216229-000 rev7

customer service: 509.536.8660 Read carefully for proper

s a l es @ho ts ta r t . c om | w w w. h ot s t a r t . c om installation and operation.

INSTALLATION INSTRUCTIONS Hotstart Manufacturing, Inc. is the owner of

all trademarks and copyrightable material
contained herein; all rights are reserved;
HOTflow™ HEATER no form of reproduction is authorized
without prior written consent from Hotstart
CSM MODEL Manufacturing, Inc.

BEFORE YOU INSTALL

HOTflow™ engine heaters feature an integrated pump that circulates warm coolant throughout the entire engine at uniform
temperatures. Constant circulation of the coolant eliminates hot spots that can deteriorate heater hoses, harm engine seals
and diminish coolant life. However, initial installation of the heating system is critical; even seemingly minor adjustments to port
location, hose routing or heater positioning may help ensure your HOTflow™ CSM heater preheats your engine effectively.

! DANGER Figure 1. Typical CSM model Style A (above) and

Style B (below). Style and configuration
Personal injury: This product generates heat during operation. Operation of may vary.
A B
a 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 C
unsafe condition can result from the generation of pressure. In EU countries, PED
(97/23/EC) compliant pressure relief may be required (125 psi maximum).
D
Hazardous voltage: Before wiring, servicing or cleaning the heating system,
turn off the power and follow your organization’s lockout and tagout procedure. E
Failure to do so could allow others to turn on the power unexpectedly, resulting
in harmful or fatal electrical shock.

! CAUTION
H G F
Electrical hazard: Power source must be properly grounded and in
A. Discharge port E. Customer control
accordance with national and local electrical codes. A user-supplied circuit
B. Pump/motor wiring entrance
breaker (rated at the appropriate amperage) is required for use in the main F.
C. Suction port Mounting base
power feed line. Do not connect heater prior to installation. (behind unit) G. Element assembly
D. Power in wiring H. Thermostat
NOTICE entrance (in element assembly)

A B C
Read instructions carefully: The HOTSTART warranty does not cover any damage D
that a heating system may sustain from improper installation, improper operation,
E
improper specification or corrosion. Before installing your heater, be sure you have the
right heating system for your application. Carefully read all instructions before installing
and energizing your heater. The safety of any system incorporating this heater is the
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.)
H G F

Corporate & Manufacturing Oil & Gas Office Europe Office Asia Pacific Office
Headquarters 21732 Provincial Blvd. HOTSTART GmbH HOTSTART Asia Pacific Ltd.
5723 E. Alki Ave Suite 170 Am Turm 86 2-27-15-4F Honkomagome
Spokane, WA 99212 USA Katy, TX 77450 USA 53721 Siegburg, Germany Bunkyo-ku, Tokyo
50 9 .5 3 6 .8660 281.600.3700 +49.2241.12734.0 113-0021, Japan
s al es@ hot start.c om o i l . ga s @ho ts ta rt. c o m e u rop e @ h o t s t a r t . c o m + 8 1 . 3 . 6 9 0 2 . 0551
a p a c @ h o t s t a r t .com

installation instructions
HOTflow™ csm heater | page 1 IOM216229-000 rev7
INSTALLING THE HEATER MOUNT HEATER

PREPARE COOLANT SYSTEM NOTICE

1. Drain and flush cooling system to remove any debris Vibration damage: Do not mount
present in the engine’s cooling system. heater directly to engine. Engine
vibration will damage heater. If the
SELECT PORTS heater is installed with rigid pipe,
connect flexible hose to inlet and
2. Select return port. The return port will allow heated outlet to isolate from vibration.
coolant to return to the engine. See Fig 2 on following
page. The return port should be located: Heater orientation: CSM units must be installed with
discharge port pointing directly upward. See Fig 2 on
•• away from the engine thermostat following page. Do not mount at an angle. An incorrectly
•• toward the rear (flywheel) of the engine oriented heater may cause heater failure.

