Hotstart Manufacturing Inc IOM216300-000 OSE Engine Heater Instruction Manual

INSTALLATION & OPERATION MANUAL
OIL CIRCULATING HEATING SYSTEM
FOR HAZARDOUS LOCATIONS
OSE

IOM216300-000 OSE Engine Heater

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:
………………………….
IMPORTANT SAFETY INFORMATION
DANGER
Hazardous voltage: Before wiring, servicing or cleaning the heating 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.
Combustion hazard: To prevent ignition of flammable or combustible atmospheres, disconnect power before servicing.
WARNING
Risk of ignition: To reduce the risk of ignition in hazardous atmospheres, disconnect the equipment from the supply circuit before opening system enclosures. Keep enclosures tightly closed when in operation.
Sealing fittings: To reduce the risk of ignition in hazardous atmospheres, conduit runs must have a sealing fitting connected within 18 inches (46 cm) of system enclosure.
WARNING
Electrical hazard: All electrical work must be done by qualified personnel in accordance with national, state and local codes.
CAUTION
Read instructions carefully: The safety of any system incorporating this equipment is the responsibility of the assembler. The safe and proper use of this equipment is dependent upon the installer following sound engineering practices. If the equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired. All applicable electrical safety standards defined by local jurisdictions must be followed.
(Reference EU directive 2014/34/EU in EU countries.)

• Read carefully: Installers and operators of this equipment 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: Use proper lifting equipment and rigging to move this equipment. Create a plan before attempting to move. Proper lifting locations are identified with labels on each system; use these locations when lifting and mounting the system.
• Rotating equipment: The heating system can start automatically and without warning. Avoid contact unless a lockout at the service panel has been installed.
• Grounding: The heating system must be connected to a suitable ground (protective earthing conductor).
• Overcurrent limiting: The power supply must be protected by a suitable 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. Suitable branch circuit protection shall be installed in accordance with Article 430 Part IV of the NEC.
• 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 radius: Do not adjust cable bend radius in the field. Cables are pre-wired to meet the minimum requirements for bend radius. If a cable is moved from factory positioning, adjust cable to ensure minimum bend radius met. For MC-HL cable, minimum bend radius is 7 × (Ø) outer diameter of the cable. For TC-ER-HL cable, minimum bend radius is 4 × (Ø) outer diameter

CERTIFICATIONS
Certifications:

• Class I Div 1 Group D T3
• Class I Zone 1 Group IIA T3

Some models:

• Class I Div 2 Group D T3
• Class I Zone 2 Group IIA T3

OVERVIEW

WARNING
System location classification: Before installing the OSE heating system, ensure all system components are suitable for the intended installation location by referring to the location classification labeling attached to the individual system components.
1.1 HEATING SYSTEM COMPONENTS
NOTE:
Component illustrations are for reference only and are not to scale. See part drawings for dimensions and specifications.

Figure 1. Typical OSE system components. Model style and configuration may vary.
See part drawings for dimensions and specifications.

A. prime button
B. local/off/remote switch
C. reset button
D. Pressure/Temperature gauge
E. Pressure relief valve
F. Oil inlet (0.5″ NPT)
G. Oil pump motor| H. Lift points
I. Oil outlet (1.0 ″ NPT)
J. Heating element assembly
K. High-limit resistance temperature device (RTD)
L. Identification plate
M. Heating tank
N. Control resistance temperature device (RTD)
---|---

1.2 OPERATION OVERVIEW
The OSE heating system is intended to maintain optimal oil temperature while the engine or compressor is shut down. The heating system may be activated locally or by optional remote control (see SECTION 2.5.2). The OSE heating system must be deactivated upon engine or compressor start-up.
During heating system operation, a rotary gear pump takes oil from the sump and forces it through the heating tank to the oil return 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 heating system should be activated locally or remotely to resume maintaining the optimal oil temperature.

Figure 2. OSE system operation. Component illustrations are for reference only and are not to scale.
See part drawings for dimensions and specifications.

