Hotstart CLV User manual

216307-000 rev1
INSTALLATION & OPERATION MANUAL
COOLANT CIRCULATING HEATING SYSTEM
CLV
MODEL

II installation & operation manual | clv heating system

I
installation & operation manual | clv heating system
IOM216307-000
IDENTIFYING YOUR SYSTEM
The Hotstart heating system is designed to heat uids for use in marine propulsion, diesel-powered generator sets,
locomotives, gas compression or any large-engine applications. The system is pre-wired, pre-plumbed and assembled on
steel plate. Each heating system has an identication plate which includes the part number and serial number.
When ordering replacement parts, be sure to reference your heating system’s model number
and serial number found on the identication plate and following label:
WARRANTY INFORMATION
Warranty information can be found at www.hotstart.com or by contacting our customer service department at
[phone]. Have your model number and serial number ready when contacting the warranty department.
COPYRIGHT
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.
U.S. PATENTS 9,784,470
REF. SERIAL NUMBER
WHEN ORDERING
REPLACEMENT PARTS
CAUTION
ATTENTION
MODEL
VOLTS HERTZ
AMPS PHASE
CONTROL CIRCUIT VOLTS
CONTROL CIRCUIT AMPS MAX
SERIAL NUMBER
OPEN CIRCUITS BEFORE WORKING ON THIS EQUIPMENT OR REMOVING COVERS.
KEEP COVERS TIGHTLY CLOSED WHILE CIRCUITS ARE ALIVE.
DÉBRANCHEZ LE CIRCUIT AVANT DE TRAVAILLER SUR CET EQUIPMENT.
GARDER LES COUVERTS FERMÉS QUAND LE CIRCUIT EST ACTIF
FILE NO.
LR7323
R
THIS CERTIFICATION COVERS THE
ELECTRICAL EQUIPMENT AND WIRING
SYSTEM ONLY
CETTE CERTIFICATION COUVRE UNIQUEMENT
LEQUIPEMENT ELECTRIQUE ET LE CABLAGE
SPOKANE, WA. U.S.A.
C US
NOTE: Typical heating
system
identication
plate. Your
identication
plate may vary.
Corporate &
Manufacturing
Headquarters
Spokane, WA, USA
509.536.8660
[email protected]
Oil & Gas Ofce
Katy, TX, USA
281.600.3700
[email protected]
Railroad Ofce
Merrillville, IN, USA
+49.2241.12734.0
[email protected]
Europe Ofce
Koln, Germany
+49.2241.12734.0
[email protected]m
United Kingdom
Ofce
Birmingham, UK
+49.2241.12734.0
[email protected]
Asia Pacic Ofce
Tokyo, Japan
+81.3.6902.0551
[email protected]

II installation & operation manual | clv heating system
IMPORTANT SAFETY
INFORMATION
WARNING
!
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.
Electrical hazard: All electrical work must be done by
qualied personnel in accordance with national, state
and local codes.
CAUTION
!
Read instructions carefully: 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.)
• Read carefully: Installers and operators of
this equipment must be thoroughly familiar
with the instructions in this manual before
commencing work.
• Hot surfaces: Avoid contact with the
system while it is in service. Some surfaces
may remain hot even if the system is not
energized.
• Proper lifting: Proper rigging and safety
equipment must be used to move this
equipment. Do not lift the heating system
by any cords, electrical conduit or cabling.
Create a plan before attempting to move.
Proper lifting locations are identied on each
system; use these locations when lifting and
mounting the system.
• Rotating equipment: The heating system
can start automatically and without warning.
Avoid contact unless a lockout at the service
panel has been installed.
• Grounding: The heater must be connected
to a suitable ground (protective earthing
conductor).
• Overcurrent limiting: The power supply must
be protected by a suitable overcurrent
limiting device.
• Power disconnection: A means to
disconnect the heater from the power supply
is required. Hotstart recommends that a
power switch or circuit breaker be located
near the heater for safety and ease of use.
NOTICE
EU Countries only: Equipment rated for the conditions
listed in EN 601010-1 1.4.1 Ingress protection rating
IP55. (Special conditions for specic applications may
apply.)