•• away from the supply port 7. Select a heater mounting position. The heater should
•• on the same side of the engine as the intended be located:
heater mounting location
•• low enough to allow the return hose to continuously
rise to the return port
3. Select supply port. The supply port will allow coolant
to flow from the engine to the heater. See Fig 2 on •• on the same side of the engine as the return port
following page. The supply port should be located: •• in a position to ensure the discharge port points
directly upward
•• toward the front (radiator) of the engine
•• at the lowest point of the engine’s water jacket
•• in a location that allows a minimum of 17 inches
(43 cm) clearance for heating element removal
•• away from the return port
NOTE For V-type engines, it is acceptable to PLUMB HEATER
select a supply port on the opposite side
of the engine as long as the supply hose is
routed properly. See PLUMB HEATER.
NOTICE
High points: Do not allow high
points along heater plumbing.
SELECT HOSE, FITTINGS & VALVES High points will restrict coolant
4. Select fittings. CSM minimum port size fitting: flow and damage heater. To avoid
high points, it may be necessary
•• 3/4 inch NPT (20 mm) to change hose routing or lower
heater mounting location.
5. Select hoses. CSM minimum hose inner diameter: Dips and bends: Do not allow dips
•• 1 inch (25 mm) or bends along heater plumbing.
Dips or bends will allow air pockets
to form, restricting coolant flow
NOTE Select hoses rated for 250 °F (121 °C) and
and damaging heater.
100 psi (690 kPa) minimum.
90° Fittings: Elbows (90° fittings) along heater plumbing
6. Select optional, user-supplied isolation valves. may restrict flow and damage heater. To minimize flow
restriction, HOTSTART recommends sweeping bends or
NOTE HOTSTART recommends installing valves to 45° fittings in place of 90° fittings.
isolate the heating system in case of service.
To minimize flow restriction, select full-flow 8. Install isolation valves to port fittings.
(full-port) ball isolation valves.
9. Route and install return hose. The return hose should
continuously rise from the heater to the return port.

10. Route and install supply hose. The supply hose

should continuously descend from the supply port
to the heater.

installation instructions
HOTflow™ csm heater | page 2
Figure 2. Example CSM installation (Style B shown). The return hose continuously
rises to the engine and supply hose continuously descends to the heater; the hoses
have no dips, bends or high points. The heater is isolated from engine vibration and
is mounted in the proper orientation.
RETURN PORT
•• Select a return port away from the engine thermostat.
•• Select a return port toward the rear of the engine.
•• Select a return port away from the supply port.

SUPPLY PORT
•• Select a supply port low on the engine.
•• Select a supply port toward the front of
the engine.
•• Select a supply port away from the
return port.

HEATER MOUNTING
•• Mount the heater in the proper orientation. Ensure
discharge port is pointing directly upward.
•• Mount the heater to a vibration-isolated surface.
•• Mount the heater on the same side as the return port.

REFILL COOLANT WIRE HEATER

15. Connect heater to an appropriately rated power source.
NOTICE NOTICE! Terminations in all enclosures require that
wire be rated at a minimum of 60 °C. Selected wire
Heater damage: When mixing coolant, only use deionized
must be sized in accordance with heater amperage.
or distilled water and low-silicate antifreeze. Refer to your
engine’s manufacturer recommendations. Do not exceed 16. Connect user-supplied 24 V DC control signal wire
60% antifreeze to 40% water ratio. Never add unmixed (typically to ignition system). NOTICE! The heating
water and antifreeze to an engine. Do not add anti-leak or system must be activated only while the engine is not in
other coolant additives. operation. To enable automatic shutdown, the heating
system requires a connected 24 V DC signal.
11. Mix coolant according to your engine manufacturer’s
MAIN TB1 CUST.
recommendations. Refill cooling system with coolant. POWER 1-phase 3-phase
TORQUE
CONTROL
R or TB1 TORQUE

NOTE HOTSTART recommends using a 50% Line 1  L1 L1 if binding screw: Signal  A1 + 4.4 lbf ∙in
15 to 20 lbf ∙in (0.5 N ∙ m)
deionized or distilled water to 50% low- Line 2  – L2 (1.7 to 2.3 N ∙ m) Signal  A2 -
silicate antifreeze mixture. if box lug:
Line 3
 N L3 40 lbf ∙in
or N
(4.5 N ∙ m) Figure 3. Typical CSM
12. Start engine. Allow engine to run until engine ground terminal 6.4 lbf ∙ in model Style B (left) and
Ground 
thermostat opens, purging air from cooling system. or lug (0.7 N ∙ m) Style A (below), showing
NOTICE! Engine must be run to eliminate air from electrical connections.
heating system before energizing heater.
TB1

