Hotstart HOTflow User manual

INSTALLATION INSTRUCTIONS
HOTow™ HEATER
CKM MODEL
Corporate & Manufacturing
Headquarters
5723 E. Alki Ave
Spokane, WA 99212 USA
509.536.8660
[email protected]
Oil & Gas Ofce
21732 Provincial Blvd.
Suite 170
Katy, TX 77450 USA
281.600.3700
[email protected]
Europe Ofce
HOTSTART GmbH
Am Turm 86
53721 Siegburg, Germany
+49.2241.12734.0
[email protected]
Asia Pacic Ofce
HOTSTART Asia Pacic Ltd.
2-27-15-4F Honkomagome
Bunkyo-ku, Tokyo
113-0021, Japan
+81.3.6902.0551
[email protected]
| PAGE 1
INSTALLATION INSTRUCTIONS
HOTow™CKM HEATER
CUSTOMER SERVICE:509.536.8660
[email protected] |www.hotstart.com
Read carefully for proper
installation and operation.
Hotstart Manufacturing, Inc. is the owner of
all trademarks and copyrightable material
contained herein; all rights are reserved;
no form of reproduction is authorized
without prior written consent from Hotstart
Manufacturing, Inc.
216326-000 rev0
A. Suction port
B. Discharge port
C. Power in wiring
entrance
D. Element assembly
E. High-limit thermostat
with manual reset
(in element assembly)
F. Air release valve
G. Control thermostat
(in enclosure)
H. Pump/motor
IOM216326-000 rev0
F
G
A
C D
H
E
B
Figure 1. Typical CKM model. Style and

BEFORE YOU INSTALL
HOTow™ 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 HOTow™ CKM heater preheats your engine effectively.
DANGER
!
Personal injury: This product generates heat during operation. Operation of
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 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).
Hazardous voltage: Before wiring, servicing or cleaning the heating
system, turn off the power and follow your organization’s lockout and
tagout procedure. Failure to do so could allow others to turn on the power
unexpectedly, resulting in harmful or fatal electrical shock.
CAUTION
!
Electrical hazard: Power source must be properly grounded and in
accordance with national and local electrical codes. A user-supplied circuit
breaker (rated at the appropriate amperage) is required for use in the main
power feed line. Do not connect heater prior to installation.
NOTICE
Read instructions carefully: The HOTSTART warranty does not cover any damage that a heating system may sustain from
improper installation, improper operation, improper specication 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 specied
by the manufacturer, the protection provided by the equipment may be impaired. All applicable electrical safety standards
dened by local jurisdictions must be followed. (Reference EU directive 2006/95/EC in EU countries.)
Check valve: HOTSTART recommends installing a customer-supplied swing-type or full-ow check (non-return) valve to
prevent coolant from owing backward through the heating tank during engine operation. Allowing coolant to ow backward
may result in pump damage.

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INSTALLATION INSTRUCTIONS
HOTow™CKM HEATER
INSTALLING THE HEATER
PREPARE COOLANT SYSTEM
1. Drain and ush cooling system to remove any debris
present in the engine’s cooling system.
SELECT PORTS
2. Select return port. The return port will allow heated coolant to
return to the engine. See Fig 2 on following page. Select the
return port using the following guidelines:
• return port must be located on the same side of the
engine as the intended heater mounting location
• return port must be located away from the engine
thermostat
• return port should be located toward the rear (ywheel) of
the engine
• return port should be located away from the supply port
3. Select supply port. The supply port will allow coolant
to ow from the engine to the heater. See Fig 2 on
following page. Select the supply port using the
following guidelines:
• Supply port may be located on the same side or opposite
side of the engine as the intended heater location
NOTE: For V-type engines, it is acceptable to
select a supply port on the opposite side
of the engine as long as the supply hose is
routed properly. See PLUMB HEATER.
• Supply port must be located at the lowest point of the
engine’s water jacket
• Supply port should be located toward the front (radiator)
of the engine
• Supply port should be located away from the return port
SELECT HOSE, FITTINGS & VALVES
4. Select ttings. CKM minimum port size tting:
• 3/4 inch NPT (20 mm)
5. Select hoses. CKM minimum hose inner diameter:
• 1 inch (25 mm)
NOTE: Select hoses rated for 250 °F (121 °C) and
100 psi (690 kPa) minimum.
6. Select optional, user-supplied isolation valves.
NOTE: HOTSTART recommends installing valves to
isolate the heating system in case of service.

