Hotstart OLA User manual

216348-000 rev1
INSTALLATION & OPERATION MANUAL
MODEL
OLA
OIL CIRCULATING HEATING SYSTEM
FOR HAZARDOUS LOCATIONS

i
installation & operation manual | ola 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. 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.
NOTE Typical heating
system
identication
plate. Your
identication
plate may vary.
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]
IOM216348-000

ii installation & operation manual | ola 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.
Electro-static discharge: Wipe all operators and hoses
with damp cloth to reduce potential for electro-static
discharge.
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 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 2014/34/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. 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 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.
• Flameproof joints: Flameproof joints are not
intended to be repaired in the eld. Do not attempt
to repair any ameproof joints that become
damaged.
• Bend radius: Do not adjust cable bend radius in the
eld. Cables are pre-wired to meet the minimum
requirements for bend radius. If a cable is moved
from factory positioning, adjust cable to ensure
minimum bend radius is 7 × (Ø) outer diameter of
the cable.
• Enclosure yield strength: The enclosures utilize
metric bolts that are Class 8.8 minimum and Class
A4-70 with a minimum yield strength of 600 MPa.
NOTICE
EU Countries only: Equipment rated for the conditions
listed in EN 601010-1 1.4.1 Ingress protection rating IP54.
(Special conditions for specic applications may apply.)
CERTIFICATIONS
Certications:
IECEx UL 18.0106X
Ex db IIA T3 Gb
DEMKO 18 ATEX
2107X
C0539 ` II 2 G Ex
db IIA T3 Gb
Standards used for
certications:
• IEC 60079-0:2011
and Corr. 1:2012
and Corr. 2:2013
• IEC 60079-1:2014
• EN 60079-0:2012
and A11:2013
• EN 60079-1:2014
• IEC TS 60079-46
Max/ Min. process uid temp. 0 °C to 80 °C
Ambient temp. -20 °C to 40 °C
Voltages 120 to 575 V AC, 50/60 Hz,1/3 phase
The following additional previous editions of Standards noted under the
“Standards” section of the Certicate were applied to integral Components
as itemized below. There are no signicant safety related changes between
these previous editions and the editions noted under the “Standards”
section.
Weg Induction Motors of Frame Size
90 to 132 IEC 60079-1 Edition 2007
Siemens Motors IEC 60079-0 Edition 2009
Siemens Motors IEC 60079-1 Edition 2007
ABB M3JP Motors IEC 60079-0 Edition 2009
ABB M3JP Motors IEC 60079-1 Edition 2007
CMP Products Limited TMC2X
Range of Cable Glands IEC 60079-1 Edition 2007
CMP Products Limited Cable Gland
Types PX** IEC 60079-1 Edition 2007
Adalet/Scott Fetzer Co. XCEX
Series Enclosures IEC 60079-0 Edition 2009
Adalet/Scott Fetzer Co. XCEX
Series Enclosures IEC 60079-1 Edition 2007

iii
installation & operation manual | ola 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
(ENGINE) | 5
2.3 OIL PLUMBING ILLUSTRATION
(COMPRESSOR WITH PRELUBE) | 6
2.4 MOUNTING | 7
2.4.1 Tank and Pump | 7
2.5 ELECTRICAL CONNECTIONS | 7
2.5.1 Main Power Supply | 7
2.5.2 Customer Interface Connections | 8
2.5.3 Motor Rotation Check | 9
3 COMPONENTS AND OPERATION | 9
3.1 INTERFACE COMPONENTS | 9
3.1.1 Local/Off/Remote Switch | 9
3.1.2 Prime Button | 9
3.1.3 Reset Button | 9
3.1.4 Pressure/Temperature Gauge | 9
3.1.5 Pressure Relief Valve | 9
3.2 SYSTEM COMPONENTS | 10
3.2.1 Motor Protection Switch | 10
3.2.2 Control TCR (Temperature Control Relay) | 10
3.2.3 High-Limit TCR (Temperature Control Relay) | 10
3.3 HEATING SYSTEM START-UP | 10
3.3.1 First Run Procedure | 11
4 MAINTENANCE AND
TROUBLESHOOTING | 11
4.1 SYSTEM FAULTS | 11
4.1.1 Oil Faults | 11
4.2 SYSTEM MAINTENANCE | 11
4.2.1 Plumbing Connections | 11
4.2.2 Electrical Connections | 12
4.2.3 System Mounting | 12
4.2.4 Magnetic Contactors | 12
4.2.5 Pump Seal | 12
4.2.6 Pressure Relief Valve | 12
4.2.7 Pressure/ Temperature Gauge | 12
4.2.8 Volatile Corrosion Inhibitor | 12
4.2.9 Temperature Control Relay | 13
4.3 RECOMMENDED MAINTENANCE | 14
4.4 STORAGE REQUIREMENTS | 14
4.5 TROUBLESHOOTING | 15

