Hotstart OCLE User manual

216272-000 rev6
INSTALLATION & OPERATION MANUAL
MODEL
OCLE
OCLA
DUAL FLUID CIRCULATING HEATING SYSTEM
FOR HAZARDOUS LOCATIONS

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installation & operation manual | ocle/ocla 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 or any large-engine applications. Each heating system has an identication plate which
includes the part number and serial number.
This operation manual describes the installation, operation and maintenance of the heating system. Model specics,
capabilities and features may vary. See part drawings for dimensions and specications.
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.
NOTE Typical heating
system
identication
plate. Your
identication
plate may vary.
IOM216272-000
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]
Railroad Ofce
8915 Broadway
Merrillville, IN 46410 USA
219.648.2448
[email protected]
Europe Ofce
HOTSTART Europe GmbH
Hansestraße 79
51149 Köln, Germany
+49.2203.98137.30
[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]

ii installation & operation manual | ocle/ocla 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 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 2014/35/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. Proper lifting locations are identied with labels 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 heating system for safety and ease
of use.
NOTICE
EU Countries only: Equipment rated for the conditions listed in EN 61010-1 1.4.1 Ingress protection rating IP54.
(Special conditions for specic applications may apply.)

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installation & operation manual | ocle/ocla heating system
TABLE OF CONTENTS
1 OVERVIEW | 1
1.1 HEATING SYSTEM COMPONENTS | 1
1.2 OPERATION OVERVIEW | 2
2 INSTALLATION | 3
2.1 OIL PLUMBING INSTALLATION | 4
2.1.1 Oil Supply | 4
2.1.2 Oil Return | 4
2.2 OIL PLUMBING ILLUSTRATION | 5
2.3 COOLANT PLUMBING INSTALLATION | 6
2.3.1 Coolant Supply | 6
2.3.2 Coolant Return | 6
2.3.3 Coolant Pressure Relief | 6
2.4 COOLANT PLUMBING ILLUSTRATION | 7
2.5 MOUNTING | 8
2.5.1 Tank and Pump | 8
2.6 ELECTRICAL CONNECTIONS | 8
2.6.1 Main Power Supply | 8
2.6.2 Customer Interface Connections | 9
2.6.3 Motor Rotation Check | 10
3 COMPONENTS AND OPERATION | 10
3.1 INTERFACE COMPONENTS | 10
3.1.1 Local/Off/Remote Switch | 10
3.1.2 Prime Button | 10
3.1.3 Reset Button | 10
3.1.4 Pressure/Temperature Gauge | 10
3.1.5 Coolant Pressure Relief Valve | 10
3.1.6 Oil Pressure Relief Valve | 10
3.2 SYSTEM COMPONENTS | 11
3.2.1 Motor Protection Switch | 11
3.2.2 Control TCR (Temperature Control Relay) | 11
3.2.3 High-Limit TCR (Temperature Control Relay) | 11
3.3 HEATING SYSTEM START-UP | 12
3.3.1 First Run Procedure | 12
4 MAINTENANCE, REPAIR AND
TROUBLESHOOTING | 12
4.1 SYSTEM FAULTS | 12
4.1.1 Coolant Faults | 12
4.1.2 Oil Faults | 12
4.2 SYSTEM MAINTENANCE | 13
4.2.1 Plumbing Connections | 13
4.2.2 Electrical Connections | 13
4.2.3 System Mounting | 13
4.2.4 Magnetic Contactors | 13
4.2.5 Pump Seal | 13
4.2.6 Pressure Relief Valve | 13
4.2.7 Pressure/ Temperature Gauge | 13
4.2.8 Volatile Corrosion Inhibitor | 13
4.2.9 Temperature Control Relay | 14
4.2.10 Resistance Temperature Device (RTD) | 15
4.2.11 Heating Tank/Elements | 16
4.2.12 Reassembly of Heating Element and Tank | 16
4.3 RECOMMENDED MAINTENANCE | 17
4.4 STORAGE REQUIREMENTS | 17
4.5 TROUBLESHOOTING | 18

