Hotstart 216370-000 rev2 EVRHEAT Series 20 Engine Heater Instruction Manual
- June 13, 2024
- HOTSTART
Table of Contents
INSTALLATION INSTRUCTIONS SERIES 20
216370-000 rev2 EVRHEAT Series 20 Engine Heater
EVRHEAT engine heating systems feature advanced temperature sensors and fluid
detection capability in a easy-to-install package, providing consistent
temperature management, reliable engine starts and reduced maintenance.
DANGER
Personal injury: This product generates heat during operation. Operation of a
heating system with closed isolation valves could result in high pressure and
serious injury. It is the responsibility of the installer and operator to
ensure that no unsafe condition can result from the generation of pressure. In
EU countries, PED (97/23/EC) compliant pressure relief may be required (125
psi maximum). 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.
CAUTION
Electrical hazard: Power source must be properly grounded and in accordance
with national and local electrical codes. A user-supplied circuit breaker
(rated at the appropriate amperage) is required for use in the main power feed
line. Do not connect heater prior to installation.
NOTICE
Read instructions carefully: The Hotstart warranty does not cover any damage
that a heating system may sustain from improper installation, improper
operation, improper specification or corrosion. Before installing your heater,
be sure you have the right heating system for your application.
Carefully read all instructions before installing and energizing your heater.
The safety of any system incorporating this heater is the responsibility of
the assembler. The safe and proper use of this heater 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.
Note: This equipment has been tested and found to comply with the limits
for a Class A digital device, pursuant to part 15 of the FCC Rules. These
limits are designed to provide reasonable protection against harmful
interference in a residential installation. This equipment generates, uses and
can radiate radio frequency energy and, if not installed and used in
accordance with the instructions, may cause harmful interference to radio
communications. However, there is no guarantee that interference will not
occur in a particular installation. If this equipment does cause harmful
interference to radio or television reception, which can be determined by
turning the equipment off and on, the user is encouraged to try to correct the
interference by one or more of the following measures:
- Reorient or relocate the receiving antenna.
- Increase the separation between the equipment and receiver.
- Connect the equipment into an outlet on a circuit different from that to which the receiver is connected.
- Consult the dealer or an experienced radio/TV technician for help.
OVERVIEW
PARTS LIST
SUPPLIED PARTS
A. EVRHEAT Series 20 engine heater
B. Mounting bracket (3/8 slots)
C. Mounting bracket fasteners × 6 (5/16-18 X 0.875)
D. 0.625” (16 mm) hose barb × 2 (shown installed on heater)
E. Hose barb installation clips × 2 (shown installed on heater)
RECOMMENDED USER-SUPPLIED PARTS
- Engine port fittings × 2 min. size 3/8 inch NPT (10 mm)
- Full-flow isolation valves × 2
- Hose (min. dia. 5/8″ (16 mm) rated for 250 °F/121 °C/ 100 psi (690 kPa)
- Hose clamps
INSTALLING THE HEATER
PREPARE COOLANT SYSTEM
-
Drain and flush cooling system to remove any debris present in the engine’s cooling system.
SELECT PORTS -
Select return port on the engine. The return port will allow heated coolant to return to the engine. The return port must be located:
• Near the rear (flywheel) of the engine
• Away from the engine thermostat
• Away from the supply port
• On the same side of the engine as the intended heater mounting location -
Select supply port on the engine. The supply port will allow coolant to flow from the engine to the heater. The supply port must be located:
• Near the front of the engine (near radiator)
• At the lowest point of the engine’s water jacket
• Away from the return port
NOTE:
For V-type engines, it is acceptable to select a supply port on the opposite side of the engine as long as the supply hose is routed properly. See PLUMB HEATER.
SELECT HOSE, FITTINGS & VALVES -
Select fittings for the engine ports. EVRHEAT Series 20 minimum engine port size fitting:
• 3/8 inch NPT (10 mm) -
Select hoses. EVRHEAT Series 20 minimum hose inner diameter:
• 5/8 inch (16 mm)
NOTE:
Select hoses rated for 250 °F (121 °C) and 100 psi (690 kPa) minimum. -
Select optional, user-supplied isolation valves.
NOTE:
Hotstart recommends installing valves to isolate the heating system in case of service. To minimize flow restriction, select full-flow (full-port) ball isolation valves.
MOUNT HEATER
NOTICE
Vibration damage: Do not mount heater directly to engine. Engine vibration will damage heater. If the heater is installed with rigid pipe, connect flexible hose to inlet and outlet to isolate from vibration.
Heater orientation: EVRHEAT Series 20 units must be installed with discharge port pointing directly upward. Do not mount at an angle. An incorrectly oriented heater may cause heater failure. -
Select a heater mounting location. The heater should be mounted:
• Low to ensure the return hose continuously rises to the return port
• On the same side of the engine as the return port
• In a position to ensure the discharge port points directly upward. -
Mount heater to vibration-isolated surface using supplied mounting bracket and fasteners. Mounting bracket may be installed in the following orientation options
PLUMB HEATER
NOTICE
High points: Do not allow high points along heater plumbing. Highpoints will restrict coolant flow and damage heater.
To avoid high points, it may be necessary to change hose
routing or lower heater mounting location.
Dips and bends: Do not allow dips or bends along heater plumbing. Dips or bends will allow air pockets to form, restricting coolant flow and damaging heater.
90° Fittings: Elbows (90°
fittings) along heater plumbing may restrict flow and damage heater. To
minimize flow restriction, Hotstart recommends sweeping bends or 45° fittings
in place of 90° fittings. -
Install isolation valves to port fittings.
