Hotstart OSE Installation & Operation Manual Download Page 1

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216300-000 rev5

OSE

INSTALLATION & OPERATION MANUAL

OIL CIRCULATING HEATING SYSTEM

FOR HAZARDOUS LOCATIONS

Summary of Contents for OSE

Page 1: ...216300 000 rev5 OSE INSTALLATION OPERATION MANUAL OIL CIRCULATING HEATING SYSTEM FOR HAZARDOUS LOCATIONS ...

Page 2: ...II installation operation manual ose heating system this page intentionally left blank ...

Page 3: ... 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 NOTE Typical heating system identification plate Your identification plate may vary Corporate Manuf...

Page 4: ...ore 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 Rotati...

Page 5: ...trol TCR Temperature Control Relay 9 3 1 3 High Limit TCR Temperature Control Relay 10 3 2 INTERFACE COMPONENTS 10 3 2 1 Prime Button 10 3 2 2 Local Off Remote Switch 10 3 2 3 Reset button Motor Protection Switch MPS 10 3 2 4 Pressure Gauge 10 3 3 HEATING SYSTEM START UP 10 3 3 1 First Run Procedure 10 4 MAINTENANCE REPAIR AND TROUBLESHOOTING 11 4 1 SYSTEM FAULTS 11 4 1 1 Oil Faults 11 4 2 SYSTEM ...

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

Page 7: ...for reference only and are not to scale 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 resis...

Page 8: ... 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 d...

Page 9: ...ure 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 installin...

Page 10: ... 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 h For diesel engine applications the oil return line must be routed to the oil discharge port located at opposite end of the oil su...

Page 11: ...LVES OIL RETURN SECTION 2 1 2 CHECK VALVE SECTION 2 1 1 PRESSURE RELIEF VALVE UP TO 65 PSI SECTION 2 1 2 OIL DISCHARGE PORT SECTION 2 1 2 E 2 E 1 V 2 V 3 V 1 V 4 COMPONENT DESCRIPTION V 1 USER SUPPLIED CHECK VALVE V 2 USER SUPPLIED FULL FLOW ISOLATION VALVE E 1 OIL PUMP E 2 OIL HEATING ELEMENT V 3 USER SUPPLIED FULL FLOW ISOLATION VALVE V 4 OPTIONAL USER SUPPLIED PRV OIL SUPPLY SECTION 2 1 1 ...

Page 12: ... OIL SUCTION PORT SECTION 2 1 1 OIL SUPPLY SECTION 2 1 1 OIL RETURN SECTION 2 1 2 E 2 E 1 V 2 V 3 V 1 COMPONENT DESCRIPTION V 1 USER SUPPLIED CHECK VALVE V 2 USER SUPPLIED FULL FLOW ISOLATION VALVE E 1 OIL PUMP E 2 OIL HEATING ELEMENT V 3 USER SUPPLIED FULL FLOW ISOLATION VALVE CHECK VALVE SECTION 2 1 1 ISOLATION VALVES ...

Page 13: ...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 haz...

Page 14: ... pump motor is not running L1 L2 TB1 L3 L1 L2 L3 13 MPS1 TB2 X1 2 4 6 1 3 5 7 8 9 1011121314 A1 A3 T1 T2 T3 13 14 A2 11 12 TCR1 CONTROL 0 100 A1 A3 T1 T2 T3 13 14 A2 11 12 TCR1 HIGH LIMIT 0 100 L1 L2 TB1 L3 TB2 X1 2 4 6 1 3 5 7 8 9 1011121314 A1 A3 T1 T2 T3 13 14 A2 11 12 TCR1 CONTROL 0 100 A1 A3 T1 T2 T3 13 14 A2 11 12 TCR1 HIGH LIMIT 0 100 A B L1 L2 TB1 L3 TB2 X1 2 4 6 1 3 5 7 8 9 1011121314 E D...

Page 15: ...leads at the main power terminal block L1 L2 L3 Reconnect power Repeat step 1 to ensure motor rotates in the correct direction 3 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 RELI...

Page 16: ...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...

Page 17: ...er 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 procedu...

Page 18: ...scharge 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 wit...

Page 19: ... ohms contact Hotstart for further assistance 4 Using the ohmmeter test for continuity between TCR terminals T2 and T3 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 3 3 If fault or temperature problems persist after start up ...

Page 20: ...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 syst...

Page 21: ... 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...

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