Circulating

Heating System

Installation & Operation Manual

216225-000 Rev 1
 HOTSTART, Inc.
P.O. Box 11245
Spokane WA 99211-0245

Customer Support: (509) 536-8660

NOTICE
When ordering replacement parts for your heating
system, always reference the heating system’s
Model Number and Serial Number.
 Important Safety Information

All electrical work must be done by qualified personnel in accordance

WARNING with the national electrical code and applicable state and local codes.

System can start automatically and without warning. Before wiring,

servicing, or cleaning the system turn off the power and install a
lockout on the heater circuits at the service panel.

Installers and operators of this equipment must be thoroughly

CAUTION 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.
Hot surfaces: avoid contact with the system while it is in
service—some surfaces may stay hot even if the system is not
energized. Use common sense when performing any
maintenance on this equipment.
Rotating equipment: system can start automatically and
without warning—avoid contact unless a lockout at the
service panel has been installed.

HOTSTART, Inc.

EAST 5723 ALKI AVENUE • P.O. BOX 11245

SPOKANE, WASHINGTON • 99211-0245 • USA
Phone: (509) 534-6171 • Fax: (509) 534-4216
 Note
This manual was prepared to assist you with the installation, operation, and maintenance of the
HOTSTART circulating heating system. We encourage you to use this manual and the attached
documentation in the appendix as your primary source of information about the heating system.
For additional information, contact:

HOTSTART, Inc.
P.O. Box 11245
Spokane, WA 99211-0245
Telephone: (509) 536-8660
Fax: (509) 534-4216

Please check the back of this manual for documents that include your system drawings, wiring
diagrams and replacement parts.

Identifying Your System

The HOTSTART heating system is a compact heating system designed for use in marine
propulsion, diesel-powered generator sets, gas compression, or any large-engine applications.
The system is pre-wired, pre-plumbed, and assembled on a steel plate and mounting channel.
Each heating system has an identification plate with the part number and serial number on it.
Please reference those numbers when ordering replacement parts.

NOTE: When ordering replacement parts, be sure to reference your heating system’s
model and serial numbers found on the identification plate.

Example label—actual label may vary slightly from model

to model, but the general layout is the same.

i
Warranty Information

The warranty below has been drafted to comply with the Federal Law applicable to products

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manufactured after December 31, 1976. This warranty gives you specific legal rights, and you
may also have other rights which vary from state to state.

HOTSTART products are warranted against defects in workmanship and materials. No other

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express warranty, written or oral, applies. No person is authorized to give any other warranty or
assume any liability except by written statement from an officer of HOTSTART, Inc.

The warranty extends for twelve months from date of shipment from factory or authorized
distributor.

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Products must be installed and maintained in accordance with HOTSTART, Inc. instructions.
Users are responsible for the suitability of the products to their application. There is no warranty
against damage resulting from corrosion, misapplication, improper specification or other

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operating conditions beyond our control. Claims against carriers for damage in transit must be
filed by the buyer.

Unauthorized alterations to factory supplied equipment voids this warranty. Consult the factory

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if modifications are required.

Absolutely no material can be returned to HOTSTART, Inc. without prior factory authorization.

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Upon factory authorization, return the defective part or product, freight prepaid, to: HOTSTART,
Inc., 5723 E. Alki, Spokane, WA 99212. Telephone (509) 534-6171; FAX (509) 534-4216.

Defective items will be repaired or replaced, at our option, at no charge. Such repair or

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replacements is the exclusive right of HOTSTART, Inc. HOTSTART, Inc. is not liable for labor
costs incurred in removal, reinstallation, or unauthorized repair of the product or for damage of
any type whatsoever including incidental or consequential damage. Some states do not allow the
exclusion or limitation of incidental or consequential damages, so the preceding limitation or

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exclusion may not apply to you.

HOTSTART, INC.

ii
Table of Contents
IDENTIFYING YOUR SYSTEM ................................................................................................ i

WARRANTY INFORMATION .................................................................................................. ii

INSTALLATION AND START-UP INSTRUCTIONS ......................................................... 1-1

Mounting .................................................................................................................... 1-1

Plumbing – Coolant Systems .................................................................................................... 1-2

Coolant Supply Line .................................................................................................. 1-2
Coolant Discharge Line ............................................................................................. 1-2
Coolant System Diagram…………………………………………………………... 1-3
Coolant Pressure Relief Valve …………………………………………………….. 1-4
Plumbing – Oil Systems ............................................................................................................. 1-5
Lube Oil Supply Line................................................................................................. 1-5
Lube Oil Supply Line Sizing Chart ........................................................................... 1-6
Lube Oil Discharge Line ............................................................................................ 1-7
Oil System Diagram ……………………………………………………………..... 1-7

SYSTEM CONTROLS.............................................................................................................. 1-9

System Components ....................................................................................................... 1-9
Main Power Supply.................................................................................................... 1-9
Pressure Switch Remote Control ............................................................................. 1-10
24 VDC Remote Control ......................................................................................... 1-11
PLC Control ....................................................................................................... 1-11
Optional 24 VDC Relay (Mechanical Systems) ................................................ 1-11

Heating System Start-Up PLC Controlled ................................................................ 1-12

Heating System Start-Up Mechanical Control.......................................................... 1-13

iii
SYSTEM OPERATION ............................................................................................................ 2-1
PLC Control Flow Detection......................................................................................... 2-1
Mechanical System Flow Detection .............................................................................. 2-1
Coolant Inlet/Outlet Process ......................................................................................... 2-2
Oil Inlet/Outlet Process ................................................................................................. 2-3
Operation (PLC Control) .............................................................................................. 2-4
Text Display ............................................................................................................... 2-5
Use of the Text Display ............................................................................................. 2-5
On/Off ........................................................................................................................ 2-5
System Temperatures ................................................................................................. 2-6
Set Temperature ......................................................................................................... 2-7
Operation (Mechanical Control) .................................................................................. 2-8