iv installation & operation manual | ola heating system
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installation & operation manual | ola heating system
1 OVERVIEW
WARNING
!
System location classication: Before installing the OLA 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. local/off/remote switch
B. prime button
C. reset button
D. Heating element
E. Oil outlet
(1″NPT)
F. High-limit resistance
temperature device (RTD)
G. Heating tank
H. Identication plate
I. Control resistance
temperature device (RTD)
J. Pressure/Temperature gauge
K. Pump motor
L. Oil pump
M. Oil inlet
(0.5″/1.0″/1.5″ NPT
see part drawings)
Figure 1. Typical OLA system
components. Model style and
conguration may vary. See part
drawings for dimensions and
specications.
I
J
K
L
M
FE
D
C
B
A
HG

2installation & operation manual | ola heating system
1.2 OPERATION OVERVIEW
The OLA heating system is intended to maintain optimal oil temperature while the engine or compressor is shut down.
The heating system may be activated locally or by optional remote control (see SECTION 2.5.2). The OLA heating
system must be deactivated upon engine start-up.
During heating system operation, a rotary gear pump takes oil from the sump and forces it through the heating tank to the
oil return line. The oil pump will continuously circulate uid throughout the engine or compressor. To maintain consistent
uid temperature, the heating element will cycle on and off at the user-selected temperature control point.
An oil check valve (user-supplied and installed near the oil suction port) prevents backow while the engine or compressor
is operating. When the engine or compressor is shut down, the heating system should be activated locally or remotely to
resume maintaining the optimal oil temperature.
OIL RETURN
OIL SUPPLY
Figure 2. OLA system
operation. Component
illustrations are for
reference only and are not
to scale. See part drawings
for dimensions and
specications.

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installation & operation manual | ola 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, damage to lubrication oil, leaks
and unexpected release of heated oil.
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 oil supply line 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 oil.

4installation & operation manual | ola 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
OLA 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
OLA 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
2-1/2 inch
NPT
3 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, typically near or on the third
inspection cover. 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 OLA 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 return line may be routed to the opposite
end of the oil sump or the oil return line
may be routed to a prelube location. See
SECTION 2.3.
Table 1. HOTSTART recommended hose inner diameters, line
lengths and elbow counts for OLA oil supply lines.

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installation & operation manual | ola heating system
2.2 OIL PLUMBING ILLUSTRATION (ENGINE)
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 | ola heating system
2.3 OIL PLUMBING ILLUSTRATION (COMPRESSOR WITH PRELUBE)
PRELUBE LOCATION
SECTION 2.1.2
OIL SUCTION PORT
SECTION 2.1.1
ISOLATION VALVE
OIL SUPPLY
SECTION 2.1.1
OIL RETURN
SECTION 2.1.2
ISOLATION VALVE
CHECK VALVE
SECTION 2.1.1
E-2E-1
V-2 V-3V-1
V-4
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
V-4 OPTIONAL USER SUPPLIED PRV

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installation & operation manual | ola heating system
2.4 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.
2.4.1 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.
2.5 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 the
National Electrical Code (NEC) or Canadian Electrical
Code (CEC), and any applicable local codes (such as
NFPA 496), 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 specic ratings.
Grounding conductor: Equipment grounding
conductors shall be sized per NEC 2017 Table 250.122
for US installations. For international installations, use
IEC 60079-0, Clause 16. Ground terminal block will
accept 16–4 AWG conductors. External grounding
connection not provided. Metallic conduit or armored
cable must be used. Wiring systems shall comply with
15.1.2 b) of IEC 60079-0.
2.5.1 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. 4 and
Table 2.
Figure 3. OLA 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. OLA underside, showing 1.25 ″NPT main power entrance
(A) and 0.5 ″NPT customer interface wiring entrance (B).
JA
BA
Copper Wire Stranding Classes – Number of Strands
Wire
Size Torque Solid Class BClass CClass GClass HClass IClass K
2/0 AWG 120in·lbs 19 37
1/0 120in· lbs 19 37
1120in· lbs 19 37 ~133 ~259 ~210 ~836
2120in· lbs 719 ~49 ~133 ~161 ~665
4120in· lbs 719 ~49 ~133 ~105 ~420
6120in· lbs 719 ~49 ~133 ~63 ~266
840in· lbs 719 ~49 ~133 ~41 ~168
10 35in· lbs 1 7 19 ~27 ~104
12 35in· lbs 1 7 19 ~19 ~65
14 35in· lbs 1 7 19 ~19 ~41
Table 2. Line Side Wire Approvals. ~Qantity of strands for Classes G,
H, I, K may vary by manufacturer. Aluminum stranded wire range: 2/0
– #6 AWG. Minimum 90 °C wire for all electrical connections.