INSTALLATION

CAUTION
Pressure hazard: Power must be turned off and locked out at the service panel when the isolation valves are in the closed position. Failure to do so may cause damage to heating system components, damage to lubrication oil, leaks and unexpected release of heated oil.
Overheating hazard: After completing line installation, top off the fluid levels to compensate for the fluid used to fill the lines and heating tank. Do not operate the heating system without the presence of fluid. Position the heating tank to ensure 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 installing a customer-supplied swing-type or full-flow check (non-return) valve to prevent oil from flowing back into the oil sump. If the pump is installed above the minimum oil level, a check valve must be installed.
Isolation valves: Hotstart recommends installing full-flow ball valves to isolate the heating system in order to perform service on the system or engine without draining the oil.
2.1 OIL PLUMBING INSTALLATION
2.1.1 OIL SUPPLY
Installing a short, straight oil supply line with a minimum of flow restriction is the most important step toward ensuring heating system longevity. When installing the OSE oil supply line, refer to the following Hotstart guidelines:

• Due to the increased viscosity of lubrication oil, the oil supply line must be as short and as straight as possible. Any 90° elbows will reduce the maximum recommended oil supply length. See Table 1 for Hotstart OSE oil supply recommendations:
  PUMP INLET| HOSE INNERDIAMETER| MAX. LINE LENGTH| MAX. ELBOWCOUNT
  ---|---|---|---
  1/2 inch NPT| 1 inch| 20 feet (6 meters)| 4

Table 1. HOTSTART recommended hose inner diameters, line lengths and elbow counts for OSE oil supply lines.
NOTE: Each additional pair of 90° elbows will reducethe maximum recommended line length by five feet (1.5 meters). To minimize flow restriction, Hotstart recommends using sweeping bends or 45° fittings.

• At a minimum, size the oil supply line per thepump 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 with a size larger inner diameter than the pump inlet.

• Install the oil suction port as low as possible in the oil sump. NOTICE! Avoid installing the oil suction port in a location that may allow debris or sediment to enter the heating system.

• Hotstart recommends installing a customersupplied, swing-type or full-flow check (non-return) valve to prevent oil flowing into the sump. Install the check valve as close to the oil supply port as possible.

• To ensure consistent oil heating, it is acceptable to select a suction port on the opposite side of the sump.

2.1.2 OIL RETURN
When installing the OSE oil return line, refer to the following Hotstart guidelines:

• At a minimum, size the oil return line per the pump outlet. NOTICE! Do not reduce the return line inner diameter.

Depending on your application, there may be additional requirements for locating the oil discharge port of the Hotstart oil heating system:

• For diesel engine applications, the oil return line must be routed to the oil discharge port located at opposite end of the oil sump. See SECTION 2.3.
• For large-sized (four- or six-throw reciprocating) compressor applications, the return line may be routed to the opposite end of the oil sump or the oil return line may be routed to a prelube location. See SECTION 2.2.
• For small- and medium-sized compressors, the oil return line may be routed to the opposite end of the oil sump or the return line may be routed to a prelube location. See SECTION 2.2. If the return line is routed to a prelube location, Hotstart requires installing a bypass to the compressor oil sump, including a customersupplied tee fitting and pressure relief valve.

Figure 3. Small compressor oil heating in lower ambient temperatures (left). High oil viscosity restricts oil flow and increases oil pressure. The pressure relief valve opens and allows oil to flow directly to the sump in addition to the prelube location. In higher temperatures, the bypass pressure relief valve is closed and oil is routed directly to the prelube location (right).
Should flow become restricted due to low ambient temperatures, the pressure relief valve along the bypass line will open and allow heated oil to route to the compressor’s oil sump. This alternate routing will allow the heating system to maintain optimal oil temperature while still providing the necessary pressure to the prelube system. See Fig. 3.
NOTE: The pressure relief valve must be designated as full-flow bypass and must be set for a maximum of 65 psi. Hotstart does not recommend noncode safety valves for this application.
2.2 OIL PLUMBING ILLUSTRATION (COMPRESSOR)

2.3 OIL PLUMBING ILLUSTRATION (ENGINE)

2.4 MOUNTING
CAUTION
Lifting hazard: 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 before attempting to move. Proper lifting locations are identified on each system; use these locations when lifting and mounting the system.
Overheating hazard: When mounting the heating tank, position the tank so that it is completely full of oil while in operation.
NOTICE
Heating system damage: Engine vibration will damage the heating system; isolate the heating system from vibration. Never mount the heating system or components directly to the engine. If the heating system is installed using rigid pipe, use a section of flexible hose to the supply and return ports to isolate the heating system from engine vibration.
Improper mounting hazard: Reference heating system component drawings before mounting the system. Unless mounted properly, the heating system will be unstable.
2.4.1 TANK AND PUMP

Figure 4. Mount OSE unit in orientation shown. Do not mount at an angle or in any other orientation.