MAINTENANCE & TROUBLESHOOTING ........................................................................ 3-1

System Maintenance ...................................................................................................... 3-1
Control Box ................................................................................................................ 3-1
Plumbing Connections ............................................................................................... 3-1
Electrical Connections ............................................................................................... 3-2
System Mounting ....................................................................................................... 3-2
Magnetic Contactors .................................................................................................. 3-2
Heating Tanks ............................................................................................................ 3-3
Pump and Motor Assemblies ..................................................................................... 3-4
Motors ................................................................................................................. 3-4
Pumps ................................................................................................................. 3-5
Flow Rates ........................................................................................................... 3-6
Flow Detection Switch (Mechanical Controlled Systems) .......................................... 3-7
MPS Reset Buttons ........................................................................................................ 3-8
Heating Element Replacement & Element Thermocouple Replacement ................. 3-9
Re-assembly of Heating Element and Tank .............................................................. 3-10
PLC Controlled Systems (Tank Thermocouple Replacement) ............................... 3-11
PLC Control Troubleshooting .................................................................................... 3-12
Mechanical System Troubleshooting ......................................................................... 3-15

iv
 Installation and Start-Up Instructions

Hazardous Voltage:
WARNING Installation and maintenance should be performed only by personnel who
are technically competent and authorized to do so. National, state, and
local electrical and safety codes must be observed. Proper grounding is
required to avoid electrical shock hazard.

Mounting and Plumbing

Mounting

CAUTION Heavy equipment:

Proper rigging and safety equipment must be used to move this
equipment—weight is not centered. Plan ahead before attempting to move
this equipment.

Mount the heating system as low and as close to the suction port on the engine as possible. If the
system is a dual fluid system (coolant and oil), it should be mounted such that both suction line
lengths are minimized with priority given to the oil suction line. The use of elbows in the
suction line(s) should be reduced or eliminated if possible.

Note: Clearance is required for heating element removal—verify that sufficient clearance exists
before mounting heating system.

To avoid vibration related problems, properly vibration-isolate the

NOTICE heating system from the engine.

Section 1 Installation and Start-Up Instructions 1-1

Plumbing - Coolant Systems

Coolant Supply Line

Connect a 1.25 inch (32mm) I.D. or larger coolant supply line from the main coolant
drain of the engine to the inlet of the heating system as shown on the following page.

Coolant Discharge Line

Connect a 1 inch (25mm) or larger coolant return line from the outlet of the heating
system to the highest possible location on the engine coolant system opposite the main
coolant drain (see diagram on following page). This connection enables heated coolant to
be circulated through the entire engine. Additional lines may be needed to heat auxiliary
components.

Fill cooling system following engine manufacturer’s recommendations. Bleed air from the
heating system and top-off coolant.

Do not reduce the inlet line.

NOTICE
o Reducing the inlet line will result in pump damage
Position the heating tank so that it is completely full of coolant
while in operation.
o Failure to completely fill the heating tank with coolant will
result in element damage.
Prime the pump and fill the suction line before starting the system.
o Pump is not self-priming. Liquid must be present in the
pump before startup. Trapped air inside the pump will
cause pump and seal damage.
Follow engine manufacturer’s recommendations for coolant mixture.
o HOTSTART recommends using pre-mixed coolant. Do
not use tap water to mix with coolant—element damage
will occur.

Section 1 Installation and Start-Up Instructions 1-2

 Coolant System Diagram

NOTE: Upon completion of coolant line installation, top-off the coolant level to
compensate for the coolant used to fill the lines and heating tank. The
system should be configured with user supplied full flow ball valves in the
coolant lines allowing maintenance on the heating system without draining
the engine coolant.

Pressure and steam hazard: power must be turned

CAUTION off and locked out at the main service panel when
the ball valves are in the closed position. Failure
to do so may result in the release of pressurized
steam.
Open ball valves before operating system.

Section 1 Installation and Start-Up Instructions 1-3

Coolant Pressure Relief Valve
The system is equipped with a pressure relief valve that is pre-set to relieve at 90 psi.
Attach pipe that is sized to the outlet of the pressure relief valve and direct it toward a
safe area. When operating properly releases are rare, but it is recommended that a bucket
or other catch-basin be located under the release pipe to avoid damage to surrounding
items if a release occurs.

Pressurized steam hazard:

WARNING
Outlet must be plumbed to a safe
place in case an over-pressure
release of hot coolant occurs.

Coolant Pressure Relief Valve

P/N: PRP203018-000

Section 1 Installation and Start-Up Instructions 1-4

Plumbing - Oil Systems

Lube Oil Supply Line

Connect an oil supply line from the sump of the engine to the suction side of the heating
system.

If the heating system is mounted above the oil level, a full flow check
NOTICE valve must be installed in the suction port at or near the sump to
avoid losing the prime of the pump during system shutdown.

The sizing of the suction line is critical to the proper operation of the heating system.
The pump requires a maximum of 7.5 psi (15 inHg) suction lift. Several factors affect the
suction lift and must be addressed. These include: the height above or below the oil that
the pump is located, the viscosity of the oil, the size and configuration of the suction line,
and the altitude of the system (barometric pressure).
The suction line size can be determined using the following calculations (see chart
on following page):
1 - The flow rate of the pump is listed in the pump and motor assemblies section of this
manual. Determine the flow rate of the system using these values. The table on the
next page displays friction losses for smooth pipes at specified flow rates and lengths.
Use this table to determine the frictional losses in the intended suction line.
2 - Determine the height differential between the pump and the level of oil in the sump.
Multiply the number of feet by 0.38—this number will be negative if the pump is
below the oil level and positive if the pump is above the oil level.
3 - Establish the altitude above sea level where the system will be operating. For every
1000 feet above sea level, 0.5 psi will need to be added. For example: if the system
will be operating at 4000 feet above sea level, 2 psi of suction lift will need to be
added.
Add the three numbers together to determine the suction lift for the proposed setup. If
the number is greater than 7.5, do not use the setup—either increase the diameter of
the suction line, move the heating system closer to the sump, or lower the system to
decrease the suction lift as necessary to achieve a number less than or equal to 7.5 psi.

NOTE: Your system should be configured with user supplied, non-restrictive ball
valves in the oil lines allowing maintenance on the heating system without
draining the engine oil.

