Hotstart CMM User manual

216383-000 rev0
INSTALLATION & OPERATION MANUAL
MODEL
CMM
CLM
COOLANT CIRCULATING HEATING SYSTEM


i
installation & operation manual | cmm/clm heating system
IDENTIFYING YOUR SYSTEM
The Hotstart heating system is designed to heat uids for use in marine propulsion, diesel-powered generator sets,
locomotives, gas compression, heavy equipment or other large-engine applications. Each heating system has an
identication 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 identication plate and following label:
WARRANTY INFORMATION
Warranty information can be found at www.hotstart.com or by contacting our customer service department at
(509)536-8660. 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.
NOTE: Typical heating
system
identication
plate. Your
identication
plate may vary.
Corporate &
Manufacturing
Headquarters
5723 E. Alki Ave.
Spokane, WA 99212 USA
509.536.8660
Oil & Gas Ofce
21732 Provincial Blvd.
Suite 170
Katy, TX 77450 USA
281.600.3700
Railroad Ofce
8915 Broadway
Merrillville, IN 46410 USA
219.648.2448
Europe Ofce
HOTSTART Europe GmbH
Hansestraße 79
51149 Köln, Germany
+49.2203.98137.30
Asia Pacic Ofce
HOTSTART Asia Pacic Ltd.
2-27-15-4F Honkomagome
Bunkyo-ku, Tokyo
113-0021, Japan
+81.3.6902.0551
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
IOM216383-000

ii installation & operation manual | cmm/clm heating system
IMPORTANT SAFETY
INFORMATION
DANGER
!
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.
WARNING
!
Electrical hazard: All electrical work must be done by
qualied personnel in accordance with national, state
and local codes.
CAUTION
!
Read instructions carefully: The safety of any system
incorporating this equipment is the responsibility
of the assembler. The safe and proper use of this
equipment is dependent upon the installer following
sound engineering practices. If the equipment is used
in a manner not specied by the manufacturer, the
protection provided by the equipment may be impaired.
All applicable electrical safety standards dened by local
jurisdictions must be followed. (Reference EU directive
2014/34/EU 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: Use proper lifting equipment and
rigging to move this equipment. Create a plan before
attempting to move. Heating systems with anges
have marked lift points. When lifting, use soft straps
and avoid placing side-loads on heating system
plumbing components, including uid pumps.
• 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 heating system 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
heating system from the power supply is required.
HOTSTART recommends that a power switch or
circuit breaker be located near the heating system
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 specic applications may apply.)

iii
installation & operation manual | cmm/clm heating system
TABLE OF CONTENTS
1 OVERVIEW | 1
1.1 HEATING SYSTEM COMPONENTS | 1
1.2 OPERATION OVERVIEW | 2
2 INSTALLATION | 3
2.1 COOLANT PLUMBING INSTALLATION | 4
2.1.1 Coolant Supply | 4
2.1.2 Coolant Return | 4
2.1.3 Coolant Pressure Relief | 4
2.2 COOLANT PLUMBING ILLUSTRATION | 5
2.3 MOUNTING | 6
2.3.1 Tank and Pump | 6
2.4 ELECTRICAL CONNECTIONS | 6
2.4.1 Main Power Supply | 6
2.4.2 Customer Interface Connections | 7
2.4.3 Motor Rotation Check | 7
3 COMPONENTS AND OPERATION | 8
3.1 INTERFACE COMPONENTS | 8
3.1.1 Local/Off/Remote Switch | 8
3.1.2 Prime Button | 8
3.1.3 Pressure/Temperature Gauge | 8
3.1.4 Pressure Relief Valve | 8
3.2 SYSTEM COMPONENTS | 8
3.2.1 Motor Protection Switch | 8
3.2.2 Control TCR (Temperature Control Relay) | 8
3.2.3 High-Limit TCR (Temperature Control Relay) | 8
3.3 HEATING SYSTEM START-UP | 9
3.3.1 First Run Procedure | 9
4 MAINTENANCE AND
TROUBLESHOOTING | 10
4.1 SYSTEM FAULTS | 10
4.1.1 Fault Signals | 10
4.2 SYSTEM MAINTENANCE | 10
4.2.1 Plumbing Connections | 10
4.2.2 Electrical Connections | 10
4.2.3 System Mounting | 10
4.2.4 System Draining | 10
4.2.5 Magnetic Contactors | 11
4.2.6 Pump Seal | 11
4.2.7 Pressure Relief Valve | 11
4.2.8 Pressure/ Temperature Gauge | 11
4.2.9 Volatile Corrosion Inhibitor | 11
4.2.10 Temperature Control Relay (TCR) | 12
4.2.11 Resistance Temperature Device (RTD) | 12
4.2.12 Heating Tank/Element | 14
4.2.13 Reassembly of Heating Element and Tank | 14
4.3 RECOMMENDED MAINTENANCE | 15
4.4 STORAGE REQUIREMENTS | 15
4.5 TROUBLESHOOTING | 16

