD cable failure Check TCR and RTD See SECTION 5 2 10 Oil temperature too low Motor failure Check motor Replace if necessary Heating element failed Check elements for continuity Replace element if necessary Element brea...