III
installation & operation manual | clv heating system
TABLE OF CONTENTS
IMPORTANT SAFETY INFORMATION | II
TABLE OF CONTENTS | III
1 OVERVIEW | 1
1.1 HEATING SYSTEM COMPONENTS | 1
1.2 OPERATION OVERVIEW | 2
2 PLUMBING INSTALLATION | 3
2.1 COOLANT PLUMBING | 4
2.1.1 Coolant Supply | 4
2.1.2 Coolant Return | 4
2.1.3 Coolant Pressure Relief | 5
2.2 COOLANT PLUMBING ILLUSTRATION | 6
2.3 MOUNTING | 7
2.3.1 Tank and Pump | 7
2.4 ELECTRICAL CONNECTIONS | 7
2.4.1 Main Power Supply | 7
2.4.2 Motor Rotation Check | 7
2.4.3 Customer Interface Connections | 8
3 SYSTEM COMPONENTS AND
OPERATION | 9
3.1 SYSTEM COMPONENTS | 9
3.1.1 Motor Protection Switch (MPS) | 9
3.1.2 Control TCR (Temperature Control Relay) | 9
3.1.3 High-Limit TCR (Temperature Control Relay) | 9
3.2 INTERFACE COMPONENTS | 9
3.2.1 On/Off/Prime Switch | 9
3.2.2 Pressure/Temperature Gauge | 10
3.2.3 Pressure Relief Valve | 10
3.3 HEATING SYSTEM START-UP | 10
3.3.1 First Run Procedure | 10
4 MAINTENANCE, REPAIR AND
TROUBLESHOOTING | 11
4.1 SYSTEM FAULTS | 11
4.1.1 Coolant Faults | 11
4.2 SYSTEM MAINTENANCE | 11
4.2.1 Plumbing Connections | 11
4.2.2 Electrical Connections | 11
4.2.3 System Mounting | 11
4.2.4 Magnetic Contactors | 11
4.2.5 Coolant Pump Seal | 11
4.2.6 Coolant Pump Replacement | 12
4.2.7 Motor Lubrication | 12
4.2.8 Pressure/Temperature Gauge | 12
4.2.9 Volatile Corrosion Inhibitor (VCI) | 12
4.2.10 Temperature Control Relay (TCR) | 13
4.2.11 Resistance Temperature Device (RTD) | 14
4.2.12 Heating Tank/Element | 15
4.2.13 Reassembly of Heating Element and Tank | 15
4.3 RECOMMENDED MAINTENANCE | 16
4.4 STORAGE REQUIREMENTS | 16
4.5 TROUBLESHOOTING | 17
4.6 REPLACEMENT PARTS LIST | 18
4.6.1 All Models | 18
4.6.2 CLV Model: CLV11102-00 | 18
4.6.3 CLV Model: CLV31802-00 | 18
4.6.4 CLV Model: CLV31804-00 | 18
4.6.5 CLV Model: CLV31800-00 | 18
4.6.6 CLV Model: CLV32404-00 | 18
4.6.7 CLV Model: CLV33004-00 | 18
5 APPENDIX | 19
5.1 INSTALLATION KITS | 19
5.1.1 Coolant Install Kit (Optional) | 20
5.1.2 CLV Installation Kit Parts List | 21

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installation & operation manual | clv heating system
1 OVERVIEW
1.1 HEATING SYSTEM COMPONENTS
The heating system consists of the following main components: Figure 1.
NOTE: Component illustrations are for reference only and are not to scale. See part drawings for dimensions
and specications.
I
A
N
L
M
E
F
J
K
G
B
D
H
C
C
A. Coolant on/off/prime switch
B. coolant fault light
C. Lift points (×3)
D. Element assembly
E. Check valve
F. Coolant outlet (1.0″ NPT standard)
G. Coolant High-Limit RTD (resistance
temperature device)
H. Heating tank
I. Coolant Control RTD (resistance
temperature device)
(located behind heating tank)
J. Coolant pressure/temperature gauge
K. Coolant pressure relief valve (0.5″ NPT)
L. Coolant inlet (1.0″NPT standard)
M. Coolant pump/motor
N. Identication plate
Figure 1. CLV heating
system components.

2installation & operation manual | clv heating system
1.2 OPERATION OVERVIEW
The CLV heating system is intended to maintain an engine’s optimal starting temperature while the
engine is shut down. The heating system may be activated locally or by optional remote control (see SECTION 2.4.3).
The CLV heating system should be deactivated upon engine start-up.
During heating system operation, a centrifugal pump takes coolant from the drain area low on the engine water jacket
and forces it through the heating tank and into the coolant return line. The coolant pump will continuously circulate uid
throughout the engine. To maintain consistent uid temperature, the heating element will cycle on and off at the user-
selected temperature control point.
A coolant check valve (included with the CLV unit and installed at the coolant outlet) prevents backow while the engine
is operating. When the engine is shut down, the heating system should be activated locally or remotely to resume
maintaining the engine’s optimal starting temperature.
Figure 2. CLV operation
overview, showing coolant
circulation. While the
heating element cycles
on and off to maintain
the preset temperature,
the pump circulates uid
continuously during
operation.
Component illustrations
are for reference only and
are not to scale. See part
drawings for dimensions
and specications.
COOLANT SUPPLY
COOLANT RETURN