8installation & operation manual | ola heating system
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).
2.5.2 CUSTOMER INTERFACE
CONNECTIONS
The following customer interface connections are
available for remote control and monitoring (See Fig. 5):
• TB2:1/TB2:2
Remote On/Off 24 V DC shutdown (C)
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.
• TB2:3/TB2:4
Fault Signal (D)
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 4.1.1).
• TB2:5/TB2:6
Motor Run Signal (E)
A motor run signal indicates the pump motor
is running. If no signal is present, the pump
motor is not running.
L1 L2
TB1
L3
L1 L2 L3
13
T1 T2 T3
13
MPS1
TB2
X1
2 4 6
1 3 5
7 8 9 10 11 12 13 14
A1 A3
T1 T2 T3
13 14 A2-
11 12
TCR1
CONTROL
0 100
A1 A3
T1 T2 T3
13 14 A2-
11 12
TCR1
HIGH
LIMIT
0 100
L1 L2
TB1
L3
L1 L2 L3
13
T1 T2 T3
13
MPS1
TB2
X1
2 4 6
1 3 5
7 8 9 10 11 12 13 14
A1 A3
T1 T2 T3
13 14 A2-
11 12
TCR1
CONTROL
0 100
A1 A3
T1 T2 T3
13 14 A2-
11 12
TCR1
HIGH
LIMIT
0 100
AB
L1 L2
TB1
L3
L1 L2 L3
13
T1 T2 T3
13
MPS1
TB2
X1
2 4 6
1 3 5
7 8 9 10 11 12 13 14
A1 A3
T1 T2 T3
13 14 A2-
11 12
TCR1
CONTROL
0 100
A1 A3
T1 T2 T3
13 14 A2-
11 12
TCR1
HIGH
LIMIT
0 100
E
D
C
Figure 5. Main power supply and customer interface connections
as shown in the OLA 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
terminal block
C. Remote On/Off
24 V DC shutdown
D. Fault signal
E. Motor run signal
12
3 4
SW1-B
X1:8P1:8
X1:9P1:9
P1:7X1:7
X1:7 X1:8
X1:9
TB2:3 TB2:4
TB2:5 TB2:6
TB2:1 TB2:2
1413
K2
K1
A1 A2
1211
K4
LOCAL SIGNAL
REMOTE SIGNAL
REMOTE ON/OFF 24 V DC
FAULT WHEN CLOSED
MOTOR ON WHEN CLOSED

9
installation & operation manual | ola heating system
2.5.3 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 2.5.1), 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 OLA 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 2.5.2.
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 4.2).
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 4.1.1).
3.1.4 PRESSURE/TEMPERATURE GAUGE
The OLA 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 PRESSURE RELIEF VALVE
CAUTION
!
Pressure relief valve: If the OLA heating system is for
use with a pressurized uid system, additional, user-
supplied pressure relief must be installed along the
heating system outlet plumbing. User-supplied pressure
relief valve plumbing must be routed back to oil sump
or to atmospheric pressure. Do not route pressure relief
plumbing back to heating system tank.
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 OLA 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).
PRESSURE RELIEF
VALVE CAP
PUMP INLET PUMP OUTLET
Figure 6. Typical OLA pump assembly. Note that the pressure relief
valve cap must always point toward the inlet side of pump.

10 installation & operation manual | ola heating system
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 TCR 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 heater. The standard setting for the control
temperature relay (TCR1) is 104 °F (40 °C). See Fig. 7.
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 uses a
resistance temperature device (RTD) located near the
tank outlet. The default setting for the high-limit TCR is
194 °F (90 °C) 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 Fig. 7.
Figure 7. OLA 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.
OLA control TCR and high-limit TCR (above). The standard setting
for TCR1 control dial (C) is 104 °F (40 °C).
L1 L2
TB1
L3
L1 L2 L3
13
T1 T2 T3
13
MPS1
TB2
X1
2 4 6
1 3 5
7 8 9 10 11 12 13 14
A1 A3
T1 T2 T3
13 14 A2-
11 12
TCR1
CONTROL
0 100
A1 A3
T1 T2 T3
13 14 A2-
11 12
TCR1
HIGH
LIMIT
0 100
L1 L2
TB1
L3
L1 L2 L3
13
T1 T2 T3
13
MPS1
TB2
X1
2 4 6
1 3 5
7 8 9 10 11 12 13 14
A1 A3
T1 T2 T3
13 14 A2-
11 12
TCR1
CONTROL
0 100
A1 A3
T1 T2 T3
13 14 A2-
11 12
TCR1
HIGH
LIMIT
0 100
A
B
L1 L2
TB1
L3
L1 L2 L3
13
T1 T2 T3
13
MPS1
TB2
X1
2 4 6
1 3 5
7 8 9 10 11 12 13 14
A1 A3
T1 T2 T3
13 14 A2-
11 12
TCR1
CONTROL
0 100
A1 A3
T1 T2 T3
13 14 A2-
11 12
TCR2
HIGH
LIMIT
0 100
A
B
C

