Oil Circulating

Heating System
Hazardous Location

Model - OLA or OLE

Installation & Operation Manual

216268-000 REV 5
Identifying Your System

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 a steel plate. Each heating system has an identification plate which
includes the part number and serial number.

Warranty information can be found at www.hotstart.com or by contacting our customer service

department at (509) 536-8660. Have your model and serial numbers ready when contacting the
warranty department.

NOTE: When ordering replacement parts, be sure to reference your heating system’s
Model and Serial Numbers found on the identification plate and the label above.

Typical label – actual label may vary slightly from model

to model, but the general layout is the same.

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 HOTSTART, Inc.

5723 E. Alki Ave. Phone: (509) 534-6171

Spokane, Washington Fax: (509) 534-4216
99212 USA

Customer Support:
Spokane (509) 536-8660
Texas (281) 600-3700
Germany +49-2241-12737-0
Japan +81-3-6902-0551
www.hotstart.com

Important Safety Information

Hazardous Voltage: Before wiring, servicing or cleaning the system, turn off the power
WARNING 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.
All wiring shall be done by qualified personnel in accordance with national, state and local
codes. Failure to properly ground the system may result in electric shock. Operation of the
system during engine operation may cause damage to the heater.

Please read carefully: The safety of any system incorporating this heater is the
CAUTION responsibility of the assembler. The safe and proper use of this heater is dependent upon
the installer following sound engineering practices. If the equipment is used in a manner
not specified by the manufacturer, the protection provided by the equipment may be
impaired. All applicable electrical safety standards defined by local jurisdictions must be
followed. (reference EU directive 2006/95/EC in EU countries)
The heater must be connected to a suitable ground (protective earthing conductor).

The power supply must be protected by a suitable overcurrent limiting device.

The means of disconnection from the power supply is required. HOTSTART

recommends that a power switch or circuit breaker be located near the heater for the
safety and ease of use.

Installers and operators of this equipment must be thoroughly familiar with the
instructions in this manual before commencing work.

Use proper lifting equipment and rigging to move this equipment. Create a plan before
attempting to move. Proper lifting locations are identified with labels on each system,
please use these locations when lifting and mounting the system.

Hot surfaces: avoid contact with the system while it is in service – some surfaces may
stay hot even if the system is not energized.

Rotating equipment: system can start automatically and without warning – avoid contact
unless a lockout at the service panel has been installed.
EU Countries Only: Equipment rated for the conditions listed in EN 601010-1 1.4.1 Ingress
NOTICE protection rating IP54. (Special conditions for specific applications may apply)

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Table of Contents
1  Installation ............................................................................................................................................ 1 
1.1  Oil Plumbing Diagram .................................................................................................................. 1 
1.2  Mounting ....................................................................................................................................... 1 
1.3  Oil Suction Line Requirements ..................................................................................................... 2 
1.4  Lube Oil Discharge Line ............................................................................................................... 3 
1.5  Main Power Supply....................................................................................................................... 3 
1.6  Customer Interface Connections ................................................................................................... 4 
2  Heating System Start-Up ...................................................................................................................... 5 
3  Overview of Operation ......................................................................................................................... 6 
4  Maintenance, Repair, and Troubleshooting ......................................................................................... 7 
4.1  System Maintenance ..................................................................................................................... 7 
4.1.1  Plumbing Connections .......................................................................................................... 7 
4.1.2  Electrical Connections .......................................................................................................... 7 
4.1.3  System Mounting .................................................................................................................. 7 
4.1.4  Magnetic Contactors ............................................................................................................. 7 
4.1.5  Pump Seal ............................................................................................................................. 7 
4.1.6  Volatile Corrosion Inhibitor (VCI) ....................................................................................... 8 
4.1.7  Storage Requirements/Periodic Maintenance ....................................................................... 8 
4.1.8  Pressure Relief Valve ............................................................................................................ 8 
4.1.9  Heating Element Replacement .............................................................................................. 9 
4.1.10  Reassembly of Heating Element and Tank ......................................................................... 10 
4.1.11  RTD Replacement ............................................................................................................... 11 
4.2  Troubleshooting .......................................................................................................................... 12 

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 1 Installation
1.1 Oil Plumbing Diagram

OIL DISCHARGE LINE ENGINE/COMPRESSOR

 Plumb to opposite end of
the oil sump.

USER
SUPPLIED
FULL FLOW
BALL
VALVES CHECK
OIL SUCTION LINE VALVE

 Suction port must be

HEATING TANK PUMP immersed at all times.
 Keep suction port off
bottom of oil pan.
HEATING SYSTEM  Suction line ID should be
determined by using the
chart on page 2.
 Suction line must be as
short and straight as
possible.