Mount the heater in a horizontal orientation with the pump and pump motor above the tank. To ensure that oil does not flow back into the sump, Hotstart recommends mounting the heater at or below the minimum oil level. If the pump is installed above the minimum oil level, a check valve must be installed. Reference drawings for mounting position. When installing the heating tank, note that the tank requires a minimum of 18 inches (46 cm) clearance to remove the element for maintenance.
2.5 ELECTRICAL CONNECTIONS
WARNING
Hazardous voltage: Before wiring, servicing or cleaning the heating 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. Install in accordance with the National Electrical Code (NEC) or Canadian Electrical Code (CEC), and any applicable local codes (such as NFPA 496), based on the installation location.
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 system for specific ratings.
Grounding conductor: Equipment grounding conductors shall be sized per NEC 2017 Table 250.122 for US installations. For international installations, use IEC 60079-0, Clause 16. Ground terminal block will accept 16–4 AWG conductors. External grounding connection not provided. Metallic conduit or armored cable must be used.

Figure 5. OSE control box underside, showing 1.25 ″ NPT main power
entrance (A) and 0.5 ″ NPT customer interface wiring entrance (B).

2.5.1 MAIN POWER SUPPLY

1. Connect the specified power from the customersupplied circuit breaker to the terminal blocks located in the main control box. See Fig. 6 on following page.
   NOTE: The specified power source must be within plus or minus 10% of the rated voltage.
   NOTE: 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. Figure 6. Main power supply and customer interface connections as shown in the OSE 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 block
   C. Remote On/Off 24 V DC shutdown
   D. Fault signal
   E. Motor run signal
   NOTE: 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.
   – For three-phase applications, the terminal blocks are labeled L1, L2 and L3 (A).
   – For single-phase applications, use the terminal blocks labeled L1 and L2 or L and N (A).

2. Connect the main power ground wire to the ground block (B).

2.5.2 CUSTOMER INTERFACE CONNECTIONS

| Copper Wire Stranding Classes – Number of Strands
---|---
WireSize| Torque| Solid| ClassB| ClassC| Class G| Class H| Class I| Class K
2/0 AWG| 120 in · lbs| | 19| 37| | | |
Jan-00| 120 in · lbs| | 19| 37| | | |
1| 120 in · lbs| | 19| 37| ~133| ~259| ~210| ~836
2| 120 in · lbs| | 7| 19| ~49| ~133| ~161| ~665
4| 120 in · lbs| | 7| 19| ~49| ~133| ~105| ~420
6| 120 in · lbs| | 7| 19| ~49| ~133| ~63| ~266
8| 40 in · lbs| | 7| 19| ~49| ~133| ~41| ~168
10| 35 in · lbs| 1| 7| 19| | | ~27| ~104
12| 35 in · lbs| 1| 7| 19| | | ~19| ~65
14| 35 in · lbs| 1| 7| 19| | | ~19| ~41

Table 2. Line Side Wire Approvals. ~Quantity of strands for Classes G, H, I, K may vary by manufacturer. Aluminum stranded wire range: 2/0 – #6 AWG. Minimum 90 °C wire for all electrical connections.
The following customer interface connections are available for remote control and monitoring:

• TB2:1/TB2:2
  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.
  NOTE: The 24 V DC shutdown 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 highlimit 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 the pump motor is running. If no signal is present, the pump motor is not running.

Figure 7. OSE motor protection switch (left), showing stop/off (A) and reset/on (B) buttons. To reset the MPS, the heating system must be switched off and either the reset button or the MPS reset/on button must be pressed.
OSE control TCR and high-limit TCR (above). The standard setting for TCR1 control dial (C) is 104 °F (40 °C).