iv installation & operation manual | ocle/ocla heating system
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installation & operation manual | ocle/ocla heating system
1 OVERVIEW
WARNING
!
System location classication: Before installing the OCLE or OCLA heating system, ensure all system components are
suitable for the intended installation location by referring to the location classication labeling attached to the individual
system components.
1.1 HEATING SYSTEM COMPONENTS
NOTE: Component illustrations are for reference only and are not to scale. See part drawings for dimensions
and specications.
A. Oil local/off/remote
switch
B. Coolant local/off/remote
switch
C. Coolant prime button
D. Oil prime button
E. Coolant reset button
F. Oil reset button
G. Coolant outlet
(1″NPT)
H. Oil outlet (1″NPT)
I. Coolant high-limit
resistance temperature
device (RTD)
J. Oil high-limit resistance
temperature device (RTD)
K. Identication plate
L. Coolant pressure/
temperature gauge
M. Pressure relief valve
(0.5″NPT)
N. Oil pressure/temperature
gauge
O. Coolant control resistance
temperature device (RTD)
P. Oil control resistance
temperature device (RTD)
Q. Coolant inlet
(1.25″ NPT)
R. Coolant pump/motor
S. Oil pump/motor
T. Oil inlet
(0.5″/1.0″/1.5″ NPT
see part drawings)
Figure 1. Typical
OCLE/OCLA system
components. Model
style and conguration
may vary. See
part drawings for
dimensions and
specications.
D
G
D
B
A
C
D
E
F
I J KH L M N
O
Q
P
R
S
T

2installation & operation manual | ocle/ocla heating system
1.2 OPERATION OVERVIEW
The OCLE/OCLA heating system is intended to maintain both optimal engine and oil temperature as well as prevent
condensation while the engine is shut down. The heating system may be activated locally or by optional remote control
(see SECTION 2.6.2). The OCLE/OCLA heating system must 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. Simultaneously, a positive displacement pump
takes oil from the sump and forces it through the heating tank to the oil return line. The coolant pump and oil 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 OCLE/OCLA unit and installed at the coolant outlet) and an oil check valve (user-
supplied and installed near the oil suction port) prevent 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.
OIL RETURN
OIL SUPPLY
Figure 2. OCLE/OCLA
system operation.
Component illustrations
are for reference only and
are not to scale. See part
drawings for dimensions
and specications.
COOLANT
SUPPLY
COOLANT
RETURN

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installation & operation manual | ocle/ocla 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, leaks, damage to lubrication oil
and unexpected release of heated coolant or heated oil.
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. Do not connect pressure relief plumbing to heating system or engine coolant
system. See SECTION 2.3.3.
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 uid supply lines to an inner diameter smaller than the pump inlet; pump seal
damage could occur.
Check valve: HOTSTART recommends installing a customer-supplied swing-type or full-ow check (non-return) valve to
prevent oil from owing back into the oil sump. If the pump is installed above the minimum oil level, a check valve must
be installed.
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 the uid.

4installation & operation manual | ocle/ocla heating system
2.1 OIL 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 to the supply and return ports to isolate
the heating system from engine vibration.
2.1.1 OIL SUPPLY
Installing a short, straight oil supply line with a minimum
of ow restriction is the most important step toward
ensuring heating system longevity. When installing
the OCLE/OCLA oil supply line, refer to the following
HOTSTART guidelines:
• Due to the increased viscosity of lubrication
oil, the oil supply line must be as short and
as straight as possible. Any 90° elbows will
reduce the maximum recommended oil
supply length. See Table 1 for HOTSTART
OCLE/OCLA oil supply recommendations:
PUMP
INLET
HOSE INNER
DIAMETER
MAX. LINE
LENGTH
MAX. ELBOW
COUNT
1/2 inch
NPT
1 inch 20 feet
(6 meters)
4
1 inch
NPT
1-1/2 inch 20 feet
(6 meters)
4
1-1/2 inch
NPT
2 inch 20 feet
(6 meters)
4
NOTE: Each additional pair of 90° elbows will reduce
the maximum recommended line length
by ve feet (1.5 meters). To minimize ow
restriction, HOTSTART recommends using
sweeping bends or 45° ttings.
• At a minimum, size the oil 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 oil suction port as low as possible
in the oil sump. NOTICE! Avoid installing
the oil suction port in a location that may
allow debris or sediment to enter the
heating system.
• HOTSTART recommends installing a
customer-supplied, swing-type or full-ow
check (non-return) valve to prevent oil owing
into the sump. Install the check valve as close
to the oil supply port as possible.
• To ensure consistent oil heating, it is
acceptable to select a suction port on the
opposite side of the sump.
2.1.2 OIL RETURN
When installing the OCLE/OCLA oil return line, refer to
the following HOTSTART guidelines:
• At a minimum, size the oil return line per the
pump outlet. NOTICE! Do not reduce the
return line inner diameter.
• The oil return line must be routed to the
oil discharge port located at the end of the
oil sump opposite the suction port. See
SECTION 2.2.
Table 1. HOTSTART recommended hose inner diameters, line
lengths and elbow counts for OCLE/OCLA oil supply lines.