Section 1 Installation and Start-Up Instructions 1-5

 Oil Pump Suction Line Sizing Chart
(SAE 40 Motor Oil at 80° - 100°F)

2 – 3 GPM Friction Losses (psi) 7 GPM Friction Losses (psi)

Length (feet) Length (feet)
Line Size ID 5 6 7 8 9 10 5 6 7 8 9 10
0.75 in 4.0 4.8 5.5 6.3 N/A N/A N/A N/A N/A N/A N/A N/A
1 in 1.5 1.8 2.2 2.5 2.8 3.1 3.1 3.7 4.3 4.9 5.5 6.2
1.25 in 0.5 0.6 0.7 0.8 1.0 1.1 1.0 1.2 1.4 1.6 1.8 2.0
1.5 in - - - - - - 0.6 0.7 0.8 0.9 1.0 1.1

10 GPM Friction Losses (psi) 20 GPM Friction Losses (psi)

Length (feet) Length (feet)
Line Size ID 5 6 7 8 9 10 5 6 7 8 9 10
1 in 4.4 5.3 6.2 7.0 N/A N/A N/A N/A N/A N/A N/A N/A
1.25 in 1.5 1.8 2.1 2.4 2.7 3.0 2.9 3.4 4.0 4.6 5.1 5.7
1.5 in 0.8 1.0 1.1 1.3 1.4 1.6 1.6 1.9 2.2 2.5 2.9 3.2
2 in - - - - - - 0.6 0.7 0.8 0.9 1.0 1.1

25 GPM Friction Losses (psi) 30 GPM Friction Losses (psi)

Length (feet) Length (feet)
Line Size ID 5 6 7 8 9 10 5 6 7 8 9 10
1.25 in 3.6 4.3 5.1 5.8 6.5 7.2 4.4 5.3 6.2 7.0 N/A N/A
1.5 in 2.0 2.4 2.8 3.2 3.6 4.0 2.3 2.7 3.2 3.7 4.1 4.6
2 in 0.7 0.9 1.0 1.2 1.3 1.5 0.9 1.1 1.2 1.4 1.6 1.8
2.5 in - - - - - - 0.4 0.5 0.6 0.7 0.8 0.9

Section 1 Installation and Start-Up Instructions 1-6

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.

Oil System Diagram

NOTICE See engine manufacturer requirements for pre-lubing. HOTSTART

does not specify flow rates or pressure for pre-lube systems.
o Continuous pre-lube can cause oil to leak into the cylinders and
cause engine damage on startup.
Lube oil pump must be primed prior to startup.
o Failure to prime the pump will result in pump and/or seal
damage.
Open ball valves prior to operating system
o Failure to open valves will damage pump

Oil Pressure Relief Valve

The oil pump has an internal pressure relief valve that is pre-set to relieve into the inlet.
No adjustments should be necessary.

Section 1 Installation and Start-Up Instructions 1-7

System Controls

System Components
The control box contains the electrical control components for the heating system.
Following is an overview of operation for the standard parts located on the system,
including:
Main Power Supply
24 VDC PLC Remote Control
24 VDC Relay Control
Pressure Switch Remote Control
Parts in the control box may vary, depending on the particular system configuration
purchased.

Main Power Supply

Connect the specified power (+ or – 10% of the rated voltage) to the terminal blocks
located in the main control box. For 3-phase applications,
the terminal blocks are labeled L1, L2, and L3. For single
phase applications, use the terminal blocks labeled L1
and L3.
The main power ground wire must be connected to the
ground lug on the electrical panel located inside the
electrical box.
The main power supply operates the heating elements and
the circulating pumps. A transformer, used to operate the
control circuit, drops the main supply voltage to 120V.
The transformer and control circuits are overload
protected with fuses and/or a circuit breaker.

All wiring shall be done by qualified personnel

WARNING
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 electric shock.
Hazardous Voltage: A lockout must be used at
the main service panel when work is being
one inside the control box to avoid
electrocution.

Section 1 Installation and Start-Up Instructions 1-8

Pressure Switch Remote Control (optional)
Shown below are the pressure switches used on the different heating systems. These
switches must be connected to the pressure side of the engine oil—not the suction side.
When oil pressure drops due to engine shut down, the switch turns on the heating system;
when oil pressure rises from engine start-up, the switch turns off the heating system.

NOTE: Care should be taken not to connect this line too close to the discharge of
the oil heating system or the pressure created by the heating system’s oil
pump could shut the heating system down.

NOTE: On the explosion resistant (ER model) heating systems, the inlet fitting of
the pressure switch should never be turned when connecting the oil line.
Hold the hex nut fitting firmly when attaching the oil line.

Explosion Resistant Watertight Pressure Switch

Pressure Switch P/N: PRP224008-000
P/N: PRP224078-000

Section 1 Installation and Start-Up Instructions 1-9

24 VDC Remote Control
PLC Controlled Systems
For remote control operation on standard PLC controlled systems, connect a 24VDC
normally closed signal (24VDC supplied when engine is running) from the engine to the
PLC. Reference the control box wiring diagram in the back of the manual for connection
locations on the input side of the PLC. The PLC will shut off the heater when 24 volts is
applied and turn the heater back on when the voltage is removed.

CPU 222 P/N: PRP221035-002 Thermocouple Module

CPU 224 P/N: PRP221035-001 P/N: PRP221042-000

Mechanically Controlled Systems

Optional 24VDC Relay Control
For remote control operation, connect a 24VDC signal from the
engine to the 24VDC relay coil. The relay will shut off the heater
when 24 volts is applied and turn the heater back on when the
voltage is removed. Reference the control box wiring diagram in
the back of the manual for connection locations.

