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Hotstart OCSM Installation & Operation Manual

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216280-000 rev5
INSTALLATION & OPERATION MANUAL
D U A L F L U I D C I R C U L AT I N G H E AT I N G S Y S T E M
MODEL
OCSM

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Summary of Contents for Hotstart OCSM

  • Page 1 216280-000 rev5 INSTALLATION & OPERATION MANUAL D U A L F L U I D C I R C U L AT I N G H E AT I N G S Y S T E M MODEL OCSM...
  • Page 2 (this page intentionally left blank)
  • Page 3 IDENTIFYING YOUR SYSTEM IOM216280-000 The HOTSTART heating system is designed to heat fluids for use in marine propulsion, diesel-powered generator sets, locomotives, gas compression or any large-engine applications. The system is pre-wired, pre-plumbed and assembled on steel plate. Each heating system has an identification plate which includes the part number and serial number.
  • Page 4 Overcurrent limiting: The power supply must be protected by a suitable overcurrent limiting device. • Power disconnection: A means to disconnect the heater from the power supply is required. HOTSTART recommends that a power switch or circuit breaker be located near the heating system for safety and ease of use.

  • Page 5: Table Of Contents

    HEATING SYSTEM START-UP | 3.3.1 First Run Procedure | MAINTENANCE, REPAIR AND TROUBLESHOOTING | SYSTEM FAULTS | 4.1.1 Faults | SYSTEM MAINTENANCE | 4.2.1 Plumbing Connections | 4.2.2 Electrical Connections | 4.2.3 System Mounting | & oCsm installation operation manual heating system...
  • Page 6 (this page intentionally left blank) & oCsm installation operation manual heating system...

  • Page 7: Overview

    NOTE: Component illustrations are for reference only and are not to scale. See part drawings for dimensions and specifications. Figure 1. Typical OCSM system components. Front view (left) and reverse view (below). Model style and configuration may vary. See part drawings for dimensions and specifications.

  • Page 8: Operation Overview

    OPERATION OVERVIEW The OCSM heating system is intended to maintain optimal engine operating temperature while the engine is shut down. The heating system may be activated locally or by a 24 V DC signal (see SECTION 2.4.3) and must be deactivated upon engine start-up.

  • Page 9: Installation

    INSTALLATION CAUTION Isolation valves: HOTSTART recommends installing full-flow ball valves to isolate the heating system in order to allow the engine and heating system to be independently drained of coolant and/or oil during servicing. Pressure hazard: Power must be turned off and locked out at the service panel when the isolation valves are in the closed position.

  • Page 10: Plumbing Installation

    PLUMBING INSTALLATION 2.1.3 OIL SUPPLY NOTICE When installing the OCSM oil supply line, refer to the following HOTSTART guidelines: Heating system damage: Engine vibration will • damage the heating system; isolate the heating system At a minimum, size the oil supply line per the from vibration.

  • Page 11: Plumbing Illustration

    COOLANT SECTION 2.1.3 COOLANT RETURN SUCTION PORT SECTION 2.1.2 SECTION 2.1.1 OIL SUPPLY SECTION 2.1.3 OIL RETURN DISCHARGE PORT SECTION 2.1.4 SECTION 2.1.4 CHECK VALVE ISOLATION VALVES COOLANT SUPPLY SECTION 2.1.1 ISOLATION VALVES & oCsm installation operation manual heating system...

  • Page 12: Mounting

    Never mount the heating Figure 5. OCSM control box side system or components directly to the engine. view, showing 0.75″ NPT main power entrance (A).

  • Page 13: Customer Interface Connections

    Figure 6. Main power supply and customer interface connections Main power terminal block Remote On/Off 24 V DC shutdown as shown in the OCSM control box. Reference electrical schematic Main power ground block drawing for proper wiring locations; the following illustrations are Fault signal typical customer interface locations.

  • Page 14: Oil Pump On/Off Switch

    MPS1 MPS1 MPS1 MPS1 Figure 7. OCSM motor protection switch (above), showing stop/off (A) and reset/on (B) buttons. To reset the MPS, the heating system must be switched off and the MPS reset/on button must be pressed. 3.1.2 OIL PUMP ON/OFF SWITCH amperage of the motor when shipped from the factory.

  • Page 15: Maintenance, Repair And Troubleshooting

    Replacement parts not obtained through HOTSTART must meet or exceed original part If installed, activate the 24 V DC signal to verify the requirements in order to maintain the compliance level of 24 V DC remote signal connection is operational.

  • Page 16: Pump Seal

    Pull plug (C) from well (A). Sensing unit (B) will be mechanical wear. If any of these conditions exist, replace the magnetic contactor. HOTSTART recommends attached to plug. contactors be replaced every five years. Remove sensing unit (B) from plug (C).

  • Page 17: Reassembly Of Heating Element And Tank

    (B) from tank. O-ring (H) is in place. Replace the heating element (B) or perform the NOTE: To prevent leaks, HOTSTART recommends necessary cleaning procedure. Ensure the element tightening element plate screws (C) to 120 lbf · O-ring (J) is in place.

  • Page 18: Recommended Maintenance

    Remove element and clean element and tank. See SECTION 4.2.7. Every three years or 25,000 hours of operation HOTSTART recommends replacing the control thermostat sensing unit every three years or 25,000 hours of operation. Thermostats are rated for 100,000 cycles. See SECTION 4.2.6.

  • Page 19: Troubleshooting

    Element contactor failed Check contacts and coil. Replace if necessary. Motor contactor failed Check contacts and coil. Replace if necessary. Control thermostat failure: Check and replace if necessary. See SECTION 4.2.6. open & oCsm installation operation manual heating system...

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