Ensure isolation valves are open. -
If necessary, rotate heater suction port to attach supply hose (see Figure 5).
-
Route and install return hose. The return hose should continuously rise from the heater to the return port.
-
Route and install supply hose. The supply hose should continuously descend from the supply port to the heater.
-
Mix coolant according to your engine manufacturer’s recommendations. Refill cooling system with coolant.
NOTE:
Hotstart recommends using a 50% deionized or distilled water to 50% low- silicate antifreeze mixture. -
Start engine. Allow engine to run until engine thermostat opens, purging air from cooling system.
-
Allow engine to cool. Check coolant level and top off as needed. NOTICE! Engine must be run to eliminate air from heating system before energizing heater.
CONNECT HEATER -
Secure power cord at intervals to avoid contact with all hot or moving parts.
-
Connect heater to a properly grounded power source following national and local electrical codes.
NOTE:
Once energized, heater will momentarily display all interface and fault lights
before normal heating operation.
OPERATION
Once connected to power, the EVRHEAT Series 20 engine heating system will
begin maintaining engine temperature.
Reference the following interface lights for operation status:
| Power | On/Green | Power to heater unit |
|---|---|---|
| Off | Unplugged/no power |
Heater
Operation| Breathing Orange| Approaching temperature setpoint.
Solid Orange| Holding/Above temperature setpoint
Off| Pump/element in standby
TROUBLESHOOTING
To ensure reliable engine heating and protect equipment, the EVRHEAT series 20 heating system will monitor and display faults related to fluid flow and heating:
Power/All Lights| Off/No lights illuminated| No device power.
➢ Verify unit is supplied with appropriate power.
---|---|---
Fluid Fault| Solid| Air pocket detected.
➢ Verify fluid presence.
➢ Verify isolation valve(s) open.
Flashing| EVR20 remains in startup mode.
➢ Verify fluid presence.
➢ Verify fluid flow through heater.
SystemFault| Flashing| EVR20 system fault present.
➢ Contact Hotstart.
If necessary, perform the following troubleshooting steps:
-
Verify fluid flow:
➢ Ensure isolation valve(s) are open.
➢ Remove 90° bends and excessive hose lengths. If necessary, reroute hoses or change port locations.
➢ Flush cooling system of contaminants and refill.
➢ Remove hose high points such as routing over the top of the engine. Remove hose dips and bends. If necessary, reroute hoses or change port locations.
➢ Remove air from engine cooling system by running engine to operating temperature.
➢ Check engine coolant level and top off as necessary. -
Energize heater. After all indicator and fault lights initially display, note any remaining lights displayed (excluding Power On ):
➢ If System Fault flashes, the heater will attempt to restart the pump every 60 seconds until either the issue resolves itself or the end-user intervenes.
➢ If the system is obstructed by engine coolant contaminants (e.g., rust or debris), flushing the EVR20 with clean fluid or water while it is unpowered may clear this error. A fluid pre-filter may be needed to prevent obstructions.
MAINTENANCE & PARTS
CAUTION
Electrical hazard: 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.
Personal injury: If equipped with isolation valves, ensure valves are open
before energizing heater. Obstructed flow may result in an unexpected release
of heated coolant, potentially causing serious injury.
PREVENTATIVE MAINTENANCE
Annually:
- Drain, clean and flush the cooling system.
- Check and replace cracked or weakened hoses.
- Check electrical wiring for wear and excessive heat.
HOSE BARB REPLACEMENT
To accommodate various engine installations, the EVRHEAT model may use either
5/8 inch hose barbs or optional 3/4 inch hose barbs. Contact Hotstart for
additional hose barb options.
-
Disconnect heater from power source. Allow heating system to cool.
-
Close isolation valves or drain coolant from heating system.
Detach return and supply hoses from heater. -
Remove hose barb clip. Remove hose barb.
-
Insert replacement hose barb. Ensure hose barb is fully seated.
-
Insert hose barb clip to lock hose barb in place.
-
Reattach return and supply hoses. Open isolation valves.
-
Start engine. Allow engine to run until engine thermostat opens, purging air from cooling system.
-
Allow engine to cool. Check coolant level and top off as needed. NOTICE! Engine must be run to eliminate air from heating system before energizing heater.
Supplier’s Declaration of Conformity
47 CFR § 2.1077 Compliance Information for
Hotstart EVRHeat Series 20
This device complies with Part 15 of the FCC Rules. Operation is subject to
the following two conditions: (1) This device may not cause harmful
interference, and (2) this device must accept any interference received,
including interference that may cause undesired operation.
Note: This equipment has been tested and found to comply with the limits for a
Class A digital device, pursuant to part 15 of the FCC Rules. These limits are
designed to provide reasonable protection against harmful interference when
the equipment is operated in a commercial environment. This equipment
generates, uses, and can radiate radio frequency energy and, if not installed
and used in accordance with the instruction manual, may cause harmful
interference to radio communications. Operation of this equipment in a
residential area is likely to cause harmful interference in which case the
user will be required to correct the interference at his own expense.
Hotstart 5723 E. Alki Ave., Spokane, WA 99212 USA
+1 509-536-8660 |
sales@hotstart.com
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
Spokane, WA, USA
509.536.8660
sales@hotstart.com
United Kingdom Office
Birmingham, UK
+44.0121.809.5468
UK@hotstart.com
installation instructions
EVrHEat sEriEs 20 HEatEr
IOM216370-000 rev2
customer service: 509.536.8660
sales@hotstart.com
www.hotstart.com