Mechanical 24V Relay

P/N: PRP224047-001

Section 1 Installation and Start-Up Instructions 1-10

Heating System Start-Up—PLC Controlled
Step 1 Check and tighten all electrical and plumbing connections.
Step 2 Check for proper rotation of the motor by quickly turning the system on and then
back off again while watching the motor shaft or fan. Single phase systems are pre-
wired to rotate the correct direction. For three phase systems: if the pump is not
rotating the correct direction; switch any two electrical leads at the power-in block. If
the system is a combination system (heats both coolant and oil), the two motors are
synchronized to turn the same direction; if one motor is turning the wrong direction, the
other will do the same. Switching the leads at the power-in block will change both
motors.
DO NOT RUN MOTOR/PUMP ASSEMBLY DRY
NOTICE MORE THAN A FEW SECONDS.
o Running a pump that is not completely filled with
liquid will cause damage to the seal

Step 3 The pumps MUST BE PRIMED. It is important to remove all trapped air in the
suction side of the system. If necessary, disconnect a fitting near the pump on the
suction line and fill with fluid. Bleed all trapped air from the pump prior to
energizing the system.
Pressurized steam hazard:
CAUTION
Open ball valves before energizing the system

Step 4 Energize the heating system by switching the power switch to the ON position or
pressing the ON/OFF button(s) on systems equipped with a text display. You should
be able to hear fluid moving through the lines. If not, loosen a fitting on the discharge
line of the pump to verify flow.
Step 5 The heating system pump will run for three minutes while initializing the PLC before
the heating element will energize. If the system does not detect flow after the heating
element energizes, it will turn the heating element off and indicate an error by either
flashing the control box pilot light, or if your system is equipped with a Text Display,
this error will be indicated on it. To clear this error, turn the system off, re-prime the
pump and check for leaks in the suction line. Verify that all isolation valves are open
and turn the system back on again. The heating system will repeat the initialization
process and flow check.
Step 6 Once flow has been established and the heating element has turned on for the first time,
the system will run automatically and maintain the fluid at the set temperature. If your
system is equipped with a Text Display you can scroll to Temperatures. This will
indicate the temperature of the fluid going into and out of the heating tank. If the
temperature at the outlet of the tank is a few degrees higher than the temperature at the
inlet, this will indicate the element is heating.
Note: If the fluid is lower than 30°F below set temperature, a Low Temp error will be
indicated. This is normal. When the heating element comes on and heats the
fluid above this temperature, the error will clear itself.

Section 1 Installation and Start-Up Instructions 1-11

Heating System Start-Up—Mechanical Control
(24 VDC Relay or Pressure Switch)

Step 1 Check and tighten all electrical and plumbing connections.

Step 2 Check for proper rotation of the motor by quickly turning the system on and then
back off again while watching the motor shaft or fan. Single phase systems are pre-
wired to rotate the correct direction. If the pump is not rotating the correct direction;
switch any two electrical leads on three phase systems at the power-in block. If the
system is a combination system, the two motors are synchronized to turn the same
direction; if one motor is turning the wrong direction, the other will do the same.
Switching the leads at the power-in block will change both motors.

DO NOT RUN MOTOR/PUMP ASSEMBLY DRY

NOTICE MORE THAN A FEW SECONDS.
o Running a pump that is not completely filled with
liquid will cause damage to the seal

Step 3 The pumps MUST BE PRIMED. It is important to remove all trapped air in the
suction side of the system. If necessary, disconnect a fitting near the pump on the
suction line and fill with fluid. Bleed all trapped air from the pump prior to
energizing the system.

Pressurized steam hazard:

CAUTION
o Open ball valves before energizing the system

Step 4 Energize the heating system by switching the power switch to the ON position.
You should be able to hear fluid moving through the lines. If not, loosen a
fitting on the discharge line of the pump to verify flow. If the minimum flow
rate is not achieved, or flow restriction in the suction line has occurred, the
heating system will automatically shut down approximately 3 minutes after
start-up. Turn the system OFF and check plumbing lines for any leaks or
restrictions. Repeat steps 2, 3, and 4.

NOTE: On initial start-up, it may take several attempts to achieve proper flow.

Step 5 Once operation is satisfactory; turn the control knob on the system time delay
relay to the desired setting. Kim Hotstart recommends a setting of 30 seconds.
Turn the heating system off and then back on to activate the new setting.

Section 1 Installation and Start-Up Instructions 1-12

 System Operation

PLC Control—Flow Detection

The PLC based heater uses temperature variation from one end of the tank to the other to verify
that there is flow when the heating element is on. Flow direction is not the same in all systems.
Reference the flow direction arrows on the heating tank to determine the direction of flow for
your system.
When the heater is turned on, the pump starts and the PLC initialization process begins. During
initial start up it is important to verify that the fluid is flowing to prevent pump damage. The
pump runs for three minutes before the heating element is allowed to turn on. This provides time
for the pump to circulate the fluid and establish a constant temperature in the fluid. The PLC then
calibrates the thermocouples as part of the initialization process.
Note: To verify that there is flow; loosen a fitting on the discharge line.
At the end of the three minutes the heating element will turn on if the temperature of the fluid is
lower than the set operating temperature. If the fluid is flowing correctly and the element is on,
the PLC will determine a temperature variation from one end of the tank to the other. The heating
process will continue.
If it is not flowing correctly then the PLC will indicate an error by flashing the pilot light on the
front of the control box or indicate an error on the text display. It will also shut off the heating
element to prevent damage to it. If there is a flow error it is important to determine the cause
and correct it to prevent pump damage. Do not leave the pump running if there is a flow
error.
Following a flow error correction (i.e. - valves closed, hose kinked, pump not primed), turn the
heater off and then back on. This will reset the PLC and restart the initialization process.

Mechanical System—Flow Detection

Following the inlet and circulation through the heating tank, the fluid passes through a flow
detection switch, which immediately shuts off the heating element anytime there is an
interruption or loss of flow, and activates the time delay relay located inside the control box. The
pump continues to circulate the fluid to restore flow.
If proper flow is not reestablished, the time delay relay shuts down the entire heating system
according to a preset time. The time delay relay is adjustable from 0 - 180 seconds. Upon an
initial system start-up, the time delay relay should be adjusted to the maximum of 180 seconds.
Once flow is achieved, Kim Hotstart recommends a setting of 30 seconds. To activate a new
setting, the heating system must be turned off and then turned back on.
This automatic system shut down feature protects the heating element and other major
components from damage. Upon a system shut down, the heating system must be reset. To reset,
turn the system off and then back on again.

Section 2 System Operation 2-1

Coolant Inlet/Outlet Process
Upon energizing the system, engine coolant, taken from the coolant drain area in the
lower section of the engine, is circulated through the heating tank via a centrifugal pump.
Coolant then passes through a check valve or optional solenoid valve, which limits
coolant backflow while the engine is operating. Finally, heated coolant is returned to the
back top of the engine at its optimum starting temperature.
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 thermostat to maintain the
temperature.

Section 2 System Operation 2-2

Oil Inlet/Outlet Process
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.