1
installation & operation manual | cmm/clm heating system
1 OVERVIEW
1.1 HEATING SYSTEM COMPONENTS
NOTE: Component illustrations are for reference only and are not to scale. See part drawings for dimensions
and specications.
Figure 1. Typical CMM/CLM
system components. Model style
and conguration may vary. See
part drawings for dimensions and
specications.
A. prime button
B. local/off/remote switch
C. remote light
D. local light
E. fault light
F. Coolant inlet
(1.0″ NPT standard)
G. Coolant pump/motor
H. Coolant pressure/
temperature gauge
I. Coolant control resistance
temperature device (RTD)
J. Tank drain plug
K. Vibration isolators × 4
L. Heating tank
M. Mounting feet
N. User interface wiring
entrance
O. Power in wiring entrance
P. Coolant high-limit resistance
temperature device (RTD)
Q. Element assembly
R. Coolant pressure relief valve
(0.5″NPT)
S. Coolant check (non-return)
valve
T. Coolant outlet
(1.0″ NPT standard)
U. Identication plate
A B C D E F
G
H
I
J
LNOP
Q
R
K
S
T
U
M

2installation & operation manual | cmm/clm heating system
1.2 OPERATION OVERVIEW
The CMM/CLM 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 2.4.2). The CMM/CLM
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 elements will cycle on and off at the user-
selected temperature control point.
A coolant check valve (included with the CMM/CLM unit and installed at the coolant outlet) prevents backow 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.
COOLANT
RETURN
COOLANT
SUPPLY
Figure 2. CMM/CLM
system operation.
Component illustrations
are for reference only and
are not to scale. See part
drawings for dimensions
and specications.
COOLANT
PRESSURE
RELIEF

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installation & operation manual | cmm/clm heating system
2 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.
Proper lifting: Use proper lifting equipment and rigging to move this equipment. Create a plan before attempting to
move. Heating systems with anges have marked lift points. When lifting, use soft straps and avoid placing side-loads on
heating system plumbing components, including uid pumps.
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 in the supply and return lines 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 | cmm/clm heating system
2.1 COOLANT PLUMBING
INSTALLATION
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 in the supply and return lines to isolate the heating
system from engine vibration.
Air lock: Avoid high points in supply and return lines
that could trap air and restrict ow. Where high points
are unavoidable, install bleed ttings to allow removal of
trapped air.
2.1.1 COOLANT SUPPLY
When installing the CMM/CLM coolant supply line, refer
to the following Hotstart guidelines (See SECTION 2.2):
• 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.
Where applicable, HOTSTART recommends
a connection point at the suction side of
the engine water pump. NOTICE! At a
minimum, suction port must be sized per
the pump inlet (1” NPT).
• 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.
NOTE: For optimal pump performance, Hotstart
recommends a minimum of 6 inches (152
mm) of straight pipe installed into pump inlet.
2.1.2 COOLANT RETURN
When installing the CMM/CLM coolant return line, refer
to the following Hotstart guidelines (See SECTION 2.2):
• Size the coolant return line per the coolant
outlet. NOTICE! Do not reduce the return
line inner diameter.
•Install the coolant discharge port as high as
possible on the engine’s water jacket at the
end of the engine opposite the suction port.
To minimize heat loss and warm-up time,
Hotstart recommends running the coolant
return directly the engine water jacket and
critical accessories, if applicable.
•If the coolant return must be connected to
the engine’s external plumbing, it should be
in a location that readily allows ow directly
into the engine’s cooling jacket and does not
allow warm coolant to bypass the engine.
•To minimize heat loss, avoid connecting the
coolant return to any location that will allow
warm coolant to pass through radiators or
heat exchangers.
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 heating system or engine
coolant system.
Figure 3. CMM/CLM system operation. Component illustrations
are for reference only and are not to scale. See part drawings for
dimensions and specications.
E-2E-1
V-1 V-4
V-2
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