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installation & operation manual | ocle/ocla heating system
2.2 OIL PLUMBING ILLUSTRATION
OIL DISCHARGE PORT
SECTION 2.1.2
OIL SUCTION PORT
SECTION 2.1.1
CHECK VALVE
SECTION 2.1.1
ISOLATION VALVE
ISOLATION VALVE
OIL SUPPLY
SECTION 2.1.1
OIL RETURN
SECTION 2.1.2
E-2E-1
V-2 V-3V-1
COMPONENT
DESCRIPTION
V-1 USER SUPPLIED CHECK VALVE
V-2 USER SUPPLIED FULL FLOW ISOLATION VALVE
E-1 OIL PUMP
E-2 OIL HEATING ELEMENT
V-3 USER SUPPLIED FULL FLOW ISOLATION VALVE

6installation & operation manual | ocle/ocla heating system
2.3 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 to the supply and return ports to isolate
the heating system from engine vibration.
2.3.1 COOLANT SUPPLY
When installing the OCLE/OCLA coolant supply line,
refer to the following HOTSTART guidelines (See
SECTION 2.4):
• 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 (A). NOTICE! At a
minimum, suction port must be sized per
the pump inlet (1.25" NPT).
• 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.
2.3.2 COOLANT RETURN
When installing the OCLE/OCLA coolant return line, refer
to the following HOTSTART guidelines( See SECTION
2.4):
• 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,
typically at the rear of the engine block on the
engine water rails (B).
2.3.3 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.

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installation & operation manual | ocle/ocla heating system
2.4 COOLANT PLUMBING ILLUSTRATION
A
B
COOLANT
SUCTION PORT
SECTION 2.3.1
COOLANT
DISCHARGE PORT
SECTION 2.3.2
ISOLATION
VALVE
ISOLATION VALVE
COOLANT RETURN
SECTION 2.3.2
COOLANT
SUPPLY
SECTION 2.3.1
PRESSURE RELIEF VALVE
SECTION 2.3.3
E-2
E-1
V-1
V-3
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 USER SUPPLIED FULL FLOW ISOLATION VALVE
PRESSURE RELIEF VALVE

8installation & operation manual | ocle/ocla heating system
2.5 MOUNTING
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.
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.
2.5.1 TANK AND PUMP
Mount the heater in a vertical orientation with tank
directly above control box and pump.Reference
drawings for mounting position. When installing the
heating system, note that the tank requires a minimum of
30 inches (63.5 cm) of clearance to remove element for
maintenance. See SECTION 4.2.11.
2.6 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.
2.6.1 MAIN POWER SUPPLY
1. Connect the specied power from the customer-
supplied circuit breaker to the terminal blocks
located in the main control box. See Fig. 5 on
following page.
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 is 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 (A).
hFor single-phase applications, use the terminal
blocks labeled L1 and L2 or L and N (A).
2. Connect the main power ground wire to the ground
block (B).
Figure 3. OCLE/OCLA
0.438 inch (11.13 mm)
diameter mounting holes
×6 (A). Mount unit in
orientation shown. Do
not mount at an angle or
in any other orientation.
Figure 4. OCLE/OCLA underside, showing 2″NPT main power
entrance (A) and 0.5″NPT customer interface wiring entrance (B).
JA
B
A