See engine manufacturer requirements for pre-lubing. HOTSTART

NOTICE does not specify flow rates or pressure for pre-lube systems.
Continual pre-lubing can cause permanent engine damage. Consult
the 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 thermostat to maintain the
temperature.

Section 2 System Operation 2-3

Operation (PLC Control)
PLC stands for Programmable Logic Controller. It has a program written and installed
into its permanent memory that uses inputs and outputs to control the heating system and
provides signaling and diagnostics of failures.
The system inputs are from the switches or a text display on the front of the control box,
a remote start/stop signal, motor protective switches, and temperatures from
thermocouples in the heating tank. Its outputs include the pump motors, heating elements
and pilot lights or text display.
The LED’s on the PLC indicate which inputs and outputs are functioning at any given
time, as well as error signaling.
A new program can be installed in the PLC by using an E-prom chip that plugs into the
top of the PLC. By cycling power off and on after plugging the e-prom chip in, the
program is replaced.

Section 2 System Operation 2-4

Text Display
For systems using the Text Display:
If the system is equipped with a text display it serves several purposes:
On/off control for the heating system
System status and system temperatures.
If an error occurs it lists the error on the display.
The text display also allows the user to set the operating temperature.

Use of the Text Display

Text Display
P/N: PRP221044-000

The photos shown are for a combination system, if your system is a single fluid
system, only the appropriate information is shown.

On/Off
If the system is equipped with a text display the ON / OFF keys toggle from ON to OFF
and control the coolant and oil heating systems independently. When an ON button is
pushed the text display shows the system status as “ON”. When it is pushed again it
shows the status as “OFF”.
Pushing the arrow keys scrolls from one window to the next. You can scroll either up or
down to get to the desired window.

Section 2 System Operation 2-5

System Temperatures
To read the system temperatures simply scroll to the window displaying the
temperatures. The two temperatures displayed are the inlet temperature and the
outlet temperature. The inlet temperature is the temperature at the inlet of the
heating tank. This is the temperature of the fluid as it comes out of the engine.
This is the minimum temperature of the engine and the temperature that cycles the
heating element. The outlet temperature is the temperature at the outlet end of the
heating tank and is used to determine that there is flow in the heating tank. When
the heating element is on and there is flow through the tank the outlet temperature
will be a few degrees higher than the inlet temperature.

Text Display Text Display

Coolant Temperature Oil Temperature

Error Codes
The window that lists “ERROR” will show “NO ERRORS REPORTED” if there are no
errors. If the system detects an error it will display it on the second line of that window.
To clear the error after making appropriate repairs or changes, turn the system off and
back on again. If the error is still displayed, it has not been fixed. Some errors will not
occur until the heating element has turned on. The pump will run for three minutes before
the heating element will turn on. The heating element will not turn on for the first time
until the inlet temperature is 10 degrees below the set temperature. Error codes are listed
on the next page. The three previous error codes are listed at the top right of this window.
The most recent error is on the left. Some errors will clear themselves. After they have
cleared they will only show on the top line as previous errors.

Text Display Coolant Errors

Text Display Oil Errors

Section 2 System Operation 2-6

Set Temperature
The “SET TEMPERATURE” window provides the opportunity for the user to change the
operating temperature of the systems. The default is set at 120°F for the coolant system
and 100°F for the oil system. To change the pre-set temperature; scroll to the appropriate
window and press “ENTER”. There will be a flashing cursor on the far right character in
the display. To increase the set temperature; press the up arrow, holding the button down
will cause it to continuously increase. To decrease the set temperature, use the down
button. When the desired temperature is displayed, press the “ENTER” button again to
set the temperature. The temperatures can only be set between the limits shown on the
display, coolant 60 – 160°F and oil 80 – 140°F. The set temperature will be stored and
used until it is changed again. Turning the system off or powering down will not change
these settings.

ERROR CODE TABLE

Code Description
1 Heating Element
2 Differential Temp / Lack of Flow
3 Low Temperature
4 Over Temperature
5 Thermocouple Open / Short
6 Motor Protective Switch Tripped
7 Thermocouple Range
8 Thermocouple Module / Power

An error is indicated when the pilot light or PLC flashes the above number of flashes
followed by a three second pause. This repeats until the error is resolved and the system
is restarted. The text display indicates the code numbers of the three most recent errors.
The code numbers are displayed from left to right with the most recent error code number
on the left.

Section 2 System Operation 2-7

Operation (Mechanical Control)
When the heating system is turned on the pump motor runs; continuously circulating
warm fluid through the engine and back to the heater.
The heating element is controlled by a thermostat, which cycles on and off to maintain
the set temperature. The standard thermostat in coolant systems turns on at 100°F and off
at 120°F, while oil systems turn on at 80°F and off at 100°F. Other thermostats are
available.
Following the inlet and circulation through the heating tank, the fluid passes through a
flow detection switch, which immediately shuts off the heating element anytime there is
an interruption or loss of flow and activates the time delay relay (shown below) located
inside the control box. The pump continues to circulate the fluid to restore flow.
If proper flow is not reestablished, the time delay relay shuts down the entire heating
system according to a preset time which is adjustable from 0 - 180 seconds. Upon an
initial system start-up, the time delay relay should be adjusted to the maximum of 180
seconds. Once flow is achieved, HOTSTART recommends a setting of 30 seconds. To
activate a new setting, the heating system must be turned off and then turned back on.
This automatic system shut down feature protects the heating element and other major
components from damage. The time delay relay and flow detection are discussed in more
detail in the System Components section of this manual.

Time Delay Relay

P/N: PRP224046-000

Section 2 System Operation 2-8

 Maintenance and Troubleshooting
System Maintenance
The following maintenance procedures are provided to ensure trouble-free operation of
your heating system:
• Control Box
• Plumbing Connections
• Electrical Connections and Contacts
• Heating Tanks/Elements
• Pump & Motor Assemblies
• System Mounting

HAZARDOUS VOLTAGE:
WARNING
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, WHICH MAY CAUSE FATAL ELECTRICAL
SHOCK.

Control Box
Periodically check gaskets for proper seals.
Check the control box for moisture (if necessary, add desiccant packets).

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.