6installation & operation manual | cmm/clm heating system
2.3 MOUNTING
CAUTION
!
Lifting hazard: Use proper lifting equipment and
rigging to move this equipment. Create a plan before
attempting to move. Heating systems with anges have
marked lift points. When lifting, use soft straps and
avoid placing side-loads on heating system plumbing
components, including uid pumps.
Overheating hazard: When mounting the heating tank,
position the tank so that it is completely full of uid while
in operation.
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.
Improper mounting hazard: Reference heating
system component drawings before mounting the
system. Unless mounted properly, the heating system
will be unstable.
2.3.1 TANK AND PUMP
Mount the heater below the uid level in the engine on
a level surface in a vertical orientation with pump motor
assembly directly above tank. Reference drawings for
mounting position.
When installing the heating system, ensure sufcient
clearance for the following components:
• Control box
Ensure the control box is accessible and the
lid may be opened.
• Pump motor cooling fan
Ensure the cooling fan is not obstructed.
• Heating element
Note the tank may require up to 30 inches
(762 mm) of clearance to remove element
for maintenance. The clearance required
for specic part numbers will be shown on
system drawings.
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. Install in accordance with any applicable
local codes based on the installation location.
Electrical hazard: The heating system must be
connected to a suitable protective earthing conductor.
The heating system’s power supply must be connected
to a suitable overcurrent limiting device. A means of
disconnection from power supply is required. Hotstart
recommends that a power switch or circuit breaker be
located near the heating system for safety and ease of
use. Reference markings on heating system for specic
ratings.
2.4.1 MAIN POWER SUPPLY
1. Connect the specied power from the customer-
supplied circuit breaker to the terminal blocks
located in the main control box. See Figure 6 on
following page.
NOTE: The specied 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.
Figure 4. Mount unit in orientation shown. Do not mount at an angle
or in any other orientation.
J
A
AB
Figure 5. CMM/CLM 0.75 inch (19.05 mm) and .38 inch (9.65 mm)
diameter mounting holes ×4 (A).
Figure 6. CMM/CLM underside, showing typical .590–1.00 (15–25
mm) main power entrance (A) and .170–.450 (4.3–11.4 mm)
customer interface wiring entrance (B). Cord grip sizes, quantities,
and styles may vary depending on system conguration.

7
installation & operation manual | cmm/clm heating system
NOTE: The main power supply operates the
heating elements and the circulating
pumps. A transformer may be used to
power the control circuit. The transformer
and control circuits are overload-protected.
hFor three-phase applications, the terminal
blocks are labeled L1,L2 and L3 (B).
hFor single-phase applications, use the terminal
blocks labeled L1 and L2 (B).
2. Connect the main power ground wire to the ground
block (A).
2.4.2 CUSTOMER INTERFACE
CONNECTIONS
NOTICE
Wiring connections: Reference electrical schematic
drawings for proper wiring locations; the following are
typical interface locations.
The following customer interface connections are
available for remote control and monitoring:
• TB2:1/TB2:2
Coolant Fault Signal (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.
• TB2:3/TB2:4
Coolant Motor Run Signal (D)
A motor run signal indicates the coolant pump
motor is running. If no signal is present, the coolant
pump motor is not running.
• TB2:5/TB2:6
Remote On/Off 24 V DC shutdown (E)
When energized, the remote on/off relay will
activate the heating system. When de-energized,
the remote on/off relay will deactivate the heating
system. Use this connection for remote operation of
the heating system when the local/off/remote
switch is turned to remote.
NOTE: The 24 V DC shutdown relay is wired NO
(normally open) from the factory. To switch
to NC (normally closed) operation, move
the wire from the K4:14 terminal to the
K4:12 terminal.
2.4.3 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 fail to create proper uid
circulation.
Figure 7. Main power supply and customer interface connections as
shown in the CMM/CLM 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
CB2
TCR1
A1 A2
TCR2
A1 A2
TR1
A1 A2
K3
A1 A2
K1
A1 A2
K2
A1 A2
X1 X2
DS2
Y
X1 X2
DS1
G
X1 X2
DS3
R
4 3
3 4
REMOTE
OFF
LOCAL
3 4
3 4
1411
K4
1413
K1
K3
11 12
TR1
1815
15 16
MPS1
13 14
1413
TCR1
FROM SHEET 1 FROM SHEET 1
BLU
BRN
BLK
TS1
BLU
BRN
BLK
TS2
1413
K2
K3
21 22
K4
A1 A2
1411
K5
A1 A2
1411
K5
SW1-2
SW1-1
SW1-4
SW1-5
TB3:5
TB3:4
TB3:3
TB3:1
TB3:2
TEMPERATURE CONTROL
HIGH LIMIT
LOCAL INDICATOR
REMOTE INDICATOR
FAULT INDICATOR
HIGH LIMIT LATCH
NO FAULT
ELEMENT
MOTOR
TCR1:T2
TCR1:T3
TCR1:T1
TCR2:T2
TCR2:T3
TCR2:T1
TB2:1
TB2:3
TB2:5
TB2:2
TB2:4
TB2:6
FAULT CONTACTS
RUN CONTACTS
24V SHUTDOWN
CUSTOMER INTERFACE
PB1
1 2
3 4
NO FAULT HEATER OFF
SSO
A B C D E