Do not hard plumb directly to the heating system, use short flexible hose runs from
CAUTION the heater inlet and outlet.

The system is equipped with a pressure relief valve that is preset to relieve at 100
psi, 6.9 bar. During normal operation, pressure releases are rare but it is
recommended that piping from the discharge port be routed to a safe location in
case of pressure release.

1.2 Mounting
System should be as close to the suction port as possible. It is recommended to mount at or below the oil
level to insure a flooded suction. A check valve should be used at the suction port on the equipment. The
system should not be mounted directly to the engine, as vibration can cause failures. Isolate when
vibration is present. Heating system should be mounted with the base plate in the vertical position such
that the outlet of the heating chamber is pointing up. Clearance is required for heating element removal.

Lifting hazard: Proper rigging and safety equipment must be used to move this
CAUTION equipment.

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1.3 Oil Suction Line Requirements

OIL SUCTION LINE REQUIREMENTS

1. FIND YOUR 2. Find the hose diameter and 3. Use the hose 4. For EACH 12.0” 5. For EACH
PUMP – the part length that will work for your diameter from step or 0.3m, the pump is 1000ft or 300m of
number is installation. Take into account the 2, to adjust the above the oil level, elevation, subtract
printed on the subtractions in steps 3-5 max length for subtract the value the value below
pump tag. pump level and below from the max from the max hose
elevation. hose length length.

PART NUMBER Number of

Hose Max Hose
PUMP MODEL Fittings
Diameter Length
PORT SIZE (90°)

Max .75”, 19mm

12.0”, 0.3m 1’, 0.3m
.75”, 19mm 8’, 2.4m 0 1.0”, 25mm
228044-000 6’, 1.8m 1 1.5”, 38mm 24.0”, .61m 2’, .61m
SG
0.5” 1.0”, 25mm 30’, 9m 0 2.0”, 51mm 48.0”, 1.2m 5’, 1.5m
15’, 4.6m 5
1.0”, 25mm 6’, 1.8m 0
228043-002 or 004 4’, 1.2m 1
GG475
1.0” 1.5”, 38mm 40’, 12m 0
30’, 9m 5
1.5”, 38mm 16’, 5m 0
228048-002 10’, 3m 2
HJ475
1.5” 2.0”, 51mm 50’, 15m 0
40’, 12m 5
1.5”, 38mm 11’, 3.4m 0
228050-002 8’, 2.4m 1
HL475
1.5” 2.0”, 51mm 30’, 9m 0
20’, 6m 5

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1.4 Lube Oil Discharge Line
Size the discharge line per the outlet of the heating system. There are two options for the
discharge line of the HOTSTART oil heating system. The heated oil can be returned to the
opposite end of the oil sump, or engine pre-lubing can be achieved by installing a tee in the
discharge line along with a solenoid valve or manual three-way valve.
Note: See engine manufacturer requirements for pre-lubing. HOTSTART does not specify
flow rates or pressure for pre-lube systems.

Do not reduce the inlet line. Pump seal damage will occur.
NOTICE
Position the heating tank so that it is completely full of oil while in operation.
Fill the suction line with oil. Pump is not self-priming. Liquid must be present in the
Pump before start-up. Trapped air inside the pump will cause pump and seal damage.
After completing oil line installation, top-off the oil level to compensate for the oil
used to fill the lines and heating tank. The system should be configured with user
supplied full port ball valves in the oil lines, allowing maintenance on the heating
system without draining the engine oil.

1.5 Main Power Supply

Connect the specified power from the customer supplied circuit breaker to the terminal blocks located in
the main control box. For three phase applications, the terminal blocks are labeled L1, L2, and L3. For
single phase applications, use the terminal blocks labeled L1 and L3 or L and N. The circuit breaker must
be near the heating system and easily accessible.
The main power ground wire must be connected to the ground lug or ground block on the electrical panel
located inside the electrical box.
The main power supply operates the heating elements and the circulating pumps. A transformer is used to
operate the control circuit. The transformer and control circuits are overload protected with fuses and/or a
circuit breaker.

All wiring shall be done by qualified personnel in accordance with national,

WARNING state and local codes. Failure to properly ground the system may result in
electric shock. Operation of the system during engine operation may cause
damage to the heater.

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.