3
installation & operation manual | clv heating system
2 PLUMBING INSTALLATION
CAUTION
!
Pressure hazard: Power must be turned off and locked out at the service panel when the isolation valves are in the
closed position. Failure to do so may cause damage to heating system components, uid leaks and unexpected release
of heated coolant.
Overheating hazard: After completing line installation, top off the uid levels to compensate for the uid used to ll
the lines and heating tank. Do not operate the heating system without the presence of uid. Position the heating tank
to ensure it is completely full of uid while in operation.
Pump priming: Fill supply line with uid. Pump is not self-priming. Fluid must be present in the pump before start-up.
Trapped air inside the pump will cause pump and seal damage.
Pump seal damage: Do not reduce the coolant supply line to an inner diameter smaller than the pump inlet; pump seal
damage will occur.
Isolation valves: Hotstart recommends installing full-ow ball valves to isolate the heating system in order to perform
service on the system or engine without draining coolant.
Pressurized steam hazard: Coolant pressure relief valve outlet must be vented to the atmosphere in case an over-
pressure release of heated coolant occurs. Do not connect pressure relief plumbing to coolant system.
CAUTION
!
Lifting hazard: Proper rigging and safety equipment must be used to move this equipment. Do not lift the heating
system by any cords, electrical conduit or cabling. Create a plan before attempting to move. Proper lifting locations are
identied on each system; use these locations when lifting and mounting the system.
NOTICE
Heating system damage: Engine vibration will damage the heating system; isolate the heating system from vibration.
Never mount the heating system or components directly to the engine. If the heating system is installed using rigid
pipe, use a section of exible hose to the supply and return ports to isolate the heating system from engine vibration.
Improper mounting hazard: Reference heating system component drawings before mounting the system. Unless
mounted properly, the heating system will be unstable.

4installation & operation manual | clv heating system
2.1 COOLANT PLUMBING
NOTICE
Heating system damage: Engine vibration will
damage the heating system; isolate the heating system
from vibration. Never mount the heating system or
components directly to the engine. If the heating system
is installed using rigid pipe, use a section of exible hose
to the supply and return ports to isolate the heating
system from engine vibration.
The following illustrations are intended for a locomotive
installation. For non-locomotive engine applications,
general installation principles still apply.
2.1.1 COOLANT SUPPLY
When installing the CLV coolant supply line, refer to the
following Hotstart guidelines (see SECTION 5.1 for
optional coolant install kit components):
• At a minimum, size the coolant supply line
per the pump inlet. NOTICE! Do not reduce
the supply line inner diameter; pump seal
damage will occur.
NOTE: To maximize ow and allow the longest
possible supply line, install the largest
practical inner diameter hose; for most
installations, Hotstart recommends using a
hose with a size larger inner diameter than
the pump inlet.
• Install the coolant suction port as low as
possible on the engine’s water jacket, typically
near the main water drain. See Figure 3.
• The coolant pump is a centrifugal-
type that is not self-priming. It must be
situated below the minimum liquid level
of the engine cooling jacket to ensure
it remains ooded and has a positive
pressure at the inlet.
• To minimize ow restriction, the coolant
supply line must be as short and as straight
as possible. Use elbow ttings sparingly;
Hotstart recommends using sweeping bends
or 45° ttings.
2.1.2 COOLANT RETURN
When installing the CLV coolant return line, refer to the
following Hotstart guidelines:
• Size the coolant return line per the pump
outlet. NOTICE! Do not reduce the return
line inner diameter.
• To minimize heat loss, avoid connecting the
coolant return to any location that will allow
warm coolant to bypass the engine or pass
through radiators or heat exchangers.
• Install the coolant discharge port as high as
possible on the engine’s water jacket on the
opposite end of the suction port; typically
near the aftercooler water line discharge port.
NOTE: To ensure even heat distribution, the coolant
return line may be split and routed to two
return ports. Size both return lines per the
outlet of the heating system. For engines
without an aftercooler, typical installation
points are along the water line from the
radiator to the engine block. See Figure 7.
Install coolant return line as follows:
1. Using appropriate ttings, install a 1 inch full-ow
ball valve at the water discharge outlet before
installing any T-ttings.
2. Place a 1/2 inch T-tting after the shutoff valve to
supply a 1/2 inch line for heating the locomotive’s
accessories. The line may be installed at either of
the following locations:
• the locomotive’s compressor (preferred)
• the locomotive’s expansion tank
(if a compressor connection is not available)
3. Install ttings at the compressor or expansion
tank to accept 1/2 inch hose. See Figure 5 and
Figure 6.
NOTE: If the locomotive has wet cab heaters,
install another 1 inch T-tting after the
shutoff valve to supply a 1/2 inch branch
line to the cab heater drain valve line.
4. Use appropriate ttings after the shutoff valve and
T-ttings to route a 1 inch inside diameter hose up
to the ceiling inside the car body to allow trapped
air to be purged from system.
Figure 3. Coolant suction port installed at main locomotive engine
drain. Note suction port (A) has been installed at the same level as
the drain (B), ensuring CLV pump will draw water from the cooling
system’s lowest point.
AB

