Hotstart OCLA Installation & Operation Manual Download

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216272-000 rev6

INSTALLATION & OPERATION MANUAL

MODEL

OCLE

OCLA

DUAL FLUID CIRCULATING HEATING SYSTEM

FOR HAZARDOUS LOCATIONS

Summary of Contents for OCLA

Page 1: ...216272 000 rev6 INSTALLATION OPERATION MANUAL MODEL OCLE OCLA DUAL FLUID CIRCULATING HEATING SYSTEM FOR HAZARDOUS LOCATIONS ...

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Page 3: ...g 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 prior written consent from Hotstart Manufacturing Inc NOTE Typical heating system...

Page 4: ...llers 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...

Page 5: ... Temperature Gauge 10 3 1 5 Coolant Pressure Relief Valve 10 3 1 6 Oil Pressure Relief Valve 10 3 2 SYSTEM COMPONENTS 11 3 2 1 Motor Protection Switch 11 3 2 2 Control TCR Temperature Control Relay 11 3 2 3 High Limit TCR Temperature Control Relay 11 3 3 HEATING SYSTEM START UP 12 3 3 1 First Run Procedure 12 4 MAINTENANCE REPAIR AND TROUBLESHOOTING 12 4 1 SYSTEM FAULTS 12 4 1 1 Coolant Faults 12 ...

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Page 7: ...witch C Coolant prime button D Oil prime button E Coolant reset button F Oil reset button G Coolant outlet 1 NPT H Oil outlet 1 NPT I Coolant high limit resistance temperature device RTD J Oil high limit resistance temperature device RTD K Identification plate L Coolant pressure temperature gauge M Pressure relief valve 0 5 NPT N Oil pressure temperature gauge O Coolant control resistance temperat...

Page 8: ... and forces it through the heating tank to the oil return line The coolant pump and oil 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 OCLE OCLA unit and installed at the coolant outlet and an oil check valve user s...

Page 9: ...sed 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 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 ...

Page 10: ...et 1 5 meters To minimize flow restriction HOTSTART recommends using sweeping bends or 45 fittings At a minimum size the oil supply line per the pump inlet NOTICE Do not reduce the supply line inner diameter pump seal damage will occur NOTE To maximize flow and allow the longest possible supply line install the largest practical inner diameter hose for most installations HOTSTART recommends using ...

Page 11: ...TION PORT SECTION 2 1 1 CHECK VALVE SECTION 2 1 1 ISOLATION VALVE ISOLATION VALVE 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 ...

Page 12: ... point at the suction side of the engine water pump A NOTICE At a minimum suction port must be sized per the pump inlet 1 25 NPT To minimize flow restriction the coolant supply line must be as short and as straight as possible 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 st...

Page 13: ...E PORT SECTION 2 3 2 ISOLATION VALVE ISOLATION VALVE COOLANT RETURN SECTION 2 3 2 COOLANT SUPPLY SECTION 2 3 1 PRESSURE RELIEF VALVE SECTION 2 3 3 E 2 E 1 V 1 V 3 V 2 COMPONENT DESCRIPTION V 1 V 2 USER SUPPLIED FULL FLOW ISOLATION VALVE E 1 COOLANT PUMP E 2 COOLANT HEATING ELEMENT V 3 USER SUPPLIED FULL FLOW ISOLATION VALVE PRESSURE RELIEF VALVE ...

Page 14: ...t procedure Failure to do so could allow others to turn on the power unexpectedly resulting in harmful or fatal electrical shock Electrical hazard All wiring shall be done by qualified personnel in accordance with national state and local codes Each system shall be grounded in accordance with the National Electrical Code Failure to properly ground the system may result in electrical shock 2 6 1 MA...

Page 15: ...nt the pump motor is not running Switch Location Signal X1 7 X1 8 X1 9 coolant H X2 7 X2 8 X2 9 oil I The switch location signal indicates the local off remote switch position off 7 local 8 remote 9 L1 L2 TB1 L3 A B Figure 5 Main power supply and customer interface connections as shown in the OCLE OCLA control box Reference electrical schematic drawing for proper wiring locations the following ill...

Page 16: ... the prime button to energize the pump motor in order to remove any air in the heating system without energizing the elements NOTICE Do not run the motor pump assembly dry for more than five seconds at a time NOTE The prime function is intended for use during the first run procedure see SECTION 3 3 1 or after performing maintenance on the heating system or plumbing see SECTION 4 3 3 1 3 RESET BUTT...

Page 17: ...F 40 C See Fig 7 3 2 3 HIGH LIMIT TCR TEMPERATURE CONTROL RELAY The high limit TCRs TCR2 and TCR4 are a protection device to prevent fluid overheating The high limit TCR uses a resistance temperature device RTD located near the tank outlet The default setting for the coolant and oil high limit TCR is 194 F 90 C and should always be at least 18 F 10 C higher than the corresponding control TCR set p...

Page 18: ...epending on the configuration of the engine 5 Turn the local off remote switch to local or remote to energize the heating system 6 Once operation is satisfactory turn the control dial on the temperature control relay TCR1 to the desired temperature setting for engine oil HOTSTART recommends a control temperature on TCR1 of 104 F 40 C The high limit temperature setting on TCR2 should be set at 194 ...

Page 19: ... 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 mechanical wear If any of these...

Page 20: ...contact HOTSTART for further assistance h h If there is no continuity between TCR terminals T2 and T3 locate connected RTD on the heating tank Unscrew the RTD plug from RTD See Table 2 and Fig 10 Fig 11 on following page 5 Using the ohmmeter touch the probes to RTD lead TS2 WHT A and lead TS2 RED B See Fig 9 Note the resistance Touch the probes to lead TS2 RED B and lead TS2 RED C to check for con...

Page 21: ...CTION 4 2 9 1 De energize the heating system Allow fluid to cool 2 Close isolation valves Drain the fluid from the heating tank Locate the RTD that requires replacement See Fig 10 3 Unscrew RTD enclosure cover and disconnect RTD leads from wire connectors See Fig 11 4 Unscrew RTD enclosure from RTD For OCLA RTD enclosure removal both enclosures may need to be removed for access 5 Unscrew RTD from ...

Page 22: ...placement elements may be a different phase configuration 6 Disconnect the ground green yellow and power electrical wires from the posts inside the cap 7 Unscrew cable gland from conduit connector entrance C Remove element conduit H and wires from the heating element See Fig 12 8 Loosen V clamp screw to remove V clamp D Detach the heating element from the tank as shown 9 Replace the heating elemen...

Page 23: ...s must be taken to ensure that the 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 b...

Page 24: ... tripped Check and reset switch If problem occurs again check motor Restart system RTD failure Check TCR and RTD See SECTION 4 2 9 RTD cable failure Check TCR and RTD See SECTION 4 2 9 Fluid 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 elements for continu...

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