Section 3 Maintenance and Troubleshooting 3-1

Electrical Connections
Excessive vibration will eventually cause terminals to loosen. Tighten at startup
and check again in a week. Periodically tighten all electrical connections every 3
months.

System Mounting
Excessive vibration may cause mounting bolts to loosen. Periodically check and
tighten all mounting bolts.
Air must be evacuated from the system prior to starting or re-starting.

Magnetic Contactors
Definite purpose magnetic contactors are used as voltage
switching controls in Kim Hotstart Heating Systems. The
contactors use 120 volt coils. To test for failure, take an Ohm
reading of the magnetic contractor’s coil winding and compare
it to a known good unit.
The contactor contacts are made of silver cadmium oxide and
should be inspected periodically for welding, arc erosion, and
mechanical wear. If any of these conditions exist, clean the
contacts or replace the contactor. Magnetic Contactor
30 Amp P/N: PRP232047-000
60 Amp P/N: PRP232049-000

Section 3 Maintenance and Troubleshooting 3-2

Heating Tanks
At least once per year, clean the interior of the heating tank and the heating element
with a wire brush and/or damp cloth. Periodically check the element for sediment
build-up around the element loops. Any scaling or build-up will shorten element life.
Maintenance and replacement procedures for the heating element are described in
System Components of this manual.
Following lengthy system shut downs, remove the terminal covers of the element
assembly as shown in System Components and check for any moisture or
condensation. Electric tubular heating elements contain a granular refractory material
called magnesium oxide (MGO) to insulate the resistor coil from the outer metal
sheath. MGO is hygroscopic, which means it has the ability to absorb moisture from
the air. MGO contaminated with moisture reduces the insulating value of the MGO
which is measured with an Ohm meter by connecting one leg of the meter to the
element and the other leg to ground. It is read as resistance in the meg-Ohms range
(1 meg-Ohm = 1 million Ohms = 1M Ohms). Low resistance (less than 1M Ohms) is
a transient condition experienced on first heat-up under normal periodic heater usage.
Moisture absorption under normal conditions does not affect heater efficiency or life.
The minimum required resistance value is 1.0M Ohms for full power voltage
operation. However, heating elements with a moisture barrier sealant such as RTV
silicone or epoxy potting will require a minimum value of 5.0M Ohms. Resistance
values should be measured with an Ohm meter by applying one lead to the
termination and the other to ground. When the heater does not meet the required
resistance value, the unit will have to be dried out prior to full power operation.
If the heater has 0.1M Ohms (100K Ohms), or better, but less than 1M Ohms, the
heater should be operated at half the rated voltage for 30 minutes to dissipate the
accumulated moisture. Disconnect the power after 30 minutes and check the
resistance. An alternative to applying voltage is to manually dry the heaters in an
oven at 300°F for 4 hours then check its resistance again.
If the resistance is higher than it was originally, repeat the process until the value
reaches the minimum requirement of 1M Ohms. The heater can then be operated at
full rated voltage.

Section 3 Maintenance and Troubleshooting 3-3

Pump and Motor Assemblies

HAZARDOUS VOLTAGE: Disconnect power and

WARNING lock out at the service panel before working on the
pump or motor.
Motors with automatic thermal protectors will
automatically restart when the protector cools.
Explosion resistant motors should only be
disassembled by an authorized service station.

Motors

Two different types of motors are used: one uses sealed bearings and the other ball
bearings. Sealed bearings require no maintenance. For ball bearing motors, lubricate
fittings according to the following directions:
NOTE: These instructions pertain to Baldor motors only. If the system is equipped
with another brand of motor, please consult the manufacturer for proper
lubrication. If lubrication instructions are shown on the motor nameplate, they
will supersede this general instruction.
Motors are pre-greased with polyurea mineral oil NGLI grade 2 type grease unless
otherwise stated on the motor nameplate. Some compatible brands of polyurea
mineral base type grease are: Chevron SRI #2, Rykon Premium #2, Shell Oil Dolium
R, or Texaco Polystar RB.

Motors are properly lubricated at the time of manufacture. It is not necessary to

lubricate at the time of installation unless the motor has been in storage for a period
of 12 months or longer.

Re-lubrication

Motors that have re-greasing provisions need to be serviced every year for 1800RPM
or less, or every 3 months for all motors rated above 1800RPM. The typical volume
of grease is 0.25 in3 (0.14 fluid oz.) for NEMA frame size 140 and 0.50 in3 (0.28
fluid oz.) for NEMA frame size 180.

Section 3 Maintenance and Troubleshooting 3-4

Pumps

HAZARDOUS VOLTAGE: Disconnect power and lock out

WARNING at the service before working on the pump or motor.
Motors with automatic thermal protectors will automatically
restart when the protector cools.

HOT LIQUID: Contents within the pump or liquid chamber

may be hot. Allow system to cool for several hours prior to
servicing.

Before opening any liquid chamber (pumping chamber, reservoir,

relief valve adjusting cap fitting, etc.). Be sure:
1. That any pressure in the chamber has been completely vented
through suction or discharge lines or other appropriate openings
or connections.
2. That the system has been locked out at the service panel.
3. That you know what liquid the pump has been handling and the
precautions necessary to safely handle the liquid. Liquid in the
pumping chamber and hoses may be hot, make sure that the
necessary precautions are taken to avoid serious injury.

Pumps - replace seals and gaskets as required. Seal life is very difficult to estimate
due to a variety of controlled and uncontrolled conditions the seal operates in. Pump
seals by nature will weep some even when new.
The mechanical seal faces cannot be operated in a dry environment. Some liquid
must pass between the rotating and stationary face in order to minimize friction and
to carry away the heat generated. If this leakage evaporates when reaching the
atmosphere, then there is no visible leakage. If it doesn’t, leakage in the order of a
few drops per day might be the best achievable. Some seal manufacturers rely on
high face loading to minimize leakage but at the expense of seal longevity. Others
do the opposite, which provides longer life but greater leakage.
Field installation of the seals is not as exact a procedure as is possible when this is
done in a factory environment with experienced assemblers. It is possible to
experience some minor leakage on field installed seals. Excessive leakage can also
be an early indication of seal failure, warning of the need for impending
maintenance. Before installing, repairing, or performing maintenance on pumps,
read and understand the pump’s instructions completely.
Undersized, long or restricted suction plumbing will cause pump seals to leak. This
creates an excessive vacuum in the seal chamber which separates the seal faces and
allows fluid to leak past the seal.

