System Overview
Shown are standard Style A and Style B heating system configurations of Hotstart HOTflow™ CSM Model heaters. This circulating heating system consists of a coolant heating tank, heating element, Coolant thermostat, a centrifugal pump, a control box with electro-mechanical controls and a mounting bracket.
Basic System Operation
Upon energizing the system, engine coolant is circulated via the centrifugal pump, through the heating tank and back to the engine. The pump stays on and continues this circulation process even when the heating elements are off to ensure uniform engine temperatures. The thermostat cycles the heating element on and off based on coolant temperature. A 24VDC signal is required to de-energize the system when the engine is running.
System Mounting Requirements
The CSM heating system must be mounted in the horizontal position. The pump shaft must be in the horizontal position at all times for proper lubrication and cooling of shaft end bearing. Be sure to mount the system as low as possible in reference to the engine coolant level.
DO NOT mount the heating system directly to the engine (the system must be isolated from engine vibration).
DO NOT mount directly to the skid if the engine is not isolated from the skid.
System Installation
Coolant Supply Line
Connect a MINIMUM 1-inch N.P.T. coolant supply hose or pipe from the main coolant drain of the engine to the inlet of the heating system. Drawing coolant from a location low in the coolant system will ensure head pressure to the pump. The supply line must remain level or angle downward to eliminate air pockets. When approaching a plumbing obstacle, go around the obstacle instead of over it.
Coolant Discharge Line
Connect a MINIMUM 1-inch N.P.T. coolant return hose or pipe from the outlet of the CSM to the highest possible location on the engine coolant system at the furthest possible location from the suction line. This connection enables heated coolant to be circulated through the entire engine.
WARNING-Personal Injury: This product generates heat during operation. Operation of heating system with closed isolation valves could result in high pressure and serious injury. It is the responsibility of the installer and operator to ensure that no unsafe condition can result from the generation of pressure. In EU countries, PED (97/23/EC) compliant pressure relief may be required (125psi maximum).
NOTE: Your system may be configured with optional, non-restrictive shut-off valves in the coolant lines allowing maintenance on the heating system without draining the engine coolant. Isolation Valves, PRP203011-000 may be ordered from Hotstart.
NOTE: If the heating system is plumbed with rigid pipe, use flexible lines near the heating system long enough to provide freedom from vibration in all directions.
Coolant Requirements
The heating system is designed for use with a 50/50 mixture of low-silicate antifreeze and distilled water. Pre-mixed products are recommended. If not using a pre-mixed solution, ensure that the liquids are well mixed prior to filling the engine’s cooling system. Do not exceed a concentration of more than 60% antifreeze as element failure can result.
NOTE: After the heating system is mounted and the engine is refilled with coolant, loosen outlet flange at pump to bleed the air out of the system. DO NOT ENERGIZE THE HEATING SYSTEM AT THIS TIME. Run the engine until it reaches normal operating temperature to eliminate trapped air that may still be present in the engine.
WARNING-Personal Injury: Hot surfaces are a potential injury hazard. It is the responsibility of the assembler to ensure that hot surfaces are not easily accessible to untrained personnel during operation.
System Wiring
Operation of the system during engine operation may cause damage to the heater. The heating element package is pre-wired specific to the system wattage and voltage. Altering the supplied wiring configuration can result in heater failure. All connections in the junction box should be checked during installation. Vibration during shipment can cause screws to loosen. All connections in the junction box should be checked at engine service intervals. Vibration can cause connections to loosen.
Wiring to heating system to be performed by a qualified electrician and conform to all national, state and local electrical codes.
Disconnect all power sources prior to performing any maintenance on the heating system.
WARNING-Hazardous Voltage: Before wiring, servicing or cleaning the system, turn off the power and install a lockout on the heater circuits at the service panel. Failure to do so could allow others to turn on power unexpectedly, resulting in fatal electrical shock.
Main Power Wiring
Connect the specified voltage and phase to the terminal blocks located in the main control box of the heating system. A user-supplied circuit breaker (rated at the appropriate amperage) is required for use in the main power feed line.
For 3 phase applications, the terminal blocks are labeled L1, L2 and L3. For single phase applications, use terminal blocks labeled L1 and L2 (2-pole contactor, no transformer) or L1 and L3 (3-pole contactor, with transformer).
24 VDC Shutdown
Connect a user-supplied source of 24 VDC electricity to the terminal blocks labeled A1 and A2 in the control box. When present, this 24 VDC shutdown signal will disable the heating system to prevent operation while the engine is running.
The standard heating systems are wired such that the relay is normally closed (a 24 VDC signal when the engine is running disables the heating system).
Terminal and Conduit Connections
The electrical enclosure of the CSM heater must remain closed to protect terminals from moisture and vapor. Make certain that proper conduit connectors are used for the installed conditions. Terminations in all enclosures require the wire be rated at a minimum of 60ºC.
Selected wire must be sized in accordance with heater amperage.
Maintenance
Periodic Maintenance
Yearly:
1. Drain, clean, and flush cooling system
2. Check for cracked and/or weakened hoses and replace if necessary
3. Tighten and check electrical wiring and connections for wear and excessive heat
4. Remove element and clean element and tank
Every 3 years or 25,000 hours of operation:
1. Replace thermostat
2. Replace contactor
WARNING-Hazardous Voltage: Before wiring, servicing or cleaning the system, turn off the power and install a lockout on the heater circuits at the service panel. Failure to do so could allow others to turn on power unexpectedly, resulting in fatal electrical shock.
Replacement Fuse Type
All replacement fuses should be:
• “slow-blow” Type
• Midget Size (10mm x 38mm)
Single Phase 120V, 208V, 220V & 240V
• 250V (Hotstart p/n: PRP231026-002)
Single and 3 Phase 400V & 480V
• Primary: 500V (Hotstart p/n: PRP231059-002)
• Secondary: 250V (Hotstart p/n: PRP231026-002)
Single and 3 Phase 575V
• Primary:600V (Hotstart p/n: PRP231068-002)
• Secondary:250V (Hotstart p/n: PRP231026-002)
System Start-Up Check List
After system installation has been completed, follow these steps for proper coolant heating system start-up.
Step 1 Check and tighten all electrical and plumbing connections. Operation of the heating system with closed isolation valves could result in serious injury.
Step 2 Ensure isolation valves are open before starting system.
Step 3 After the heating system is mounted and the engine is refilled with coolant, loosen outlet flange at pump to bleed the air out of the system. Do not energize the heating system at this time. Run the engine until it reaches normal operating temperature to eliminate trapped air that may still be present in the engine’s cooling system.
Step 4 Standard systems are equipped with a fixed thermostat that is pre-set at 49 ºC.
For more information and detailed diagrams and schematics, click here to download and see this file