8installation & operation manual | cmm/clm heating system
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 fan at the rear of
the motor. Refer to markings on pump for correct
rotation direction.
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.
3 COMPONENTS AND
OPERATION
The following is an operational description for each of
the CMM/CLM interface and system components.
NOTE: Components installed in control box may
vary depending on the particular system
conguration purchased.
3.1 INTERFACE COMPONENTS
3.1.1 LOCAL/OFF/REMOTE SWITCH
• local – The system is on and will run
continuously until manually shut off.
• off – The system is shut off.
• remote – The system is on and will run
based on an input signal. In this state, the 24
V DC shutdown may be used to activate and
deactivate the system.
3.1.2 PRIME BUTTON
When the system is not running, press and hold the
prime button to energize the pump motor in order to
remove any air in the heating system without energizing
the elements.
3.1.3 PRESSURE/TEMPERATURE GAUGE
The CMM/CLM system features a temperature/pressure
gauge mounted at the heating tank inlet. The gauge will
indicate a pressure increase when the pump motor is
engaged by pressing and holding the prime button or
during normal operation. The gauge will also indicate the
uid’s current temperature.
NOTE: Your system’s operating pressure may vary
depending on the conguration of the engine.
3.1.4 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.
3.2 SYSTEM COMPONENTS
3.2.1 MOTOR PROTECTION SWITCH
The motor protection switch (MPS1) protects the pump
motor from overloads. The MPS will be set at the full load
amperage of the motor when shipped from the factory.
To reset the MPS, the local/off/remote switch must
be switched to off and the operator must press the
MPS reset/on button. See Figure 8. For additional
troubleshooting, see SECTION 4.5.
3.2.2 CONTROL TCR (TEMPERATURE
CONTROL RELAY)
The control TCR (TCR1) is used to control the heating
element and maintain 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
heater. The standard setting for the control relay (TCR1)
is 50 °C (122 °F) and 10% (5 °C/9 °F) hysteresis. The TCR
will turn the heating element off at 50 °C (122 °F) and
turn the element back on at 45 °C (113 °F) with these
set points. NOTICE! Decreasing the hysteresis below
10% may increase the cycles of the contactor,
shortening its expected life and potentially
overheating it. See Figure 8.

9
installation & operation manual | cmm/clm heating system
3.2.3 HIGH-LIMIT TCR (TEMPERATURE
CONTROL RELAY)
The high-limit TCR (TCR2) is a protection device to
prevent uid overheating. The high-limit TCR connects
to a second resistance temperature device (RTD) located
near the tank outlet. The default setting for the coolant
high-limit TCR is 90 °C (194 °F) and should always be at
least 10 °C (18 °F) higher than the control TCR set point.
The high-limit TCR hysteresis is not used in the high-limit
control. See Figure 8.
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 ve seconds at a time. 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 relay (TCR2) must be set at least 10 °C (18 °F)
higher than the control temperature control relay (TCR1)
for proper heating operation. This will prevent nuisance
tripping of the high-limit circuit.
Seal damage: Pump seal faces may adhere while in
storage. Before energizing the pump motor for the rst
time, remove the pump shaft guards and rotate the shaft
by hand to ensure the seal faces move freely.
3.3.1 FIRST RUN PROCEDURE
1. For three-phase applications, ensure a motor rotation
check has been performed prior to introducing uid to
the pumps (see SECTION 2.4.3).
NOTE: Single-phase motors are prewired at the
factory to ensure rotation in the correct
direction. If a single-phase pump motor
rotates in the incorrect direction, contact
Hotstart for re-wiring instructions.
2. Check and tighten all electrical and plumbing
connections.
Figure 8. CMM/CLM motor protection switch (left), showing reset/
on (A) and (B) stop/off buttons. To reset the MPS, the heating system
must be switched off and the MPS reset/on button must be pressed.
CLM/CMM control TCR and high-limit TCR (above). The standard
setting for TCR1 coolant control dial (C) is 50 °C (122 °F). The
standard setting for TCR2 coolant high-limit dial (D) is 90 °C (194 °F).
BA
C D
BA
C D

