Hotstart OCSM Installation & Operation Manual Download Page 1 | Manualshive

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216280-000 rev5

INSTALLATION & OPERATION MANUAL

MODEL

OCSM

DUAL FLUID CIRCULATING HEATING SYSTEM

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Summary of Contents for OCSM

Page 1: ...216280 000 rev5 INSTALLATION OPERATION MANUAL MODEL OCSM DUAL FLUID CIRCULATING HEATING SYSTEM ...

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Page 3: ...FORMATION 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 pr...

Page 4: ...rs 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 ar...

Page 5: ...RATION 7 3 1 INTERFACE COMPONENTS 7 3 1 1 On Off Switch 7 3 1 2 Oil Pump On Off Switch 8 3 1 3 Prime Button 8 3 1 4 Fault Light 8 3 2 CONTROL BOX INTERNAL COMPONENTS 8 3 2 1 Motor Protection Switch 8 3 3 HEATING SYSTEM START UP 8 3 3 1 First Run Procedure 8 4 MAINTENANCE REPAIR AND TROUBLESHOOTING 9 4 1 SYSTEM FAULTS 9 4 1 1 Faults 9 4 2 SYSTEM MAINTENANCE 9 4 2 1 Plumbing Connections 9 4 2 2 Elec...

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

Page 7: ...h optional E Coolant outlet 1 0 NPT F Oil inlet 0 5 NPT G Control thermostat H Coolant inlet 1 0 NPT I Oil pump motor assembly J Coolant to oil heat exchanger K Oil outlet 0 5 NPT L Lift points M Coolant pump motor assembly N Element assembly O Tank assembly K I H A B C L F G E O J Figure 1 Typical OCSM system components Front view left and reverse view below Model style and configuration may vary...

Page 8: ... line When preheating an engine from a cold soak or during other periods where oil viscosity prevents oil circulation the heating system oil pump may be disabled using the oil pump on off switch available as an option on specified heating system models The coolant and oil pumps will continuously circulate fluid To maintain consistent fluid temperature the heating element will cycle on and off When...

Page 9: ...U countries PED 97 23 EC compliant pressure relief may be required 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 f...

Page 10: ...ant return line per the coolant outlet NOTICE Do not reduce the return line inner diameter Install the coolant discharge port as high as possible on the engine s water jacket at the end of the engine opposite the suction port typically at the rear of the engine block 2 1 3 OIL SUPPLY When installing the OCSM oil supply line refer to the following HOTSTART guidelines At a minimum size the oil suppl...

Page 11: ...NT SUCTION PORT SECTION 2 1 1 COOLANT DISCHARGE PORT SECTION 2 1 2 COOLANT RETURN SECTION 2 1 2 COOLANT SUPPLY SECTION 2 1 1 ISOLATION VALVES CHECK VALVE OIL SUPPLY SECTION 2 1 3 OIL RETURN SECTION 2 1 4 OIL DISCHARGE PORT SECTION 2 1 4 OIL SUCTION PORT SECTION 2 1 3 ISOLATION VALVES ...

Page 12: ...TE 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 NOTE The main power supply operates the heating element and the oil pump A transformer is used to operate the control circui...

Page 13: ...ystem shutdown triggered by either the high limit temperature control relay or the motor protection switch see SECTION 4 1 1 3 COMPONENTS AND OPERATION The following is an operational description for each of the OCSM interface and system components NOTE Components installed in control box may vary depending on the particular system configuration purchased 3 1 INTERFACE COMPONENTS 3 1 1 ON OFF SWIT...

Page 14: ...switched to off and the operator must press the MPS reset button see Figure 7 See SECTION 4 1 1 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...

Page 15: ...t the system and reset the fault the on off switch must be switched to off Once the coolant temperature drops below the high limit turn the switch to on to resume operation 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 procedu...

Page 16: ...sing unit into plug Push plug into well Hand tighten hex nut to well 6 To ensure proper installation and temperature regulation re energize and operate heating system Refer to SECTION 3 3 1 for system start up procedures 4 2 7 HEATING TANK ELEMENTS WARNING Hazardous voltage Before wiring servicing or cleaning the heating system turn off the power and follow your organization s lockout and tagout p...

Page 17: ...e with thermostat plate E Reconnect electrical connections to original positions Ensure the enclosure O ring H is in place NOTE To prevent leaks HOTSTART recommends tightening element plate screws C to 120 lbf in 13 5 N m B C D E F J I H G A Tank Drain B Element C Element plate bolts D Wiring enclosure E Thermostat clip F Enclosure cover G High limit thermostat H Enclosure O ring I Element plate J...

Page 18: ...e element and clean element and tank See SECTION 4 2 7 Every three years or 25 000 hours of operation HOTSTART recommends replacing the control thermostat sensing unit every three years or 25 000 hours of operation Thermostats are rated for 100 000 cycles See SECTION 4 2 6 Every five years Replace magnetic contactors See SECTION 4 2 4 4 4 STORAGE REQUIREMENTS If long term storage is necessary prec...

Page 19: ...replace if needed Restart system Motor protection switch tripped Check and reset switch If problem occurs again check motor and check oil viscosity Restart system If oil is cold leave MPS off or turn Oil Pump On Off switch to off until heating system brings engine to optimal temperature Fluid temperature too low Motor failure Check motor Replace if necessary Heater has been turned off and fluid is...

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