5
installation & operation manual | clv heating system
hIf locomotive engine is turbocharged, the
coolant return line may be split and routed
to two return ports. Size both return lines per
the outlet of the heating system. The water
discharge ow must be directed to the upper
after-cooler tubes on both sides. Fittings must
be welded to the tubes at 45° angles to force
most coolant toward the locomotive engine and
allow some coolant to ow to the turbochargers.
See Figure 7.
hIf engine is supercharged, install a single return
port at the radiator Y-pipe. See Figure 8.
2.1.3 COOLANT PRESSURE RELIEF
To safeguard personnel and equipment, attach an
appropriately sized pipe to the pressure relief valve and
route to a safe area, bucket or catch-basin. CAUTION!
Coolant pressure relief valve outlet must be plumbed to
a safe area in case an over-pressure release of heated
coolant occurs. Do not connect pressure relief plumbing
to coolant system.
Figure 4. Coolant return hose (1/2 inch inner diameter) as installed
on locomotive compressor. If a connection to the compressor cannot
be made, utilize an alternative connection to the expansion tank.
Figure 5. Coolant return hose (1/2 inch inner diameter) as installed
at the locomotive's expansion tank.
Figure 6. Typical coolant discharge ports installed on a turbocharged
engine. The return line is split into two ports, installed at a welded
45° tting to ensure majority of heated coolant is transferred to
engine. Note incorrectly oriented tting (inset). This tting must be
angled in the opposite direction to allow proper ow.
Figure 7. Coolant discharge port installed in non-turbocharged
(supercharged) engine. Discharge port is located at radiator Y-pipe.
Figure 8. CLV system operation. Component illustrations are for
reference only and are not to scale. See part drawings for dimensions
and specications.
V-4
V-1
COMPONENT DESCRIPTION
V-1
V-2
USER SUPPLIED FULL FLOW ISOLATION VALVE
E-1
COOLANT PUMP
E-2
COOLANT HEATING ELEMENT
V-3 CHECK (NON-RETURN) VALVE
PRESSURE RELIEF VALVE
V-4
USER SUPPLIED FULL FLOW ISOLATION VALVE
V-3
V-2
E-2
E-1

6installation & operation manual | clv heating system
2.2 COOLANT PLUMBING ILLUSTRATION
PRESSURE
RELIEF
VALVE
SECTION 2.1.3
COOLANT RETURN
SECTION 2.1.2
COOLANT
DISCHARGE
PORT
SECTION 2.1.2
COOLANT
SUCTION PORT
SECTION 2.1.1
COOLANT SUPPLY
SECTION 2.1.1
ISOLATION VALVES

7
installation & operation manual | clv heating system
2.3 MOUNTING
2.3.1 TANK AND PUMP
Mount the heater in a vertical orientation with pump motor
assemblies directly below control box or in a horizontal
orientation with the heating tanks directly above the
control box and pumps. Reference drawings for mounting
position. When installing the heating system, HOTSTART
recommends 30 inches (76 cm) of clearance to remove
element for maintenance. Reference part drawings for
minimum clearance required for your model.
2.4 ELECTRICAL CONNECTIONS
WARNING
!
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.
Electrical hazard: All wiring shall be done by qualied
personnel 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 electrical shock.
2.4.1 MAIN POWER SUPPLY
1. Connect the specied power from the user-
supplied circuit breaker to the terminal blocks
located in the main control box.
NOTE: The specied power source must be within
plus or minus 10% of the rated voltage.
NOTE: The circuit breaker must be near the
heating system and easily accessible.
Hotstart recommends connecting the
heating system to a circuit breaker rated for
125% of the system’s maximum load.
NOTE: The main power supply operates the
heating elements and the circulating
pumps. A transformer may be used to
operate the control circuit. The transformer
and control circuits are overload-protected.
hFor three-phase applications, the terminal
blocks are labeled L1,L2 and L3.
hFor single-phase applications, use the terminal
blocks labeled L1 and L2.
See Figure 11 on following page.
2. Connect the main power ground wire to the ground
lug or ground block on the electrical panel located
inside the electrical box.
2.4.2 MOTOR ROTATION CHECK
NOTICE
Pump rotation (three-phase only): For three-phase
applications, check for proper pump rotation prior to
introducing uid to the pump. Reverse rotation while
the pump is lled with uid will cause pump seal failure.
Pump damage: Do not run the motor/pump assembly
dry for more than a few seconds. Running a motor/
pump for a prolonged period without being completely
lled with uid may cause damage to the pump seal.
The following procedures are for three-phase
applications only. Single-phase systems are prewired to
ensure the pump motor rotates in the correct direction.
1. With main power connected to the heating system
motor (see SECTION 2.4.1), energize the pump
while observing the rotation of the pump motor fan
at the rear of the motor. Refer to rotation decal on
motor for correct rotation.
hIf the pump motor does not rotate in the correct
direction, disconnect power and switch any two
electrical leads at the main power terminal block
(L1, L2, L3). Reconnect power. Repeat step 1 to
ensure motor rotates in the correct direction.
NOTE: For systems installed on mobile equipment that
may connect to power at multiple locations,
ensure all shore power connection points have
consistent phase sequences.
Figure 9. CLV 0.438 inch (11.13 mm)
diameter mounting holes ×6 (A).
Mount unit in either orientation shown.
Do not mount at an angle or in any
other orientation.
Figure 10. Underside
of CLV control box,
showing 0.75 ″NPT
main power entrance
(A) and 0.5 ″NPT
customer interface
wiring entrance (B).
A
B
J
J
A
A
J
J
A
A