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installation & operation manual | ocle/ocla heating system
2.6.2 CUSTOMER INTERFACE
CONNECTIONS
The following customer interface connections are
available for remote control and monitoring:
• Remote On/Off 24 V DC shutdown (G)
TB2:9/TB2:10
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 local/
off/remote switch is turned to remote.
NOTE: The 24 V DC shutdown connection is
wired NC (normally closed) from the
factory; see system wiring schematic for
directions to switch to NO (normally open)
operation.
• Fault Signal
TB2:1/TB2:2 coolant (C)
TB2:5/TB2:6 oil (E)
The fault signal will indicate a heating system
shutdown, triggered by either the high-
limit temperature control relay or the motor
protection switch (see SECTION 4.1).
• Motor Run Signal
TB2:3/TB2:4 coolant (D)
TB2:7/TB2:8 oil (F)
A motor run signal indicates the pump motor
is running. If no signal is present, the pump
motor is not running.
• Switch Location Signal
X1:7/X1:8/X1:9 coolant (H)
X2:7/X2:8/X2:9 oil (I)
The switch location signal indicates the
local/off/remote switch position:
off: 7, local: 8, remote: 9.
L1
L2 TB1
L3
A
B
Figure 5. Main power supply and customer interface connections
as shown in the OCLE/OCLA control box. Reference electrical
schematic drawing for proper wiring locations; the following
illustrations are typical customer interface locations.
A. Main power
terminal block
B. Main power
ground block
C. Coolant fault
signal
D. Coolant motor run
signal
E. Oil fault signal
F. Oil motor run
signal
G. Remote On/Off
24 V DC shutdown
H. Coolant switch
location signal
I. Oil switch
location signal
L1
L2 TB1
TB2
L3
1 2
4
6
8
10
3
5
7
9
X2 X1
C
D
E
F
GHI
TB2:10 TB2:9
K1
A1 A2
12
3 4
SW1-B
X1:8P1:8
X1:9P1:9
P1:7X1:7
X1:7 X1:8
X1:9
TB2:1 TB2:2
TB2:3 TB2:4
1413
K2
K4
11 12
12
3 4
SW3-B
X2:8P2:8
X2:9P2:9
P2:7X2:7
X2:7 X2:8
X2:9
TB2:5 TB2:6
TB2:7 TB2:8
1413
K6
K8
11 12
REMOTE ON/OFF
24 V DC
LOCAL SIGNAL
– COOLANT
REMOTE SIGNAL
– COOLANT
LOCAL SIGNAL
– OIL
REMOTE SIGNAL
– OIL
FAULT WHEN
CLOSED – COOLANT
MOTOR ON WHEN
CLOSED – COOLANT
FAULT WHEN
CLOSED – OIL
MOTOR ON WHEN
CLOSED – OIL

10 installation & operation manual | ocle/ocla heating system
2.6.3 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 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 2.6.1), 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.
3 COMPONENTS AND
OPERATION
The following is an operational description for each of
the OCLE/OCLA interface and system components.
NOTE: Components installed in control box may
vary depending on the particular system
conguration purchased.
3.1 INTERFACE COMPONENTS
3.1.1 LOCAL/OFF/REMOTE SWITCH
• local – The system is on.
• off – The system is shut off.
• remote – The system will turn on and shut
off on a signal from the 24 V DC remote
connection. See SECTION 2.6.2.
3.1.2 PRIME BUTTON
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. NOTICE! Do not run
the motor/pump assembly dry for more than ve
seconds at a time.
NOTE: The prime function is intended for use during
the rst run procedure (see SECTION 3.3.1) or
after performing maintenance on the heating
system or plumbing (see SECTION 4.3).
3.1.3 RESET BUTTON
Press the reset button to reset the pump motor protection
switch without opening the control box. The reset function
is intended for use immediately following resolving and
repairing a system fault (see SECTION 4.1).
3.1.4 PRESSURE/TEMPERATURE
GAUGE
The OCLE/OCLA model 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 conguration of the engine.
3.1.5 COOLANT 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. See SECTION 2.3.3.
3.1.6 OIL PRESSURE RELIEF VALVE
PRESSURE RELIEF
VALVE CAP
PUMP INLET PUMP OUTLET
Figure 6. Typical OCLE/OCLA pump assembly. Note that the
pressure relief valve cap must always point toward the inlet side of
pump.