2.5.3 MOTOR ROTATION CHECK
Pump rotation (three-phase only): For three-phase applications, check for proper pump rotation prior to introducing fluid to the pump. Reverse rotation while the pump is filled with fluid will cause pump seal failure.
Pump damage: Do not run the motor/pump assembly dry for more than a few seconds. Running a motor/ pump for a prolonged period without being completely filled with fluid may cause damage to the pump seal.
The following procedures are for three-phase applications only. Single-phase systems are prewired to ensure the pump motor rotates in the correct direction.

1. With main power connected to the heating system motor (see SECTION 2.5.1), energize the pump while observing the rotation of the pump motor fan at the rear of the motor. Refer to rotation decal on motor for correct rotation.
   – If the pump motor does not rotate in the correct direction, disconnect power and switch any two electrical leads at the main power terminal block (L1, L2, L3). Reconnect power. Repeat step 1 to ensure motor rotates in the correct direction.

COMPONENTS AND OPERATION

The following is an operational description for each of the OSE interface and system components.
NOTE: Components installed in control box may vary depending on the particular system configuration purchased.
3.1 SYSTEM COMPONENTS
3.1.1 PRESSURE RELIEF VALVE
The oil pump pressure relief valve is internal to the pump and releases pressure from the discharge side of the pump to the suction side of the pump. No external routing for discharge is required.
3.1.2 CONTROL TCR (TEMPERATURE CONTROL RELAY)
The control TCR is used to control the temperature of the oil. The TCR uses a resistance temperature device (RTD) to sense the oil temperature as the oil enters the heater. The standard setting for the control temperature relay (TCR1) is 104 °F (40 °C). See Fig. 7.
3.1.3 HIGH-LIMIT TCR (TEMPERATURE CONTROL RELAY)
The high-limit TCR (TCR2) is a protection device to prevent overheating of oil in the system. The high-limit TCR uses an RTD located inside the element enclosure. The default setting 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.
3.2 INTERFACE COMPONENTS
3.2.1 PRIME BUTTON
The prime button is used to remove remaining air in the supply and return lines without energizing the heater element.
3.2.2 LOCAL/OFF/REMOTE SWITCH

• local – The system is on.
• off – The system is off.
• remote – The system is turned on and remotely controlled.

3.2.3 RESET BUTTON/MOTOR PROTECTION SWITCH (MPS)
The motor protection switch (MPS) protects the pump motor from overloads. The MPS will be set at the full load amperage of the motor when shipped from the factory. To reset the MPS, the local/off/remote switch must be switched to off and the operator must press the reset button. See SECTION 4.1.1.
3.2.4 PRESSURE GAUGE
The oil pressure gauge will indicate a pressure increase when the pump motor is engaged by pressing the prime button or during normal operation.
NOTE: Your system’s operating pressure may vary depending on the configuration of the engine or compressor.
3.3 HEATING SYSTEM START-UP
WARNING
Hazardous voltage: Before wiring, servicing or cleaning the heating 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.
NOTICE
Pump damage: Do not run the motor/pump assembly dry for more than a few seconds. Running a pump that is not completely filled with oil will cause damage to the pump seal.
Proper heating operation: The high-limit temperature control relay (TCR2) must be set at least 18 °F (10 °C) higher than the control temperature control relay (TCR1) for proper heating operation. This will prevent nuisance tripping of the high-limit circuit.
3.3.1 FIRST RUN PROCEDURE

1. Check and tighten all electrical and plumbing connections.

2. Ensure isolation valves are open before energizing the system.

3. Press and hold the prime button to check the pump for proper rotation. NOTICE! Do not run the motor/pump assembly dry for more than a few seconds. If you are operating a three-phase heating system, check for proper rotation of the pump motor when the system is energized. If the pump motor is not rotating in the correct direction, switch any two electrical leads at the main power terminal block.
   NOTE: Single-phase systems are prewired to ensure the pump motor rotates in the correct direction.

4. Bleed all trapped air from the heating system by opening a plug or pipe fitting at or near the pump. Press and hold the prime button to evacuate any remaining air in 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 or compressor.