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1.6 Customer Interface Connections
Reference electrical schematic and control box drawing for proper wiring locations. Shown below are
typical customer interface locations.
Local and Remote signals indicate switch position. The Fault signal indicates a fault. The Run signal
indicates the pump is running. The 24 VDC connections are for remote control of the heater while the
switch is in the Remote position. The 24VDC remote control relay is wired N/C from the factory, see
system wiring diagram for directions to switch to N/O operation.

Typical Customer Interface: see included drawings and wiring

diagram for specific system locations.

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2 Heating System Start-Up
Step 1 Check and tighten all electrical and plumbing connections.
Step 2 Ensure isolation valves are open before energizing the system.
Step 3 Check for proper rotation of the motor by pressing the prime button while watching
the motor shaft or fan. Single phase systems are pre-wired to rotate in the correct
direction. On a three phase system, if the pump is not rotating in the correct direction,
switch any two electrical leads at the main power terminal block.
DO NOT RUN MOTOR/PUMP ASSEMBLY DRY FOR MORE THAN A FEW
NOTICE SECONDS.
Running a pump that is not completely filled with liquid will cause damage to the
pump seal.
Step 4 Bleed all trapped air from the heating system by opening a plug or pipe fitting at or near
the pump. Press and hold the prime button to evacuate any remaining air in the lines.
When all the air is evacuated, the discharge pressure gauge should indicate pressure.
Step 5 Energize the heating system by switching the control switch to the Local position. A
pressure gauge should indicate pressure if the system is working correctly.

Hazardous Voltage: Before wiring, servicing or cleaning the system,

WARNING 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.

Step 6 Once operation is satisfactory, turn the control dials on the Temperature Control Relay
TCR1 to the desired temperature setting. HOTSTART recommends a control
temperature (on TCR1) of 40 °C (104 °F). The high limit temperature setting (on TCR2)
should be set at 90 °C (194 °F).
The high limit TCR must be set at least 10 °C (18 °F) higher than the control TCR
NOTICE for proper heating operation. This will avoid nuisance tripping of the high limit
circuit.

Step 7 Change the switch to the Remote position and verify that the 24 V DC controls operate
properly (refer to Section 3.3 for operation).

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3 Overview of Operation
When the system is energized, a positive displacement rotary gear pump takes oil from the engine sump
and forces it through the heating tank and into the return line. The return line can be routed back to the
sump, or can be sent to the top of the engine for pre-lube and post-lube purposes.

Note: See engine manufacturer requirements for pre-lubing. HOTSTART does not specify flow rates
or pressure for pre-lube systems.

Continual pre-lubing can cause permanent engine damage. Consult the

NOTICE engine manufacturer for proper pre-lube techniques.

The heating system is designed to run continuously while the engine is not running. The heating element
will cycle on and off with the system temperature controller to maintain the temperature.

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4 Maintenance, Repair, and Troubleshooting
4.1 System Maintenance
Instructions for the following maintenance procedures are provided to ensure trouble-free operation of
your heating system. Replacement parts must meet or exceed original part requirements in order to
maintain the compliance level of the original heater.
• Plumbing Connections
• Electrical Connections and Contacts
• System Mounting
• Magnetic Contactors
• Pump Seal
• Volatile Corrosion Inhibitor
• Storage Requirements/Periodic Maintenance
• Pressure Relief Valve
• Heating Tanks/Elements

After maintenance is performed, refer to the start-up section of this manual.

Hazardous Voltage: Before wiring, servicing or cleaning the system, turn
WARNING 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.

4.1.1 Plumbing Connections

Periodically check plumbing connections for leaks and, if necessary, tighten connections. A
loose connection on the suction side will cause a loss of flow and cavitation in the pump. It can
also pull air into the heating tank and cause an element failure.

4.1.2 Electrical Connections

Vibration may eventually cause terminals to loosen. Tighten at start-up and check again in a
week. Tighten all electrical connections every 3 months.

4.1.3 System Mounting

Vibration may cause mounting bolts to loosen. Periodically check and tighten all mounting bolts.

4.1.4 Magnetic Contactors

Magnetic contactors are used as voltage switching controls for motors and heating elements in
HOTSTART Heating Systems. The contactors use 120 or 240 V coils. To test for failure, check
for continuity across the coil connections; an open or direct-short reading indicates a failed
contactor coil.
The contactor contacts should be inspected periodically for welding, arc erosion, and mechanical
wear. If any of these conditions exist, clean the contacts or replace the contactor.

4.1.5 Pump Seal

Leakage can occur at any time throughout the life of the seal. Always replace the seal at the first
sign of leakage. If the heating system is installed on an engine that is used for a critical
application, replace the seal annually. Instructions to replace the seal are included with the new
seal.