8installation & operation manual | clv heating system
2.4.3 CUSTOMER INTERFACE
CONNECTIONS
The following customer interface connections are
available for remote control and monitoring:
• Coolant Fault Signal
TB2:1/TB2:2 (C)
The fault signal will indicate a coolant
heating system shutdown, triggered by
either the high-limit temperature control
relay or the motor protection switch (see
SECTION 4.1.1).
• Coolant Motor Run Signal
TB2:3/TB2:4 (D)
A motor run signal indicates the coolant
pump motor is running. If no signal is present,
the pump motor is not running.
• Remote On/Off 24 V DC shutdown (E)
TB2:5/TB2:6
When activated, the remote on/off
connection shuts down the heating system.
When deactivated, normal heating will
resume. Use this connection for remote
operation of the heater when the on/off/
prime switch is turned to on.
NOTE: The 24 V DC shutdown connection is
wired NC (normally closed) from the
factory; applying 24 V DC will shut down
the heating system. See system wiring
schematic for directions to switch to NO
(normally open) operation.
• External Remote
TB2:7/TB2:8 (F)
The external remote connections allow a
remote switch or relay to control the heating
system when the on/off/prime switch is
in the on position. The system will run when
there is continuity between TB2:7 and TB2:8,
and will shut down when continuity is broken.
These connections are jumpered from the
factory, and the jumper must be removed to
use this feature. This can be used together
with the 24V DC remote feature, but neither
will override the other. Refer to system
nameplate for control voltage/amperage
when selecting and wiring an external switch
or relay.
• Fault Signal Relay
TR2 (G)
The Fault Signal Relay introduces a small
time delay to prevent a false fault signal when
the system is switched off or starting up. This
is set for a minimum delay from the factory,
but the delay may be increased to up to 10
seconds if desired.
Figure 11. Main power supply and
customer interface connections
as shown in the CLV control box.
Reference electrical schematic
drawing for proper wiring locations;
the following illustrations are typical
customer interface locations but
may not apply to all models.
A. Main power ground block
B. Main power terminal block
C. Coolant fault signal
D. Coolant motor run signal
E. Remote On/Off 24 V DC
shutdown
F. External remote
G. Fault signal relay
CB2
TCR1
A1 A2
TCR2
A1 A2
TR1
A1 A2
K3
A1 A2
K1
A1 A2
K2
A1 A2
X1 X2
DS1
G
X1 X2
DS2
R
1413
K1
TCR2
1211
K3
11 12
TR1
1815
15 16
MPS1
13 14
1413
TCR1
FROM SHEET 1 FROM SHEET 1
TS1
BLU BRN
BLK
TS2
BLU BRN
BLK
1411
K3
K4
11 12
TR2
1815
1413
K2
K4
A1 A2
TR2
A1 A2
FAULT SIGNAL RELAY
TCR1:T2
TCR1:T3
TCR1:T1
TCR2:T2
TCR2:T3
TCR2:T1
A
B
NOTES :
2.
K4 RELAY WIRED FOR NORMALLY CLOSED FROM
FACTORY. TO CHANGE K4 TO NORMALLY OPEN,
MOVE WIRE FROM K4:12 TO K4:14 AND REPLACE
WIRE LABEL.
3.
REMOVE BLACK JUMPER LINKING TB2:7 & TB2:8
TO USE AN EXTERNAL SWITCH OR RELAY.
2
TB2:8
EXTERNAL REMOTE
(JUMPERED FROM FACTORY)
TB2:7
CUSTOMER INTERFACE
24V SHUTDOWN
RUN CONTACTS
FAULT CONTACTS
TB2:6
TB2:4
TB2:2
TB2:5
TB2:3
TB2:1
CUSTOMER INTERFACE
TB2:7
TB2:8
TB3:1
SW1
ONOFF PRIME
11 12
13 14
SW1
ONOFF PRIME
1 2
3 4
K1:43
MOTOR
TB3:2
TEMPERATURE CONTROL
HIGH LIMIT
ON INDICATOR
FAULT INDICATOR
HIGH LIMIT LATCH
NO FAULT
ELEMENT
3
3
3
3
3
3
3
3
3
3
3
4
4
CONTACT STATE
SW1 STATE 3-4 11-12 13-14
OFF X
PRIME X
ON X X
X = CLOSED
D
C
B
A
A
B
C
D
1
2
3
4
5
6
7
8
8
7
6
5
4
3 2
1
SPOKANE, WA.
CLV 3-PHASE WIRING SCHEMATIC
TITLE
04
N/A N/A
N/A
MA 01/28/2015
1:1
CO8384
08/12/2014 DG
2 OF 2
ORIGIN
UNLESS OTHERWISE SPECIFIED
DIMENSIONS ARE IN INCHES [mm]
This drawing and the information shown on it are property of Hotstart, Inc.
and are for the sole purpose of doing business with us. Any copying or transmittal to others
of this information is strictly prohibited without prior written consent from Hotstart.
PROPRIETARY INFORMATION
Hotstart
(Except as noted)
.XXX
.XX
ANGULAR
TOLERANCES
THIRD ANGLE
PROJECTION
DO NOT SCALE DRAWING
APPROVED BY
DRAWN BY
APPROVALS DATE
A-7978-3
REV.
SHEET
B
DWG. NO.
SIZE
SCALE
BA
C D E F G

