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10

installation

 & 

operation

 

manual

 | 

ocle

/

ocla

 

heating

 

system

 

2.6.3  MOTOR ROTATION CHECK

NOTICE

Pump rotation (three-phase only): 

For three-phase 

applications, check for proper pump rotation prior to 
introducing fluid to the pump. Reverse rotation while 
the pump is filled with fluid will cause pump seal failure.

Pump damage:

 Do not run the motor/pump assembly 

dry for more than a few seconds. Running a motor/
pump for a prolonged period without being completely 
filled with fluid may cause damage to the pump seal.

The following procedures are for three-phase 

applications only. Single-phase systems are prewired to 

ensure the pump motor rotates in the correct direction. 

1. 

With main power connected to the heating system 

motor 

(see 

SECOIO  2.6.1

)

, energize the pump 

while observing the rotation of the pump motor fan 

at the rear of the motor. Refer to rotation decal on 

motor for correct rotation.

 

h

If the pump motor does not rotate in the correct 

direction, disconnect power and switch any two 

electrical leads at the main power terminal block 

(

L1, L2, L3

). Reconnect power. 

Repeat step 1 

to 

ensure motor rotates in the correct direction.

COMPONENTS AND 

OPERATION

The following is an operational description for each of 

the OCLE/OCLA interface and system components.

 OOE:

 

  Components installed in control box may 

vary depending on the particular system 

configuration purchased.

3.1 

INTERFACE COMPONENTS

3.1.1  LOCAL/OFF/REMOTE SWITCH

• 

local

 – The system is on.

• 

off

 – The system is shut off.

• 

remote

 – The system will turn on and shut 

off on a signal from the 24 V DC remote 

connection. 

See 

SECOIO  2.6.2.

3.1.2  PRIME BUTTON

Press and hold the 

prime

 button to energize the pump 

motor in order to remove any air in the heating system 

without energizing the elements. 

 OOICE! 

Do not run 

the motor/pump assembly dry for more than five 
seconds at a time.

 OOE:

 

 The 

prime

 function is intended for use during 

the first run procedure (

see 

SECOIO  3.3.1

) or 

after performing maintenance on the heating 

system or plumbing (

see 

SECOIO  4.3

)

.

3.1.3  RESET BUTTON

Press the 

reset

 button to reset the pump motor protection 

switch without opening the control box. The reset function 

is intended for use immediately following resolving and 
repairing a system fault (

see 

SECOIO  4.1)

.

3.1.4  PRESSURE/TEMPERATURE 

GAUGE

The OCLE/OCLA model 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.

 OOE:

 

  Your system’s operating pressure may vary 

depending on the configuration of the engine.

3.1.5  COOLANT PRESSURE RELIEF VALVE

CAUTION

!

Pressurized steam hazard:

 Coolant pressure relief valve 

outlet must be plumbed to a safe area in case an over-
pressure release of heated coolant occurs.

The coolant pressure relief valve is mounted at the 

coolant heating tank outlet and is set to relieve at 100 

psi (690 kPa). During normal operation, pressure release 

events are rare. To safeguard personnel and equipment, 

attach an appropriately sized pipe to the pressure relief 

valve outlet and direct flow to a safe area, bucket or 

other catch-basin. 

See 

SECOIO  2.3.3

.

3.1.6  OIL PRESSURE RELIEF VALVE

PRESSURE RELIEF 

VALVE CAP

PUMP INLET

PUMP OUTLET

Figure 6.  Typical OCLE/OCLA pump assembly. Note that the 
pressure relief valve cap must always point toward the inlet side of 
pump.

Содержание OCLA

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

Страница 2: ... this page intentionally left blank ...

Страница 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...

Страница 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...

Страница 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 ...

Страница 6: ...iv installation operation manual ocle ocla heating system this page intentionally left blank ...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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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