(full-port) ball isolation valves.
MOUNT HEATER
NOTICE
Vibration damage: Do not mount
heater directly to engine. Engine
vibration may damage heater.
If the heater is installed with
rigid pipe, connect exible hose
to inlet and outlet to isolate
from vibration.
Heater orientation: CKM
heaters may be mounted straight
horizontally or vertically; do not
mount at an angle. If mounted
vertically, all dips and horizontal
hose routing must be eliminated.
An incorrectly oriented heater may
cause heater failure.
Outlet orientation: If mounting
heater horizontally, inlet and outlet
must face upward. If mounting
heater vertically, ensure outlet is
at top of heater. Do not attempt
to mount heater at an angle
or in any other orientation. An
incorrectly oriented outlet may
cause heater failure.
7. Select a heater mounting
position using the following
guidelines:
• Heater must be low enough to allow the return hose to
continuously rise to the return port.
• Heater must be on the same side of the engine as the
return port.
• Heater must be in a location that allows a minimum of 10
inches (26 cm) clearance for element removal.
PLUMB HEATER
NOTICE
High points: Do not allow high points
along heater plumbing. High points
will restrict coolant ow and damage
heater. To avoid high points, it may be
necessary to change hose routing or
lower heater mounting location.
Dips and bends: Do not allow dips
or bends along heater plumbing.
Dips or bends will allow air pockets
to form, restricting coolant ow and
damaging heater.
90° Fittings: Elbows (90° ttings)
along heater plumbing may restrict ow and damage
heater. To minimize ow restriction, HOTSTART
recommends sweeping bends or 45°ttings in place of
90° ttings.

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INSTALLATION INSTRUCTIONS
HOTow™CKM HEATER
8. Install isolation valves to port ttings.
9. Route and install return hose. NOTICE! The return
hose must continuously rise from the heater to the
return port.
10. Route and install supply hose. NOTICE! The supply
hose must continuously descend from the supply
port to the heater.
11. If installed, open supply port isolation valve and return
port isolation valve. WARNING! Operation of a heating
system with closed isolation valves could result in high
pressure and serious injury.
REFILL COOLANT
NOTICE
Heater damage: When mixing coolant, only use deionized
or distilled water and low-silicate antifreeze. Refer to your
engine’s manufacturer recommendations. Do not exceed
60% antifreeze to 40% water ratio. Never add unmixed
water and antifreeze to an engine. Do not add anti-leak or
other coolant additives.
12. Mix coolant according to your engine manufacturer’s
recommendations. Rell cooling system with coolant.
NOTE: HOTSTART recommends using a 50%

silicate antifreeze mixture.
13. Start engine. Allow engine to run until engine
thermostat opens, purging air from engine cooling
system. NOTICE! Engine must be run to eliminate air
from heating system before energizing heater.
14. When engine has reached operating temperature, shut
engine off and check for coolant leaks. Allow engine to
cool. Check coolant level and top off as needed.
15. To ensure all air has been
purged, open heater air release
valve. Allow air to vent from
heater. Close valve as coolant
begins venting. Wipe excess
coolant from heater.
WIRE HEATER
16. Connect heater to an appropriately rated power source.
NOTICE! Terminations in all enclosures require that
wire be rated at a minimum of 90 °C. Selected wire
must be sized in accordance with heater amperage.
Figure 2. Example CKM installation. 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 a 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 outlet is
pointing directly upward.
• Mount the heater to a vibration-isolated surface.
• Mount the heater on the same side as the return port.
MAIN
POWER CONNECTION
Line 1 ¨A black wire
Line 2 ¨B black wire
Ground ¨C green ground
screw
Figure 3. Typical
CKM model, showing
main power electrical
connections.
C
B
A