9
installation & operation manual | clv heating system
3 SYSTEM COMPONENTS
AND OPERATION
3.1 SYSTEM COMPONENTS
3.1.1 MOTOR PROTECTION SWITCH (MPS)
The motor protection switch (MPS) protects the pump
motor from overloads. See Figure 12.The MPS will be
set at the full load amperage of the motor when shipped
from the factory. To reset the MPS, the on/off/prime
switch must be switched to off and the operator must
press the MPS reset/on button. See SECTION 4.1.1.
3.1.2 CONTROL TCR (TEMPERATURE
CONTROL RELAY)
The control TCR (TCR1) is used to control the
temperature of the uid. The control TCR uses a
resistance temperature device (RTD) to sense the
temperature of the uid as it enters the heating tank. The
standard setting for the coolant control temperature relay
(TCR1) is 122 °F (50 °C) at 10% hysteresis. See Figure 12.
The TCR will turn the heating element off at 122°F (50°C)
and back on at 113°F (45°C) with these set points.
NOTICE! Decreasing the hysteresis below 10% may
increase the cycle rate of the element contactor,
shortening the contactor’s expected life and
potentially overheating the contactor.
3.1.3 HIGH-LIMIT TCR (TEMPERATURE
CONTROL RELAY)
The high-limit TCR (TCR2) is a protection device to
prevent uid overheating. The high-limit TCR uses a
resistance temperature device (RTD) located near the
tank outlet. The default setting for the coolant high-limit
TCR is 194 °F (90 °C) at 0% hysteresis and should always
be at least 18 °F (10 °C) higher than the control TCR set
point. The high-limit TCR hysteresis is not used in the
high-limit control. See Figure 12.
3.2 INTERFACE COMPONENTS
The following is an operation description for the standard
parts located in the system.
NOTE: Parts in the control box may vary depending on
the particular system conguration purchased.
3.2.1 ON/OFF/PRIME SWITCH
• on – The system is on. The pump will run
continuously while the heating element
A B
C D
CLV control and high-limit TCRs (above). The standard setting for TCR1 control dial
(A) is 122 °F (50 °C). The standard setting for TCR2 high-limit dial (B) is 194 °F (90 °C).
CLV motor protection switch (right), showing stop/off (C) and reset/on (D) buttons. To reset the
MPS, the heating system must be switched off and the MPS reset/on button must be pressed.
A B
C D

10 installation & operation manual | clv heating system
cycles on and off to maintain the coolant
temperature. The 24V DC shutdown and/or
external remote may be used to activate or
deactivate the system.
• off – The system is shut off.
• prime – Turn and hold the switch to prime
to energize the pump motor in order to
remove any air in the heating system without
energizing the elements.
3.2.2 PRESSURE/TEMPERATURE
GAUGE
The CLV model features a temperature/pressure gauge
mounted at the inlet of the heating tank. The gauge
will indicate a pressure increase when the pump motor
is engaged by turning and holding the on/off/prime
switch to prime or during normal operation. The gauge
will also indicate the current incoming uid temperature.
NOTE: Your system’s operating pressure may vary
depending on the conguration of the engine.
3.2.3 PRESSURE RELIEF VALVE
CAUTION
!
Pressurized steam hazard: Coolant pressure relief valve
outlet must be plumbed to a safe area in case an over-
pressure release of heated coolant occurs.
The coolant pressure relief valve is mounted at the
coolant heating tank outlet and is set to relieve at 100
psi (690 kPa). During normal operation, pressure release
events are rare. To safeguard personnel and equipment,
attach an appropriately sized pipe to the pressure relief
valve outlet and direct ow to a safe area, bucket or
other catch-basin.
3.3 HEATING SYSTEM START-UP
WARNING
!
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.
NOTICE
Pump damage: Do not run the motor/pump assembly
dry for more than a few seconds. Running a pump that
is not completely lled with uid will cause damage to
the pump seal.
Proper heating operation: The high-limit temperature
control relays (TCR2, TCR4) must be set at least 18
°F (10 °C) higher than the corresponding control
temperature control relay for proper heating
operation. This will prevent nuisance tripping of
the high-limit circuit.
3.3.1 FIRST RUN PROCEDURE
1. Check and tighten all electrical and plumbing
connections.
2. Ensure isolation valves are open before energizing
the system.
3. Check the pump for proper rotation. NOTICE!
Do not run the motor/pump assembly dry for
more than a few seconds.
hFor three-phase heating systems, briey turn
and hold the on/off/prime switch to prime
while observing the rotation of the pump motor
fan at the rear of the motor. If the pump motor
is not rotating in the correct direction, switch any
two electrical leads at the main power terminal
block. See SECTION 2.4.1.
hSingle-phase systems are prewired to ensure the
pump motors rotate in the correct direction.
4. Bleed all trapped air from the heating system and
connecting plumbing by opening plugs or pipe
ttings as needed. Turn and hold the on/off/
prime switch to prime to evacuate any remaining
air in the lines.
NOTE: When priming the pump, the pressure
gauge should indicate an increase in
pressure. Your system’s operating pressure
may vary depending on the conguration
of the engine.
NOTE: Remaining air may be evacuated from
the pump using the air bleed screw on
the pump housing. Unscrew the pump air
bleed screw to vent trapped air. Tighten
screw once coolant begins venting.
5. Turn the on/off/prime switch to on to energize
the heating system.
6. Once operation is satisfactory, turn the control
dial on the temperature control relay TCR1 to the
desired temperature setting for engine coolant.
TCR1 is set to a control temperature setting of 122
°F (50 °C) and TCR2 is set to a high-limit setting of
194 °F (90 °C) at the factory. See SECTION 3.1.2
and SECTION 3.1.3.