5. Turn the local/off/remote switch to local to energize the heating system.

6. Once operation is satisfactory, turn the control dials on the temperature control relay TCR1 to the desired temperature setting. 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 3.1.2 and SECTION 3.1.3.

7. To verify that the 24 V DC customer controls operate properly, turn the local/off/remote switch to remote.

MAINTENANCE, REPAIR AND TROUBLESHOOTING

4.1 SYSTEM FAULTS
4.1.1 OIL FAULTS
If there is a failure in the system that causes a high temperature to occur, the high-limit temperature controller (TCR2) will shut down the entire heating system, including the pump motor. The fault light will illuminate. To restart the system, the local/off/ remote switch must be switched to off and then back to either local or remote to resume operation.
A failure in the pump motor that causes the motor protection switch to trip will shut down the entire system. A fault signal will be transmitted. If this failure occurs, the local/off/remote switch must be switched to off and the operator must press the reset button
to reset the fault. For additional troubleshooting, see SECTION 4.5.
4.2 SYSTEM MAINTENANCE
WARNING
Hazardous voltage: Before wiring, servicing or cleaning the heating 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.
Instructions for the following maintenance procedures are provided to ensure trouble-free operation of your heating system. Replacement parts must meet or exceed original part requirements in order to maintain the compliance level of the original heater.
NOTE: After maintenance is performed, refer to SECTION 3.3 for system start-up procedures.
4.2.1 PLUMBING CONNECTIONS
Periodically check plumbing connections for leaks and, if necessary, tighten connections. A loose connection on the suction side will cause a loss of flow and cavitation in the pump. It can also pull air into the heating tank and cause an element failure.
4.2.2 ELECTRICAL CONNECTIONS
Vibration may cause terminals to loosen. At start-up, tighten electrical connections. Check connections again in a week. Tighten all electrical connections every three months.
4.2.3 SYSTEM MOUNTING
Vibration may cause mounting bolts to loosen. Periodically check and tighten all mounting bolts.
4.2.4 MAGNETIC CONTACTORS
Magnetic contactors are used as voltage switching controls for motors and heating elements in Hotstart heating systems. The contactors use 120 volt or 240 volt coils. To test for failure, check for continuity across the coil connections; an open or direct-short reading indicates a failed 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
Pump mechanical seals are controlled leakage devices and are not intended to create a zero leak seal. Some leaking from seal is expected during normal operation. If seal becomes worn, replacement pump seals are available.
NOTE: Instructions to replace the pump seals are included with replacement seals.
4.2.6 PRESSURE RELIEF VALVE
The oil pump pressure relief valve is internal to the pump and releases pressure from the discharge side of the pump to the suction side of the pump. No maintenance for this part is required.
4.2.7 PRESSURE GAUGE
The oil pressure gauge will indicate a pressure increase when the pump motor is engaged by pressing the prime button or during normal heater operation. No maintenance for this part is required.
4.2.8 VOLATILE CORROSION INHIBITOR (VCI)
A volatile corrosion inhibitor (VCI) is provided with each control box and should be replaced once a year.
4.2.9 TEMPERATURE CONTROL RELAY
WARNING
Hazardous voltage: Before wiring, servicing or cleaning the heating 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.
If the OSE heating system does not maintain the desired preset control temperature or signals a high-limit temperature fault immediately upon system start-up, the TCR (temperature control relay), the RTD (resistance temperature device), or the RTD cable may require replacement. To perform this troubleshooting, you will need:

• Ohmmeter

1. De-energize the heating system. Verify fluid is present and flow is not restricted. Check temperature gauge to ensure the liquid in the tank is below 122 °F (50 °C).

2. Verify the control TCR (TCR1) is set correctly. Verify that high-limit TCR (TCR2) is set at least 18 °F (10 °C) higher than the control TCR set point. If the measured resistance is between 80 and 120 ohms continue troubleshooting. Proceed to step 3.

3. Using the ohmmeter, measure the resistance between TCR terminals T1 and T2 (See Fig. 8):
   – If the measured resistance is between 80 and 120 ohms continue troubleshooting. Proceed to step 4.
   – If the resistance is lower than 80 ohms or higher than 120 ohms, contact Hotstart for further assistance.