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installation & operation manual | ocle/ocla heating system
The oil pump pressure relief valve is internal to the pump
and releases pressure from the discharge side of the
pump to the suction side of the pump at 75 psi (525
kPa). No plumbing for this component is required. The
pressure relief valve cap must always point toward the
inlet side of the pump.
The OCLE/OCLA heating system is designed to not
exceed 125 psi (862 kPa); however, the oil pump will not
exceed 75 psi (517 kPa). In the event the pressure relief
valve is activated, the pump will continue to produce
flow, but will not exceed a pressure of 75 psi (517 kPa).
3.2 SYSTEM COMPONENTS
3.2.1 MOTOR PROTECTION SWITCH
The motor protection switch (MPS) 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
reset button or press the MPS reset/on button (B). See
Fig. 7. For additional troubleshooting, see SECTION 4.5.
3.2.2 CONTROL TCR (TEMPERATURE
CONTROL RELAY)
The control TCRs (TCR1 and TCR3)are used to control
the temperature of the corresponding 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 coolant control temperature relay
(TCR1) is 122 °F (50 °C). The standard setting for the oil
control temperature relay (TCR3) is 104 °F (40 °C).
See Fig. 7.
3.2.3 HIGH-LIMIT TCR (TEMPERATURE
CONTROL RELAY)
The high-limit TCRs (TCR2 and TCR4) are 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 and oil
high-limit TCR is 194 °F (90 °C) and should always be at
least 18 °F (10 °C) higher than the corresponding control
TCR set point. The high-limit TCR hysteresis is not used
in the high-limit control. See Fig. 7.
Figure 7. OCLE/OCLA motor protection switch (left), showing stop/
off (A) and reset/on (B) buttons. To reset the MPS, the heating
system must be switched off and either the reset button or the
MPS reset/on button must be pressed.
OCLE/OCLA control TCR and high-limit TCR (left). The standard
setting for TCR1 coolant control dial (C) is 122 °F (50 °C). The
standard setting for TCR3 oil control dial (D) is 104 °F (40 °C).
TCR4
TCR3
TCR2
TCR1
HIGH LIMIT
OIL
CONTROL
OIL
HIGH LIMIT
COOLANT
CONTROL
COOLANT
0000
MPS1
MPS2
C
T1 T2 T3
L1 L2 L3
T1 T2 T3
L1 L2 L3
13
14
13
14
A3A1
T2 T3T1
11 12
A2-14
13
A3A1
T2 T3T1
11 12
A2-14
13
A3A1
T2 T3T1
11 12
A2-14
13
A3A1
T2 T3T1
11 12
A2-14
13
A
B
D
TCR4
TCR3
TCR2
TCR1
HIGHLIMIT
OIL
CONTROL
OIL
HIGHLIMIT
COOLANT
CONTROL
COOLANT
0000
MPS1 MPS2
T1 T2 T3
L1 L2 L3
T1 T2 T3
L1 L2 L3
13
14
13
14
A3A1
T2 T3T1
11 12
A2-14
13
A3A1
T2 T3T1
11 12
A2-14
13
A3A1
T2 T3T1
11 12
A2-14
13
A3A1
T2 T3T1
11 12
A2-14
13
TCR4
TCR3
TCR2
TCR1
HIGH LIMIT
OIL
CONTROL
OIL
HIGH LIMIT
COOLANT
CONTROL
COOLANT
0000
MPS1 MPS2
C
T1 T2 T3
L1 L2 L3
T1 T2 T3
L1 L2 L3
13
14
13
14
A3A1
T2 T3T1
11 12
A2-14
13
A3A1
T2 T3T1
11 12
A2-14
13
A3A1
T2 T3T1
11 12
A2-14
13
A3A1
T2 T3T1
11 12
A2-14
13
A
B
D

12 installation & operation manual | ocle/ocla heating system
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 18 °F (10 °C)
higher than the control temperature control relay (TCR1)
for proper heating operation. This will prevent nuisance
tripping of the high-limit circuit.
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
2.6.3).
NOTE: Single-phase systems are prewired to
ensure the pump motor rotates in the
correct direction. A motor rotation check is
not necessary for single-phase systems.
2. Check and tighten all electrical and plumbing
connections.
3. Ensure isolation valves are open before energizing
the system.
4. Bleed all trapped air from the heating system by
opening a plug or pipe tting at or near the pump.
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 conguration
of the engine.
5. Turn the local/off/remote switch to local or
remote 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 oil.
HOTSTART recommends a control temperature on
TCR1 of 104 °F (40 °C). The high-limit temperature
setting on TCR2 should be set at 194 °F (90 °C).
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 signal connection
(if installed).
4 MAINTENANCE,
REPAIR AND
TROUBLESHOOTING
4.1 SYSTEM FAULTS
A failure in the pump motor that causes the motor
protection switch (MPS1 or MPS2) to trip will shut
down the respective heating system. 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 reset button (or the MPS reset/
on button) to reset the fault. (See SECTION 3.1.3.)
If there is a failure that causes a high temperature to
occur, the high-limit temperature controller (TCR2 or
TCR4) will shut down the respective heating system,
including the pump motor. 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
uid temperature drops below the high-limit preset (See
SECTION 3.2.3.). For additional troubleshooting, see
SECTION 4.5.
4.1.1 COOLANT FAULTS
A fault signal will be transmitted if:
• The coolant pump motor protection switch is
tripped (MPS1).
• The coolant high-limit temperature is
exceeded (TCR2).
4.1.2 OIL FAULTS
A fault signal will be transmitted if:
• The oil pump motor protection switch is
tripped (MPS2).
• The oil high-limit temperature is exceeded
(TCR4).