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installation & operation manual | ola 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
2.5.3).
NOTE: Single-phase systems are prewired to
ensure the pump motor rotates in the
correct direction. A motor rotation check is
not necessary.
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 AND
TROUBLESHOOTING
4.1 SYSTEM FAULTS
4.1.1 OIL FAULTS
A fault signal will be transmitted if:
• The oil pump motor protection switch is
tripped (MPS1).
• The oil 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. 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) will
shut down the 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.
4.2 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

12 installation & operation manual | ola heating system
compliance level of the original heating system.
NOTE: After maintenance is performed, refer to
SECTION 3.3 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)
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.

13
installation & operation manual | ola 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 OLA 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 3.
5. Using the ohmmeter, touch the probes to
RTD lead TS2:WHT (A) and lead TS2:RED (B). See
Fig. 11. Note the resistance. Touch the probes to
lead TS2:WHT (A) 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:WHT (A) and lead TS2:RED (C), the RTD is
functioning properly. Replace the RTD cable.
hIf the resistance between RTD lead TS2:WHT
(A) and ead TS2:RED (B) is not between
80 and 120 ohms or there is no continuity
between lead TS2:WHT (A) and lead TS2:RED
(C), the RTD is malfunctioning. Replace the RTD.
L1 L2
TB1
L3
L1 L2 L3
13
T1 T2 T3
13
MPS1
TB2
X1
2 4 6
1 3 5
7 8 9 10 11 12 13 14
A1 A3
T1 T2 T3
13 14 A2-
11 12
TCR1
CONTROL
0 100
A1 A3
T1 T2 T3
13 14 A2-
11 12
TCR2
HIGH
LIMIT
0 100
A
B
L1 L2
TB1
L3
L1 L2 L3
13
T1 T2 T3
13
MPS1
TB2
X1
2 4 6
1 3 5
7 8 9 10 11 12 13 14
A1 A3
T1 T2 T3
13 14 A2-
11 12
TCR1
CONTROL
0 100
A1 A3
T1 T2 T3
13 14 A2-
11 12
TCR1
HIGH
LIMIT
0 100
Figure 8. Control (TCR1) and
high-limit (TCR2) TCR 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 Oil Control 40 °C Oil Tank Inlet
TCR2 Oil High-limit 90 °C Oil Tank Outlet
Table 3. TCR types, default temperature settings and
corresponding RTD positions.

14 installation & operation manual | ola heating system
4.3 RECOMMENDED MAINTENANCE
INTERVAL MAINTENANCE TASK
At initial start-up Tighten electrical connections. See SECTION 3.1.1.
One week after initial start-up Check and tighten electrical connections. See SECTION
4.2.2.
Every three months Tighten electrical connections.
Annually Drain, clean and ush heating system.
Check for cracked or weakened hoses and replace if
necessary.
Check electrical wiring and connections for wear and
excessive heat.
Check mounting bolts and tighten if necessary.
Remove element and clean element and tank.
Every ve years Replace magnetic contactors. See
SECTION 4.2.4.
4.4 STORAGE REQUIREMENTS
If long-term storage is necessary, precautions must be
taken to ensure that the heating system is operational
for start-up. Steps must be taken to ensure that water
ingress is mitigated at all locations. All plugs and caps
must remain tight and a suitable cover must be provided
for the system. The cover must shield the system from
direct rain and protect from any directed spray that may
occur.
For any storage longer than three months, desiccant
bags must be placed next to the system if it is still in
the original packaging and inside the control box. If
the storage duration will be one year or longer, the
volatile corrosion inhibitor inside the control box must be
replaced at six month intervals.
New pump motors placed in long-term storage for a
year or longer may require relubrication before initial
use. If your pump motor has provisions for relubrication,
refer to the pump motor manufacturer’s relubrication
recommendations. Refer to the pump motor nameplate
for lubrication type.