2.
Check and tighten all electrical and plumbing
connections.
3.
Ensure isolation valves are
open
before energizing
the system.
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:
If equipped, the oil pump on/off switch
must be in the on position for the oil pump
to prime.
5.
Turn the
on
/
off
switch to
on
to energize the
heating system.
6.
If installed, activate the 24 V DC signal to verify the
24 V DC remote signal connection is operational.
4
MAINTENANCE,
REPAIR AND
TROUBLESHOOTING
4.1
SYSTEM FAULTS
4.1.1 FAULTS
A fault signal will be transmitted if:
•
The motor protection switch is tripped
(MPS1).
•
The high-limit temperature is exceeded.
A failure in the pump motor that causes the motor
protection switch (MPS1) to trip will disable oil circulation.
Coolant heating will not be affected but a fault signal
will be transmitted and the fault light will illuminate. If
this failure occurs, the
on
/
off
switch must be switched
to
off
and the operator must press the MPS reset/on
button to reset the fault. (
See
SECTION 3.2.1.
)
If MPS faults are caused by the oil pump drawing excess
current due to high oil viscosity, the oil pump may be
disengaged using the Oil Pump On/Off switch (optional
on specified heating system models only). Disengaging
the oil pump will not reset an MPS fault. To reset the
fault, the MPS reset/on button must be pressed.
If there is a failure that causes a high temperature to
occur, the heating system will shut down, including
the coolant and oil pump motors. A fault signal will be
transmitted and the fault light will illuminate. To restart
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 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 not obtained
through HOTSTART must meet or exceed original part
requirements in order to maintain the compliance level of
the original heating system.
NOTE:
After maintenance is performed,
refer
to
SECTION 3.3.1
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