4. Using the ohmmeter, test for continuity between TCR terminals T2 and T3:
   – 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 3.3). If fault or temperature problems persist after start-up, contact Hotstart for further assistance.
   – If there is no continuity between TCR terminals T2 and T3, locate connected RTD on the heating tank. Unscrew the RTD plug from RTD. Figure 8. Control (TCR1) and high-limit (TCR2) TCR showing terminals T1, T2 and T3.
   Table 2. TCR types, default temperature settings and corresponding RTD positions.

5. Using the ohmmeter, touch the probes to RTD pin 1 and pin 3. See Fig. 8. Note the resistance. Touch the probes to RTD pin 1 and pin 4 to check for continuity:
   – If the resistance between RTD pin 1 and pin 3 is between 80 and 120 ohms and there is continuity between RTD pin 1 and pin 4, the RTD is functioning properly. Replace the RTD cable.
   – If the resistance between RTD pin 1 and pin 3 is not between 80 and 120 ohms or there is no continuity between pin 1 and pin 4, the RTD is malfunctioning. Replace the RTD.

Figure 9. RTD leads and connectors shown on the RTD assembly, TSX:WHT (A), TSX:RED (red wire) (B), TSX:RED (black wire) (C), and Ground (D). Disconnect wire from connector as shown.
4.3 RECOMMENDED MAINTENANCE

SECTION 4.2.2.
Every three months| Tighten electrical connections.
Annually| Drain, clean and flush heating system.
Check for cracked or weakened hoses and replace if necessary.
Check electrical wiring and connections for wear and excessive heat.
Check mounting bolts and tighten if necessary.
Every five years| Replace magnetic contactors. See SECTION 4.2.4.

4.4 STORAGE REQUIREMENTS
If long-term storage is necessary, precautions must be taken 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 placed next to the system if it is still in the original packaging and inside the control box. If he storage duration will be one year or longer, the volatile corrosion inhibitor inside the control box must be replaced at six month intervals.
New pump motors placed in long-term storage for a year or longer may require relubrication before initial use. If your pump motor has provisions for relubrication, refer to the pump motor manufacturer’s relubrication recommendations. Refer to the pump motor nameplate for lubrication type.
4.5 TROUBLESHOOTING

lines. Restart system.
Isolation valves may be closed| Open valves. Restart system.
Hose kinked or crushed| Remove obstruction. Restart system.
Leak in suction line| Repair leak. Restart system.
Pump motor turning backwards| Reverse any two leads on power (in three-phase system). Restart system. See SECTION 3.3.
Control TCR failure: closed| Check and replace if necessary. See SECTION 4.2.9.
Motor failure| Check and replace if necessary. Restart system.
Motor contactor failure| Check contacts and replace if needed. Restart system.
Motor protection switch tripped| Check and reset switch. If problem occurs again, check motor. Restart
system.
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 continuity. Replace element if necessary.
Element fuses failed or element breaker tripped.| Check all element fuses for continuity and replace if necessary. Reset
breaker.
Element contactor failed| Check contacts and coil. Replace if necessary.
Motor contactor failed| Check contacts and coil. Replace if necessary.
Control TCR failure: open| Check and replace if necessary. See SECTION 4.2.9.

SPOKANE, WA
U.S.A.

REF. SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS
MODEL____
VOLTS __ HERTZ____
AMPS. PHASE__
CONTROL CIRCUITVOLTS____
CONTROL CIRCUIT AMPS. MAX
SERIALNUMBER__
U.S. PATENTS 4,245,593, 4,249,491
CAN. PATENTS 1,087,473, 1,082,541
CAUTION
OPEN CIRCUITS BEFORE WORKING ON THIS EQUIPMENT OR REMOVING COVERS.
KEEP COVERS TIGHTLY CLOSED WHILE CIRCUITS ARE ALIVE.
NOTE:
Typical heating system identification plate. Your identification plate may vary.

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.
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.

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
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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|

216300-000
rev5

Documents / Resources

| Hotstart Manufacturing Inc IOM216300-000 OSE Engine Heater [pdf] Instruction Manual
IOM216300-000 OSE Engine Heater, IOM216300-000, OSE Engine Heater, Engine Heater, Heater
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