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INSTALLATION INSTRUCTIONS
HOTow™CKM HEATER
TROUBLESHOOTING
To ensure coolant is owing, check the outlet temperature.
If the coolant temperature along the return hose exceeds
140 °F (60 °C) or the pump produces a loud, rattling sound
during operation, it may indicate:
• Air pockets are restricting ow. Air may collect due to
loops in hose, routing hose over the top of the engine,
excessive hose lengths, or kinks. Reroute hoses or change
port locations.
• Contaminants in the coolant are restricting ow. Flush
coolant system and rell.
If the heater is inoperative, check power source. If problem
persists, the high-limit thermostat may need to be reset. To
reset the high-limit thermostat: (See Fig. 5.)
MAINTENANCE & PARTS
CAUTION
!
Electrical hazard: Before wiring, servicing or cleaning
the heating system, turn off the power and follow your
organization’s lockout and tagout procedure. Failure to do
so could allow others to turn on the power unexpectedly,
resulting in harmful or fatal electrical shock.
Personal injury: If equipped with isolation valves, ensure
valves are open before energizing heater. Obstructed ow
may result in an unexpected release of heated coolant,
potentially causing serious injury.
PREVENTATIVE MAINTENANCE
Annually:
• Check and replace cracked or weakened hoses.
• Check electrical wiring for wear and excessive heat
• Remove element and clean element and tank
Every three years or 25,000 hours of operation:
• Replace control thermostat sensing unit.
THERMOSTAT REPLACEMENT
To replace the control or high-limit thermostat: (See Fig. 6.)
1. Disconnect heater from power
source. Allow heating system
to cool.
2. Remove enclosure cover:
hIf replacing control thermostat
(B), remove control thermostat
enclosure (C) cover (A).
hIf replacing high-limit
thermostat (E), remove
element enclosure cover.
3. Unscrew and remove sensing
unit and ange assembly.
hIf removing control
thermostat, disconnect
terminals from thermostat
sensing unit spade
connectors.
hIf removing high-limit
thermostat, disconnect
terminals. Unscrew mounting
clip (F) and remove thermostat
from recessed space (D).
4. Insert new sensing unit and
ange assembly.
hIf replacing control thermostat,
reconnect terminals to
thermostat sensing unit spade
connectors. Screw thermostat
ange in place to secure.
hIf replacing high-limit
thermostat, insert thermostat
in recessed space. Screw
mounting clip in place to
secure. Reconnect wire leads.
5. Reattach enclosure cover.
Reconnect heater to power
source.
1. Disconnect heater from
power source. Allow heating
system to cool.
2. Remove enclosure cover.
3. Locate the high-limit
thermostat. Press thermostat
reset button (A).
4. Reattach enclosure cover.
NOTICE! Before energizing
heater, check for ow
restrictions along hose
routing or bleed air from
tank. If high-limit persists,
check control thermostat.
5. Reconnect heater to power
source.
A
L1
L2 M1
USER-SUPPLIED
MAIN
POWER IN
TS1 HIGH-LIMIT
MANUAL RESET
TS2 CONTROL HR1
Figure 5. High-limit thermostat
reset button.
Figure 4. Typical CKM wiring schematic with continuous pump operation
(above) and with temperature-controlled pump operation (below). See

L1
L2 M1
USER-SUPPLIED
MAIN
POWER IN
TS1 HIGH-LIMIT
MANUAL RESET
TS2 CONTROL HR1
A
B
C
DE F
Figure 6. Replacing control
(above) and high-limit (right)
thermostat assemblies.