Section 3 Maintenance and Troubleshooting 3-5

Flow Rates

Standard Pump Flow Rates and Motor Hp

Oil Pumps
Wattage (kW) GPM Hp
2.5 2.8 1
6 10 1
9-12 20 2

Coolant Pumps
9-36 40 3/4

*Note: For 50Hz systems, flow is decreased to 83% of the 60Hz systems shown

Section 3 Maintenance and Troubleshooting 3-6

Flow Detection Switch (Mechanical Controlled Systems)
Inspect the flow detection (flow control) switch periodically for foreign buildup on
the shuttle body. To clean the flow detection switch, follow these steps:
Step 1 Shut OFF fluid supply to the heating system.
Step 2 Remove the bonnet nut and lift out the entire
switch assembly.
Step 3 Remove accumulated sediment from the switch
body with a damp cloth.
Step 4 Check the switch for proper operation by sliding
the shuttle and magnet up over the main shaft as
shown below. If the shuttle hangs up or does
not slide smoothly, remove the lock ring from
the bottom of the switch assembly and slide the
shuttle, magnet and spring off.
Explosion resistant
Step 5 Remove foreign matter and rough spots from P/N: PRP224033-200
the shaft with denatured alcohol. Watertight P/N:
PRP224033-000
Step 6 Reassemble the switch and check it again for
proper operation (reference step 4).
CAUTION: Extreme care must be taken
during the next step to avoid Bonnet Nut
electrocution. Do not touch
any of the components inside
any of the electrical enclosures
during this test. Switch Body

Step 7 To test operation of the switch

assembly, turn ON the main power.
When the magnet on the shuttle is slid
up the shaft, the magnetic contactor that
operates the heating element should Tension Spring

close.
Magnet
CAUTION: When testing the flow switch, do
not operate the heating system
Plunger Body
longer than 5 seconds or damage
to the heating element may Lock Ring
occur.
Step 8 Once the switch assembly is working Base
properly, reassemble the flow switch flwdect2.ai

and set the time delay relay to the

desired setting. The recommended
setting is 30 seconds.

Section 3 Maintenance and Troubleshooting 3-7

MPS Reset Buttons
Both the NEMA 12 and the Explosion Resistant model control boxes contain motor
protector switches to safeguard against overloads and short-circuits.
On an Explosion Resistant model, press the RESET button on the control box’s lid to
reset the motor protector switch (inside the control box).
On a NEMA 12 model, it is necessary that you open the control box to reset the motor
protector switch:
BUTTON POSITIONS
1. Check the position of the Motor Protective
Switch NEUTRAL
NORMAL
green START and the red 1 3 5 Switch tripped if both buttons are up
STOP RESET buttons on the L1 L2 L3 TE
ST
TE
ST

S
TEST

S
motor protector switch. In

TA
TA

R
R

T
T
START

S ES
S ES

TO E
TO E

R
(GREEN)

R
normal operation the red

P T
P T
STOP
STOP RESET button is up RESET
(RED)

and the green START button T1 T2 T3

is down. 2 4 6 TO RESET THE SWITCH

1. Press red STOP RESET button.
2. If both buttons are up, the
switch has been tripped. To TE
ST
2. Press the green START button.

S
TA
reset, first press the red STOP

R
T
S ES
TO E
R

P T
TE

RESET button and then press ST

S
TA
R
T
S ES
TO E
the green START button. The

P T
switch is reset. resetsw.eps

MPS Part Numbers

Amp Rating (Range) Part Number

0.6 – 1.0 PRP232036-000
1.0 – 1.6 PRP232036-001
1.6 – 2.5 PRP232036-002
2.5 – 4.0 PRP232036-003
4.0 – 6.3 PRP232036-004
6.3 – 10.0 PRP232036-005
10.0 – 16.0 PRP232036-006

Note: The current draw on the MPS must be set to within 10% of the motor’s FLA (Full
Load Amp) rating. Failure to set the MPS properly can result in the premature failure of
the motor.

Section 3 Maintenance and Troubleshooting 3-8

Heating Element Replacement & Element Thermocouple Replacement
To replace the heating element or perform routine maintenance, follow these steps. 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.

WARNING
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, WHICH MAY CAUSE FATAL ELECTRICAL SHOCK.

Step 1 Turn the heating system OFF and lock out at the service.
Step 2 Drain the fluid from the heating tank.
Step 3 Remove the cap from the
heating element.
Ground
Step 4 The wire connections (Green)
inside the cap of the
heating element
correspond to one of the Element Thermocouple
phase configurations (PLC Only)
shown on the following
page. Note your unit’s
phase configuration.
Jumper
*Replacement elements
can be a different phase
configuration. Wire Thermo,Cup v1.eps
replacement elements to
the cup washers on the replacement element studs.
Remove the ground (green) and power electrical wires from the posts inside the
cap.
Step 5 On PLC controlled systems, remove the thermocouple from the heating element
burr after removing compression fitting nut. See Step 4 of Thermocouple
Replacement.
Step 6 Remove the conduit conductor and electrical wires from the heating element.
Step 7 Remove the V-clamp to remove the heating element from the heating tank as
shown on the next page.
Step 8 Replace the heating element or perform the necessary cleaning procedure.
Ensure the O-ring is in place.

Section 3 Maintenance and Troubleshooting 3-9

Re-assembly of Heating Element and Tank
To reassemble the heating element and tank,
follow the steps listed on page 3-8 in reverse Cap
order. Make sure the ground and power electrical
wires are properly reconnected using the washers,
Heating Element
cup washers and nuts supplied (please note Wattage Information
diagram at bottom of page). Replace
Thermocouple using the old thermocouple and
compression fitting or replace with a new one.

Heating
Element

V-Clamp

O-Ring

Tank

elmntre.eps

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

Section 3 Maintenance and Troubleshooting 3-10

PLC Controlled Systems
(Tank Thermocouple Replacement)
One of the system thermocouples is located inside the thermocouple housing at the end of
each heating tank as shown below. To replace this thermocouple, follow the steps listed
below.