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installation & operation manual | clv heating system
4 MAINTENANCE,
REPAIR AND
TROUBLESHOOTING
4.1 SYSTEM FAULTS
4.1.1 COOLANT FAULTS
The coolant fault light will display if:
• The coolant pump motor protection switch is
tripped (MPS1).
• The coolant high-limit temperature is
exceeded (TCR2).
A failure in the pump motor that causes the motor
protection switch (MPS1) to trip will shut down the
heating system. A fault signal will be transmitted and the
coolant fault light will illuminate. If this failure occurs, the
on/off/prime switch must be switched to off and the
operator must press the MPS reset/on button to reset the
fault. (See SECTION 3.1.1.)
If there is a failure that causes a high temperature to
occur, the high-limit temperature controller (TCR2)
will shut down the heating system, including the
pump motor. A fault signal will be transmitted and the
coolant fault light will illuminate. To restart the system,
the on/off/prime switch must be switched to off
and then back to on to resume operation once the
uid temperature drops below the high-limit preset.
Restarting the system remotely will also reset a high-limit
fault. (See SECTION 3.1.3.)
NOTE: A high-limit fault can only occur when the
heating element is energized.
For additional troubleshooting, see SECTION 4.5.
4.2 SYSTEM MAINTENANCE
WARNING
!
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.
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 heating system.
NOTE: After maintenance is performed, refer
to SECTION 3.3.1 for system start-up
procedures.
4.2.1 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.
4.2.2 ELECTRICAL CONNECTIONS
Vibration and thermal cycling may cause terminals
to loosen. After initial first run, disconnect power and
tighten electrical connections (see SECTION 4.3).
Check connections again in a week. Tighten all electrical
connections every three months.
4.2.3 SYSTEM MOUNTING
Vibration may cause mounting bolts to loosen.
Periodically check and tighten all mounting bolts.
4.2.4 MAGNETIC CONTACTORS
Magnetic contactors are used to control motors and
heating elements in Hotstart heating systems. The
contactor coils operate at the system’s nameplate control
voltage. To test for failure, check for continuity across
the coil connections (A1 and A2); an open or direct-short
reading indicates a failed contactor coil.
With power disconnected, verify that the mechanism of
the contactor moves freely and is not stuck in an open
or closed position. With the contacts held closed, check
for unusually high resistance across the main poles.
For contactors with screw terminals, verify that all wire
connections are properly tightened.
Magnetic contactors have finite life cycles, as they
contain moving parts and electrical contacts that will
wear out with use. Replace contactors that develop
functional problems or show obvious external signs
of heat damage. Hotstart recommends that element
contactors be replaced at least every five years as a
preventative maintenance measure.
NOTE: Higher-current systems or systems operating in
high ambient temperatures may require more
frequent contactor replacement.
4.2.5 COOLANT PUMP SEAL
Coolant pump mechanical seals are controlled leakage
devices and are not intended to create a zero leak seal.
Some leaking from the seal is expected during normal
operation. If seal becomes worn, replacement pump
seals are available. To ensure pump seal longevity,
ensure the supply lines do not restrict flow excessively
(see SECTION 2.1.1 and SECTION 2.1.2) and run the

12 installation & operation manual | clv heating system
heating system for 20 minutes monthly during offseason
periods (see SECTION 4.4.
NOTE: Instructions to replace the pump seals are
included with replacement seals.
4.2.6 COOLANT PUMP REPLACEMENT
Before installing a replacement pump, the replacement
pump component will require volute adjustment for
proper fit.
1. Unscrew four volute screws See Figure 12.
Remove volute.
2. Rotate volute 90 degrees as shown.
3. Reattach volute and secure using volute screws.
4. Tighten volute screws.
4.2.7 MOTOR LUBRICATION
Motors are installed with initial lubrication. If your motor
has provisions for relubrication, refer to the motor
manufacturer for recommended relubrication schedule
intervals. For recommended lubrication type, refer to the
motor nameplate.
NOTE: New motors installed on heating systems
placed in extended storage for a year or longer
may require relubrication. See SECTION 4.4.
4.2.8 PRESSURE/TEMPERATURE
GAUGE
The pressure/temperature gauge will indicate a pressure
increase when the pump motor is engaged by turning
and holding the on/off/prime switch to prime
or during normal heater operation. The gauge will
also indicate the current temperature of the uid. No
maintenance for this parts is required.
4.2.9 VOLATILE CORROSION
INHIBITOR (VCI)
A volatile corrosion inhibitor (VCI) is provided with each
control box and should be replaced once a year.
NOTE: Heating systems placed in extended storage
will require that the VCI is replaced at six month
intervals. See SECTION 4.4.
A
Figure 12. CLV pump,
motor and pump volute,
showing volute screws
(A). Volute will need to
be rotated 90 degrees as
shown prior to installation
on the CLV heating system.
Figure 13. CLV pump,
motor and pump volute,
rotated in correct
installation orientation.
Note that pump and
motor appearance may
vary depending on CLV
model. Orienation of
motor terminal box and
pump inlet/outlet are
critical.

