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216383-000 rev0

INSTALLATION & OPERATION MANUAL

MODEL

CMM

CLM

COOLANT CIRCULATING HEATING SYSTEM

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Summary of Contents for CLM

Page 1: ...216383 000 rev0 INSTALLATION OPERATION MANUAL MODEL CMM CLM COOLANT CIRCULATING HEATING SYSTEM ...

Page 2: ......

Page 3: ...g system identification plate Your identification plate may vary 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 Railroad Office 8915 Broadway Merrillville IN 46410 USA 219 648 2448 railroad hotstart com Europe Office HOTSTART Europe GmbH Hans...

Page 4: ...uipment 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 Heating systems with flanges have marked lift points W...

Page 5: ...ef Valve 8 3 2 SYSTEM COMPONENTS 8 3 2 1 Motor Protection Switch 8 3 2 2 Control TCR Temperature Control Relay 8 3 2 3 High Limit TCR Temperature Control Relay 8 3 3 HEATING SYSTEM START UP 9 3 3 1 First Run Procedure 9 4 MAINTENANCE AND TROUBLESHOOTING 10 4 1 SYSTEM FAULTS 10 4 1 1 Fault Signals 10 4 2 SYSTEM MAINTENANCE 10 4 2 1 Plumbing Connections 10 4 2 2 Electrical Connections 10 4 2 3 Syste...

Page 6: ...iv installation operation manual cmm clm heating system ...

Page 7: ...ff remote switch C remote light D local light E fault light F Coolant inlet 1 0 NPT standard G Coolant pump motor H Coolant pressure temperature gauge I Coolant control resistance temperature device RTD J Tank drain plug K Vibration isolators 4 L Heating tank M Mounting feet N User interface wiring entrance O Power in wiring entrance P Coolant high limit resistance temperature device RTD Q Element...

Page 8: ...o the coolant return line The coolant pump will continuously circulate fluid throughout the engine To maintain consistent fluid temperature the heating elements will cycle on and off at the user selected temperature control point A coolant check valve included with the CMM CLM unit and installed at the coolant outlet prevents backflow while the engine is operating When the engine is shut down the ...

Page 9: ...commends installing full flow ball valves to isolate the heating system in order to perform service on the system or engine without draining coolant Pressurized steam hazard Coolant pressure relief valve outlet must be vented to the atmosphere in case an over pressure release of heated coolant occurs Do not connect pressure relief plumbing to coolant system Proper lifting Use proper lifting equipm...

Page 10: ...Use elbow fittings sparingly Hotstart recommends using sweeping bends or 45 fittings NOTE For optimal pump performance Hotstart recommends a minimum of 6 inches 152 mm of straight pipe installed into pump inlet 2 1 2 COOLANT RETURN When installing the CMM CLM coolant return line refer to the following Hotstart guidelines See SECTION 2 2 Size the coolant return line per the coolant outlet NOTICE Do...

Page 11: ...g system 2 2 COOLANT PLUMBING ILLUSTRATION COOLANT SUCTION PORT SECTION 2 1 1 COOLANT DISCHARGE PORT SECTION 2 1 2 ISOLATION VALVE COOLANT SUPPLY SECTION 2 1 1 COOLANT RETURN SECTION 2 1 2 COOLANT PRESSURE RELIEF VALVE SECTION 2 1 3 ISOLATION VALVE ...

Page 12: ...L 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 any applicable local codes based on the installation location Electrical hazard Th...

Page 13: ...m Use this connection for remote operation of the heating system when the local off remote switch is turned to remote NOTE The 24 V DC shutdown relay is wired NO normally open from the factory To switch to NC normally closed operation move the wire from the K4 14 terminal to the K4 12 terminal 2 4 3 MOTOR ROTATION CHECK NOTICE Pump rotation three phase only For three phase applications check for p...

Page 14: ...SSURE TEMPERATURE GAUGE The CMM CLM system features a temperature pressure gauge mounted at the heating tank inlet The gauge will indicate a pressure increase when the pump motor is engaged by pressing and holding the prime button or during normal operation The gauge will also indicate the fluid s current temperature NOTE Your system s operating pressure may vary depending on the configuration of ...

Page 15: ...h limit temperature control relay TCR2 must be set at least 10 C 18 F higher than the control temperature control relay TCR1 for proper heating operation This will prevent nuisance tripping of the high limit circuit Seal damage Pump seal faces may adhere while in storage Before energizing the pump motor for the first time remove the pump shaft guards and rotate the shaft by hand to ensure the seal...

Page 16: ...d 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 MPS reset on button to reset the fault See SECTION 3 2 1 If there is a failure that causes a high fluid temperature to occur the high limit temperature controller TCR2 will shut down the heating system including the pump motor The fault light will illumina...

Page 17: ...a preventative maintenance measure NOTE Higher current systems or systems operating in high ambient temperatures may require more frequent contactor replacement 4 2 6 PUMP SEAL If seal becomes worn replacement pump seals are available To improve pump seal longevity ensure the supply line does not restrict flow excessively see SECTION 2 1 1 NOTE Instructions to replace the pump seals are included w...

Page 18: ...nd 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 1 If fault or temperature problems persist after start up contact HOTSTART for further assistance h If there is no continuity between TCR terminals T2 and T3 locate conn...

Page 19: ...heating system Allow fluid to cool 2 Close isolation valves Drain fluid from the heating tank see SECTION 4 2 4 Locate the RTD that requires replacem ent See Figure 13 3 Unscrew RTD plug Remove plug Unscrew RTD from tank See Figure 14 4 Screw replacement RTD to tank When tightening ensure plug is aligned with notch orientated as shown in Figure 15 5 Fit RTD plug to RTD Ensure plug is aligned corre...

Page 20: ...screw cable gland F from conduit connector entrance H Remove electrical cable and wires from the heating element See Figure 17 7 Loosen V clamp nut to remove V clamp C Slide the heating element out of tank as shown 8 Replace the heating element G or perform the necessary cleaning procedure Ensure the O ring D is intact and in place before securing V Clamp 4 2 13 REASSEMBLY OF HEATING ELEMENT AND T...

Page 21: ... 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 the storage duration will be one year or longer the volatile corrosion inhibitor inside ...

Page 22: ...tactor Replace if needed See SECTION 4 2 5 Motor protection switch tripped Check and reset switch If problem occurs again check motor Restart system See SECTION 4 1 RTD failure Check TCR and RTD See SECTION 4 2 10 RTD cable failure Check TCR and RTD See SECTION 4 2 10 Fluid temperature too low Motor failure Check motor Replace if necessary Heating system has been turned off and fluid is cold Allow...

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