Thermocouple P/N: PRP224066-001

Compression fitting P/N: PRP218068-001

WARNING
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, WHICH MAY CAUSE FATAL ELECTRICAL SHOCK.

Step 1 Remove the cover of the service entrance enclosure.

Step 2 Disconnect the thermocouple wires in the control box at the thermocouple
module.
Step 3 Attach a string to the end of the thermocouple wires where they were removed
from the thermocouple module. Then pull the wires and the string out of the
conduit at the service entrance. The string will provide a way to pull the new
thermocouple wires through the conduit back into the control box.
Step 4 Loosen the nut on the compression fitting that is holding the thermocouple in
place. The nut can be loosened using a deep offset box wrench or a deep socket.
Run the end of the wires, removed at the thermocouple module, through the
wrench or socket and slide it down onto the nut. If a socket is used, put Vise
Grip Pliers on the top of the socket to turn it (the wires go through the drive
hole).
Step 5 Pull the thermocouple out of the compression fitting, if you plan to re-use the
thermocouple, save the nut and compression fitting on the thermocouple. If not,
replace the compression fitting as well as the thermocouple.
Reassemble in reverse order making sure that the wire end of the thermocouple extends
1/4 inch above the compression fitting.

Section 3 Maintenance and Troubleshooting 3-11

PLC Control Troubleshooting
PLC (programmable logic controller) controlled heating systems indicate some of the
most common errors, either on the text display, or with a flashing light on the control box
lid. If more than one error exists at the same time, only the last error will show on the
display. The three previous codes will be listed at the top right of the text display.
The following Code Numbers and Descriptions are provided to indicate the type of error:
ERROR CODE TABLE
Code Description
1 Heating Element
2 Differential Temp/Lack of Flow
3 Low Temperature
4 Over Temperature
5 Thermocouple Open/Short
6 Motor Protective Switch Tripped
7 Thermocouple Range
8 Thermocouple Module/Power
Error is indicated when the Text Display reads out the error and the pilot light or PLC
light flashes the above number of flashes followed by a three second pause. Repeats until
repaired and system restarted.

Section 3 Maintenance and Troubleshooting 3-12

 PLC System Troubleshooting
Code Error Code Description Possible Causes Solutions
Check element for continuity,
1 Heating Element Heating element failure
replace if necessary.
Check all element fuses for
Element fuses failed continuity and replace as
necessary
Heating element Check contacts and coil.
contactor failure Replace if needed
Differential Temp / Lack of Bleed all trapped air from
2 Pump not primed properly
Flow lines

Isolation valves may be closed Open valves

Hose kinked or mashed Remove obstruction

Leak in suction line Repair leak

Pump motor turning Reverse any two leads on

backwards power in (3 phase systems)
Motor protective switch Check and reset, if problem
tripped happens again check motor
Heater has been turned off, Allow time for heater to heat fluid.
3 Low Temperature
fluid is cold Error will clear automatically.
Check elements for continuity
Heating element failure
and replace if needed
Check contacts and coil.
Contactor failure
Replace if needed
Check fuse and replace if
Blown fuse
needed
Shut system down and restart
Could be a result of another watch for other errors.
error below: Only the last error will be
displayed
Motor protective switch Check and reset, if problem
tripped happens again check motor
Check contacts and coil
Motor contactor failure
replace if needed
Motor failure Check and replace if needed

Section 3 Maintenance and Troubleshooting 3-13

 PLC System Troubleshooting (cont.)
Code Error Code Description Possible Causes Solutions
Check Thermocouple and
4 Over Temperature Thermocouple failure
replace if necessary
Check contacts and coil
Motor contactor failure
replace if needed
Motor failure Check and replace if needed
Shut system down; allow
cooling to normal temp and
restart.
Could be a result of another
error below Original error should be
displayed first before high
temp error, if caused by
another error.
Check for "Differential temp /
Pump not primed properly
lack of flow error", see above
Isolation valves may be closed Open isolation valves
Hose kinked or mashed Repair or replace
Leak in suction line Repair
Pump motor turning Reverse any two leads on
backwards power in (3 phase systems)
Check thermocouple and
5 Thermocouple Open / Short Thermocouple failure
wiring replace if needed
Check and reset, if problem
Motor Protective Switch happens again check motor
Motor Protective Switch Tripped and wiring
6
Tripped
Motor overload, warm oil by
Cold oil
other means, then restart
Replace with original
7 Thermocouple Range Improper thermocouple used
equipment parts only
Thermocouple Module / Power to thermocouple Check wiring from PLC to
8
Power module lost thermocouple module
Red lights on thermocouple
Thermocouple module failed module indicate a failure, check
wiring, replace if needed

Section 3 Maintenance and Troubleshooting 3-14

 Mechanical System Troubleshooting
Symptoms Possible Causes Solutions
Bleed all trapped air from
Pump not primed properly
lines
Isolation valves may be closed Open valves
Hose kinked or mashed Remove obstruction
Lack of Flow Leak in suction line Repair leak
Reverse any two leads on
Pump motor turning backwards
power in (3 phase systems)
Check and reset, if problem
Motor protective switch tripped
happens again check motor
Allow time for heater to
Heater has been turned off, fluid is cold
heat fluid
Check elements for
Heating element failed continuity and replace if
needed
Check all element fuses for
Element fuses failed continuity and replace as
necessary
Check contacts and coil.
Element contactor failed
Low Temperature Replace if needed
Check and reset, if problem
Motor protective switch tripped
happens again check motor
Check contacts and coil
Motor contactor failed
replace if needed
Check and replace if
Motor failed
needed
Check and replace if
Thermostat failed
needed
Flow switch shut down See lack of flow above
Check contacts and coil
Motor contactor failure
replace if needed
Check and replace if
Motor failure
needed
Check for "Differential temp
Pump not primed properly / lack of flow error", see
above
Over Temperature Isolation valves may be closed Open isolation valves
Hose kinked or mashed Repair or replace
Leak in suction line Repair
Check and replace if
Flow switch failed
needed
Check and replace if
Thermostat failed
needed
Check motor and wiring,
Motor or wiring short circuit
Motor Protective Switch replace if needed
Tripped Motor overload, warm oil by
Cold oil
other means, then restart

Section 3 Maintenance and Troubleshooting 3-15