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4.1.6 Volatile Corrosion Inhibitor (VCI)
A VCI is provided with each control box and should be replaced once a year.

4.1.7 Storage Requirements/Periodic Maintenance

If extended storage is necessary, precautions must be taken to ensure that the heating system is
operational for startup. If possible, it is always best to store the system in its original
packaging. If that is not possible, steps must be taken to ensure that water ingress is mitigated at
all locations. This means that any and all plugs and caps must remain tight and a suitable cover
shall be given to 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 3 months, desiccant bags must be
placed next to the system if it is still in the original packaging and inside the control box. For
storage that lasts longer than a year, the volatile corrosion inhibitor inside the control box must be
replaced after 6 months.

Yearly:
 Drain, clean, and flush heating system
 Check for cracked and/or weakened hoses and replace if necessary
 Tighten and check electrical wiring and connections for wear and excessive heat
 Check mounting bolts and tighten if necessary
 Remove element and clean element and tank

Every 3 years or 25,000 hours of operation:

 Replace heating element contactor(s)

4.1.8 Pressure Relief Valve

The pressure relieve valve on coolant systems must be periodically checked and replaced when
appropriate. At a minimum, the valve should be removed from the system, checked for deposits
and corrosion, and tested to ensure that it relieves at the proper pressure.

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4.1.9 Heating Element Replacement
To replace the heating element or perform routine maintenance, observe the following procedure. The
wattage and phase of the heating element are listed on the identification label on the outside of the
element. Reference this label for the replacement element part number.
Hazardous Voltage: Before wiring, servicing or cleaning the system, turn
WARNING 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.

Step 1 Turn the heating system OFF, close isolation valves, and lock out at the service panel.

Step 2 Drain the fluid from the heating tank.

Step 3 Remove the cap from the heating element service entrance enclosure.
Step 4 The wire connections inside the enclosure correspond to one of the phase configurations shown
at the bottom of the page. Note your unit’s phase configuration.
NOTE: Replacement elements can be a different phase configuration. Wire replacement
elements to the cup washers on the replacement element studs.
Disconnect the ground (green) and power electrical wires from the posts inside the cap.
Step 5 Remove the conduit connector and electrical wires from the heating element.
Step 6 Remove the V-clamp to detach the heating element from the tank as shown on the next page.
Step 7 Replace the heating element or perform the necessary cleaning procedure. Ensure the O-ring is
in place.

1 Phase Parallel 1 Phase Series 3 Phase Delta 3 Phase Wye

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4.1.10 Reassembly of Heating Element and Tank
To reassemble the heating element and tank, follow the steps listed on the previous page in reverse order.
Make sure the ground and power electrical wires are properly reconnected using the washers, cup washers
and nuts supplied (please note diagram at bottom of the previous page).

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4.1.11 RTD Replacement
The high limit RTD is located inside the element enclosure and the other control RTD is located at the
inlet side of the tank as shown below. To replace this RTD, follow the steps listed below.

High Limit RTD Control RTD

Hazardous Voltage: Before wiring, servicing or cleaning the system, turn

WARNING 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.

Step 1 Remove the cover of the service entrance enclosure.

Step 2 Disconnect the RTD wires in the service entrance taking care to note current wiring.
Step 3 Drain the tank and remove the RTD.
Step 4 Reassemble in reverse order.

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4.2 Troubleshooting

Faults indicated by the system only occur from an overheating condition or a tripped motor protective
switch.

Symptom Possible Causes Solution

Bleed all trapped air from lines, restart

Pump not primed properly
system

Isolation valves may be closed Open valves, restart system

Hose kinked or crushed Remove obstruction, restart system

Leak in suction line Repair leak, restart system

Reverse any two leads on power in (3

Indicated Pump motor turning backwards
phase systems), restart system
System Fault
Check and replace if needed, restart
TCR1 failed closed
system
Check and replace if needed, restart
Motor failure
system
Check contacts and coil replace if
Motor contactor failure
needed, restart system
Check and reset, if problem happens
Motor protective switch tripped
again check motor, restart system

Motor failure Check and replace if needed

TCR1 failed Check and replace if needed

Heater has been turned off, fluid is cold Allow time for heater to heat fluid

Check elements for continuity and

Heating element failed
replace if needed
Low Check all element fuses for continuity and
Element fuses failed or Breaker Tripped
Temperature replace as necessary or reset breaker

Element contactor failed Check contacts and coil replace if needed

Check contacts and coil replace if

Motor contactor failed
needed

Motor failed Check and replace if needed

TCR1 failed open Check and replace if needed

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