13
installation & operation manual | ocle/ocla heating system
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 may cause terminals to loosen. At start-up,
tighten electrical connections. 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 as voltage switching
controls for motors and heating elements in HOTSTART
heating systems. The contactors use 120 volt or 240
volt coils. To test for failure, check for continuity across
the coil connections; an open or direct-short reading
indicates a failed contactor coil.
The contacts on the magnetic contactor should be
inspected periodically for welding, arc erosion and
mechanical wear. If any of these conditions exist, replace
the magnetic contactor. HOTSTART recommends
contactors be replaced every five years.
4.2.5 PUMP SEAL
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 2.3.1)
NOTE: Instructions to replace the pump seals are
included with replacement seals.
4.2.6 PRESSURE RELIEF VALVE
The oil pump pressure relief valve is internal to the pump
and releases pressure from the discharge side of the
pump to the suction side of the pump. No maintenance
for this part is required.
4.2.7 PRESSURE/ TEMPERATURE
GAUGE
The oil pressure/temperature gauge will indicate a
pressure increase when the pump motor is engaged
by pressing the prime button or during normal heater
operation. The gauge will also indicate the current uid
temperature. No maintenance for this part is required.
4.2.8 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 that the VCI is replaced at six month
intervals. See SECTION 4.4.

14 installation & operation manual | ocle/ocla heating system
4.2.9 TEMPERATURE CONTROL RELAY
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 OCLE/OCLA 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 Fig. 8):
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 4). 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 Fig. 10, Fig. 11 on
following page.
5. Using the ohmmeter, touch the probes to RTD
lead TS2:WHT (A) and lead TS2:RED (B). See Fig.
9. Note the resistance. Touch the probes to lead
TS2:RED (B) and lead TS2:RED (C) to check for
continuity:
hIf the resistance between RTD lead TS2:WHT
(A) and lead TS2:RED (B) is between 80 and
120 ohms and there is continuity between RTD
TS2:RED (B) and lead TS2:RED (C), the RTD is
functioning properly. Replace the RTD cable.
hIf the resistance between RTD lead TS2:WHT
(A) and lead TS2:RED (B) is not between
80 and 120 ohms or there is no continuity
between lead TS2:RED (B) and lead TS2:RED
(C), the RTD is malfunctioning. Replace the RTD.
See SECTION 4.2.10.
TCR4
TCR3
TCR2
TCR1
HIGHLIMIT
OIL
CONTROL
OIL
HIGHLIMIT
COOLANT
CONTROL
COOLANT
0000
MPS1 MPS2
T1 T2 T3
L1 L2 L3
T1 T2 T3
L1 L2 L3
13
14
13
14
A3A1
T2 T3T1
11 12
A2-14
13
A3A1
T2 T3T1
11 12
A2-14
13
A3A1
T2 T3T1
11 12
A2-14
13
A3A1
T2 T3T1
11 12
A2-14
13
TCR4
TCR3
TCR2
TCR1
HIGH LIMIT
OIL
CONTROL
OIL
HIGH LIMIT
COOLANT
CONTROL
COOLANT
0000
MPS1 MPS2
T1 T2 T3
L1 L2 L3
T1 T2 T3
L1 L2 L3
13
14
13
14
A3A1
T2 T3T1
11 12
A2-14
13
A3A1
T2 T3T1
11 12
A2-14
13
A3A1
T2 T3T1
11 12
A2-14
13
A3A1
T2 T3T1
11 12
A2-14
13
Figure 8. Control and
high-limit TCRs showing
terminals T1, T2 and T3.
Figure 9. RTD leads and connectors shown on the RTD assembly,
TSX:WHT (A), TSX:RED (red wire) (B), TSX:RED (black wire) (C), and
Ground (D). Disconnect wire from connector as shown.
OS2EWHO
OS2ERTD
OS2ERTD
(W)
D
A
B
C
TCR TYPE RTD Position
TCR1 Coolant Control 50 °C Coolant Tank Inlet
TCR2 Coolant High-limit 90 °C Coolant Tank Outlet
TCR3 Oil Control 40 °C Oil Tank Inlet
TCR4 Oil High-limit 90 °C Oil Tank Outlet
Table 2. TCR types, default temperature settings and
corresponding RTD positions.