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installation & operation manual | clv heating system
4.2.10 TEMPERATURE CONTROL RELAY
(TCR)
WARNING
!
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.
If the CLV heating system does not maintain the desired
preset control temperature or signals a high-limit
temperature fault immediately upon system start-up,
the TCR (temperature control relay), the RTD (resistance
temperature device), or the RTD cable may require
replacement. To perform this troubleshooting, you
will need:
• Ohmmeter
1. De-energize the heating system. Verify uid
is present and ow is not restricted. Check
temperature gauge to ensure the liquid in the tank
is below 122 °F (50 °C).
2. Verify the control TCR is set correctly. Verify that
high-limit TCR is set at least 18 °F (10 °C) higher
than the control TCR set point.
3. Using the ohmmeter, measure the resistance
between TCR terminals T1 and T2. (See Figure 14.)
hIf the measured resistance is between 80 and
120 ohms continue troubleshooting. Proceed
to step 4.
hIf the resistance is lower than 80 ohms or
higher than 120 ohms,contact HOTSTART
for further assistance.
4. Using the ohmmeter, test for continuity between
TCR terminals T2 and T3:
hIf there is continuity between TCR terminals
T2 and T3, the TCR, RTD and RTD cable are
functioning correctly. Close control panel.
Allow uid to cool below high-limit preset
temperature. Perform system start-up (see
SECTION 3.3.1). If fault or temperature
problems persist after start-up, contact
Hotstart for further assistance.
hIf there is no continuity between TCR terminals
T2 and T3, locate connected RTD on the
heating tank. Unscrew the RTD plug from
RTD. See Table 2 and Figure 14, Figure 15. on
following page.
5. Using the ohmmeter, touch the probes to RTD
pin 1 and pin 3. See Figure 15.Note the resistance.
Touch the probes to RTD pin 1 and pin 4 to check
for continuity:
hIf the resistance between RTD pin 1 and
pin 3 is between 80 and 120 ohms and there
is continuity between RTD pin 1 and pin 4, the
RTD is functioning properly. Replace the
RTD cable.
hIf the resistance between RTD pin 1 and pin 3
is not between 80 and 120 ohms or there is
no continuity between pin 1 and pin 4, the
RTD is malfunctioning. Replace the RTD. See
SECTION 4.2.11.
PIN 1
(BROWN
WIRE)
PIN 3
(BLUE
WIRE)
PIN 4
(BLACK
WIRE)
Figure 14. Control TCR (TCR1) and
high-limit TCR (TCR2) showing
terminals T1, T2 and T3.
Figure 15. RTD pins 1, 3 and 4. The resistance between pin 1 and
pin 3 should measure between 80 and 120 ohms. There should be
continuity between pin 1 and pin 4.
TCR TYPE RTD Position
TCR1 Coolant Control 50 °C Coolant Tank Inlet
TCR2 Coolant High-limit 90 °C Coolant Tank Outlet
Table 2. TCR types, default temperature settings and
corresponding RTD positions.

14 installation & operation manual | clv heating system
4.2.11 RESISTANCE TEMPERATURE
DEVICE (RTD)
WARNING
!
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.
High-limit or control resistance temperature devices
(RTDs) sense temperature to either control uid
temperature or protect the system and uid from
overheating. To replace a resistance temperature device
(RTD), use the following procedures.
NOTE: Before removing and replacing an RTD, ensure
the RTD is malfunctioning. See SECTION
4.2.10.
1. De-energize the heating system. Allow uid to cool.
2. Close isolation valves. Drain uid from the heating
tank. Locate the RTD that requires replacement.
See Figure 16.
3. Unscrew RTD plug. Remove plug. See Figure 16.
4. Unscrew RTD from tank. See Figure 17.
5. Screw replacement RTD into tank. When tightening,
ensure plug is aligned with notch toward top of
tank. See Figure 18.
6. Fit RTD plug to RTD. Ensure plug is aligned
correctly with notch. Push plug in rmly. Screw RTD
plug to RTD to secure in place.
7. To ensure proper installation and temperature
regulation, re-energize and check heating system
for proper operation. Refer to SECTION 3.3.1 for
system start-up procedures.
Figure 16. CLV high-
limit RTD (A), control
RTD (B) and RTD
plug detail (C).
Figure 17. High-limit RTD
shown removed from CLV
heating tank.
Figure 18. Proper RTD
orientation. Note the notch
centered at the top of the
RTD connection.
A
B
C