13. When engine has reached operating temperature,

TB1

shut engine off and check for coolant leaks. A1 A2

+ -
A1 A2
T1
L1 L2 L3
A1 A2
+ -
T1
14. Allow engine to cool. Check coolant level and top off L1 L2 L3
L1 N

R
as needed. 4 C1 2
TB2 A1 A2
T1 T2

3 11 2
K2

K1

F1 F2 F3
2A 2A 2A

TB2 A1 A2

installation instructions
HOTflow™ csm heater | page 3

3 11 2
 USER-SUPPLIED
PREVENTATIVE MAINTENANCE
N

MAIN
POWER IN
Annually:
L1
OR •• Check and replace cracked or weakened hoses.
K1 K1 K1 K1

••
FUSE
Check electrical wiring for wear and excessive heat.
24 V DC
(USER-SUPPLIED)
K2
RELAY
N/C •• Remove element and clean element and tank.
P SERIES
PARALLEL Every three years or 25,000 hours of operation:
K1 •• Replace control thermostat.
••
THERMOSTAT
Replace contactor.
USER-SUPPLIED
Figure 4. Typical CSM wiring
THREE-PHASEschematic without control transformer

(above) andL3 OR N
with controlONLYtransformer (below). See label attached to control THERMOSTAT & ELEMENT
POWER INbox lid for your specific wiring schematic.
MAIN
L2

L1 OR L
To replace the thermostat or clean tank: (See Fig. 5)
USER-SUPPLIED OR
FUSE FUSE K1 K1THREE-PHASE
K1 K1 K1 K1 1. Disconnect heater from power 3. Replace thermostat unit or
L3 OR N ONLY
source. Allow heating system clean tank:
MAIN
L2
CONTROL TRANSFORMER
to cool.
hh If replacing thermostat, loosen
POWER IN

L1 OR L
FUSE
OR
DELTA
2. Remove element assembly thermostat clip. Remove
K2
RELAY
FUSE FUSE K1 K1 K1 K1 K1 K1
enclosure cover: thermostat. Place new
24 V DC N/C
(USER-SUPPLIED)
hh If cleaning tank, unscrew thermostat in recessed space.
P
CONTROL TRANSFORMER
WYE
wiring enclosure screws to Tighten thermostat clip.
FUSE
K1 DELTA remove wiring enclosure. hh If cleaning tank, ensure
24 V DC
RELAY
THERMOSTAT
K2
Unscrew element plate screws. element O-ring is in place.
N/C
(USER-SUPPLIED)
Remove plate and element
P WYE
K1 K1
OR
K1 K1 from tank. 4. Reconnect electrical
connections. Reattach
K1 hh If replacing thermostat, enclosure, element plate,
disconnect terminals from
THERMOSTAT
O-rings and enclosure cover.
SERIES
thermostat sensing unit spade
OR
K1 K1
PARALLEL
K1 K1 connectors. 5. Reconnect heater to power
TROUBLESHOOTING source.

To ensure coolant is flowing, check the outletSERIES

temperature. ELEMENT O-RING
PARALLEL
If the coolant temperature along the return hose exceeds ELEMENT PLATE

140 °F (60 °C) or the pump produces a loud, rattling sound

during operation, it may indicate: ENCLOSURE O-RING

•• Air pockets are restricting flow. Air may collect due

to loops in hose, routing hose over the top of the
engine, excessive hose lengths, or kinks. Reroute TANK
hoses or change port locations. THERMOSTAT

•• Contaminants in the coolant are restricting flow. Flush ELEMENT

coolant system and refill.

ELEMENT PLATE
SCREWS

MAINTENANCE & PARTS WIRING ENCLOSURE

THERMOSTAT
CLIP

! CAUTION
ENCLOSURE COVER
Electrical hazard: Before wiring, servicing or cleaning
the heating system, turn off the power and follow your THERMOSTAT
CLIP Figure 5. Cleaning
organization’s lockout and tagout procedure. Failure to do element or replacing
so could allow others to turn on the power unexpectedly, thermostat (above)
resulting in harmful or fatal electrical shock. and thermostat/
CONTROL element wiring detail
Personal injury: If equipped with isolation valves, ensure THERMOSTAT
(left). Wiring and
valves are open before energizing heater. Obstructed flow SENSING
UNIT configuration may
may result in an unexpected release of heated coolant, vary.
potentially causing serious injury.

installation instructions
HOTflow™ csm heater | page 4