10 installation & operation manual | cmm/clm heating system
3. Ensure isolation valves are open before energizing
the system.
4. Bleed all trapped air from the heating system and
connecting plumbing by opening plugs or pipe
ttings as needed. Press and hold the prime button
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 conguration
of the engine.
NOTE: Remaining air may be evacuated from the
pump using the pump air bleed screw.
Unscrew the pump air bleed screw to vent
trapped air. Tighten screw once coolant
begins venting. See Figure 9.
5. Turn the local/off/remote switch to local to
energize the heating system.
6. 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 50 °C (122 °F) and TCR2 is
set to a high-limit setting of 90 °C (194 °F) at the
factory. See SECTION 3.2.2 and SECTION 3.2.3.
7. Turn the local/off/remote switch to remote
to verify the 24 V DC remote on/off connection (if
used).
8. Disconnect power to the heating system
and tighten all electrical connections. See
SECTION 4.2.2.
4 MAINTENANCE AND
TROUBLESHOOTING
4.1 SYSTEM FAULTS
A failure in the pump motor that causes the motor
protection switch (MPS1) to trip will shut down the
heating system. The fault light will illuminate and a
fault signal will be transmitted. If this failure occurs, the
local/off/remote switch must be switched to off
and the operator must press the MPS reset/on button
to reset the fault. (See SECTION 3.2.1.)
If there is a failure that causes a high uid temperature
to occur, the high-limit temperature controller (TCR2)
will shut down the heating system, including the pump
motor. The fault light will illuminate and a fault signal
will be transmitted. To restart the system, the local/
off/remote switch must be switched to off and then
back to local or remote to resume operation once the
system has cooled back down. (See SECTION 3.2.3.)
For additional troubleshooting, see SECTION 4.5.
4.1.1 FAULT SIGNALS
A fault signal will be transmitted if:
•The pump motor protection switch is tripped
(MPS1).
•The high-limit temperature is exceeded
(TCR2).
4.2 SYSTEM MAINTENANCE
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.
A
Figure 9. CMM/CLM pump bleed screw (A). Unscrew bleed screw to
vent trapped air. Tighten screw once coolant begins to vent.

11
installation & operation manual | cmm/clm heating system
4.2.4 SYSTEM DRAINING
Use the following points for draining purposes (see
SECTION 4.2.11 and SECTION 4.2.12):
• Coolant tank plug (A)
4.2.5 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.
4.2.6 PUMP SEAL
If seal becomes worn, replacement pump seals are
available. To improve pump seal longevity, ensure
the supply line does not restrict flow excessively (see
SECTION 2.1.1).
NOTE: Instructions to replace the pump seals are
included with replacement seal kits.
4.2.7 PRESSURE RELIEF VALVE
The pressure relief valve on coolant systems must be
periodically checked and replaced when appropriate.
At a minimum, the valve should be removed from the
system, checked for deposits and corrosion, and tested
to ensure that it relieves the proper pressure.
4.2.8 PRESSURE/ TEMPERATURE
GAUGE
The pressure/temperature gauge will indicate a pressure
increase when the respective pump motor is engaged
by pressing the prime button or during normal heating
system operation. The gauge will also indicate the
current uid temperature. No maintenance for this part
is required.
4.2.9 VOLATILE CORROSION
INHIBITOR
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 the VCI to be replaced at six month
intervals. See SECTION 4.4.
A
Figure 10. CMM/CLM, showing drain plug (A) at coolant tank.

12 installation & operation manual | cmm/clm 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 CMM/CLM 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 50 °C (122 °F).
2. Verify the control TCR is set correctly. Verify that
high-limit TCR is set at least 10 °C (18 °F) higher
than the control TCR set point.
3. Using the ohmmeter, measure the resistance
between TCR terminals T1 and T2 (See Figure 11):
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 1 and Figure 11, Figure 12 on the
following page.
5. Using the ohmmeter, touch the probes to RTD
pin 1 and pin 3. See Figure 12.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.
4.2.11 RESISTANCE TEMPERATURE
DEVICE (RTD)
PIN 1
(BROWN
WIRE)
PIN 3
(BLUE
WIRE)
PIN 4
(BLACK
WIRE)
Figure 11. Control and high-
limit TCRs (TCR1 and TCR2)
showing terminals T1, T2 and
T3.
TCR TYPE RTD Position
TCR1 Coolant Control 50 °C Tank Inlet
TCR2 Coolant High-limit 90 °C Tank Outlet
Table 1. TCR types, default temperature settings and
corresponding RTD positions.
Figure 12. 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.
BA

13
installation & operation manual | cmm/clm heating system
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 (see SECTION 4.2.4). Locate the RTD that
requires replacem ent. See Figure 13.
3. Unscrew RTD plug. Remove plug. Unscrew RTD
from tank. See Figure 14.
4. Screw replacement RTD to tank. When tightening,
ensure plug is aligned with notch orientated as
shown in Figure 15
5. 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.
6. To ensure proper installation and temperature
regulation, re-energize and operate heating system.
Refer to SECTION 3.3.1 for system start-up
procedures.
Figure 13. CMM/CLM
control RTD (A), high-limit
RTD (B), and plug detail
(C).
Figure 14. Control RTD
shown removed from
CMM/CLM heating tank.
Figure 15. Proper RTD
orientation. Note the notch
angled downward and to the
right at approximately the 5
o’clock position.
C
A
B

14 installation & operation manual | cmm/clm heating system
4.2.12 HEATING TANK/ELEMENT
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.
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 sediment build-up
around the element loops. Any scaling or build-up will
shorten element life.
To replace the heating element or perform routine
maintenance, use the following procedures. See Figure
16. The wattage and phase of the heating element are
listed on the identication plate on the outside of the
element (B). Reference this label for the replacement
part number.
1. De-energize the heating system. Allow uid to cool.
2. Close isolation valves. Drain the uid from the
heating tank (E). See SECTION 4.2.4.
3. Remove the cap (A) from the heating element
service entrance enclosure.
4. Note your unit’s jumper conguration. See Figure
17. NOTICE! Elements are congured from
the factory. Retain original jumper placement
during element reassembly. Altering element
conguration or jumper placement may cause
heating system failure.
NOTE: Replacement elements may be a different
jumper conguration.
5. Disconnect the ground (green/yellow) and power
electrical wires from the terminals inside the cap.
6. Unscrew cable gland (F) from conduit connector
entrance (H). Remove electrical cable and wires
from the heating element. See Figure 17.
7. Loosen V-clamp nut to remove V-clamp (C). Slide
the heating element out of tank as shown.
8. Replace the heating element (G) or perform the
necessary cleaning procedure. Ensure the O-ring
(D) is intact and in place before securing V-Clamp.
4.2.13 REASSEMBLY OF HEATING
ELEMENT AND TANK
To reassemble the heating element and tank, follow the
steps listed in SECTION 4.2.12 in reverse order. Make
sure the ground and power electrical wires are properly
reconnected using the provided nuts.
Tighten the following components:
• V-clamp nut (C) to 20 N m (180 lbf in)
• Element terminal nuts to 1.6 N m (14 lbf in)
NOTE: System wattage may be changed by replacing
the element assembly. Prior to changing
wattage, contact Hotstart with your system’s
part number and serial number to ensure it is
safe to do so, or if other components need to
be changed for proper operation.
E
D
C
F
G
H
B
A
Figure 16. Removing and replacing the heating element.
The heating system should be drained, cleaned and ushed
annually. See SECTION 4.3
A. Element service
entrance cap
B. Element identication
plate
C. V-clamp
D. O-ring
E. Tank
F. Element cable grip and
element cable
G. Element
H. Cable connector
entrance
THREE-PHASE
DELTA
THREE-PHASE
WYE
SINGLE-PHASE
PARALLEL
SINGLE-PHASE
SERIES
THREE-PHASE
DELTA
THREE-PHASE
WYE
SINGLE-PHASE
PARALLEL
SINGLE-PHASE
SERIES
THREE-PHASE
DELTA
THREE-PHASE
WYE
SINGLE-PHASE
PARALLEL
SINGLE-PHASE
SERIES
THREE-PHASE
DELTA
THREE-PHASE
WYE
SINGLE-PHASE
PARALLEL
SINGLE-PHASE
SERIES
Figure 17. Heating element jumper congurations. Replacement
elements may be a different jumper conguration.
This manual suits for next models
1
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