Hotstart Catalog - Davidson Sales Co.

Installation Instructions for Tank-style HeatersThe HOTSTART engine heater operates on the principle of a thermosiphon. As coolant flows into the heater intake opening, it is warmedby the element and begins to rise. The heated coolant exits through the heater outlet opening creating continuous circulation. The heaterthermostat senses the temperature of the coolant and cycles the heater on and off.For “V” engines larger than eight cylinders or over1000 CID (15L), HOTSTART recommends using aHOTflow heater. Please refer to pages 22-24 tospecify the proper size heater.Prior to heater installation, inspect the coolant supply. Contaminatedcoolant will limit heater performance and cause premature elementfailure. Check your engine manufacturer’s recommendations for theproper coolant. Only de-ionized or distilled water and a low-silicateantifreeze should be used and not exceed a 60% antifreeze to 40%water ratio. The use of hard water or water softened with salts is oneof the most common causes of failure to the heating element. Acooling system containing anti-leak additive will also result in elementfailure.MOUNTINGMount the heater in a horizontal position with the outlet neck pointedup. Position the heater outlet directly under the engine port to whichcoolant returns. Proper positioning of the heater will eliminatehorizontal sections or dips in the outlet hose which restrictscirculation.Using supplied hardware, mount heater to the engine frame or skid.(See Figure 2). The heater must be mounted below the lowest level ofthe engine water jacket to ensure a good gravity flow of coolant tothe heater.DO NOT mount the heater to the engine. Engine vibration candamage the heater and void the warranty.PLUMBINGHeater Outlet: Install the hose between the outlet of the heater andthe coolant return port on the engine. The hose must be routed toensure a continuous rise from the heater to the engine (See Figure 3).Heater Inlet: Connect hose from the inlet of the heater to where thecoolant will be pulled out of the engine. There must be no high spotsin the routing of the hose (See Figure 3).DO NOT route outlet hose above engine block connection, or loop orkink hoses. This will cause air locks in the hose and block circulationof the coolant by the heater.Follow the engine manufacturer’s specifications for coolant. Refill thecooling system with the outlet hose disconnected to eliminate airpockets in the heater. Start engine and allow it to run until the enginethermostat opens. This will help purge the air out of the heater andplumbing. Once the engine has reached operating temperature, shutoff and inspect for leaks and check coolant level. Top off the coolantif necessary.WIRING1 PHASE up to 480VAC:Single phase heaters rated up to 480V may be powered directlywithout the use of a control relay or contactor.OVER 480VAC or 3 PHASE:If the power to the heater is greater than 480V or is 3 phase, theheater thermostats must be used in a control circuit with a contactorfor switching the main power to the heating elements. ContactHOTSTART for recommended control boxes.On standby and automatic start engines, heaters should be deenergizedupon engine start-up. The engine heater should notoperate during engine operation. See pages 37, 38, and 39 or consultHOTSTART for recommendations on your specific applications.YESYESYES1 2Coolant FlowOutletHORIZONTAL MOUNT InletFIGURE 1Lowest level of water jacketFIGURE 2NOFIGURE 3FIGURE 4NONOOutletInletVERTICAL MOUNTNOTo ensure the heater has been installed correctly, the coolanttemperature going into the engine should be well below 200°F (93°C).A heater outlet temperature higher than 200°F or an inlet hose that ishotter than the outlet hose indicates limited or no circulation. Highoutlet temperatures result in decreased heater/hose life and poorengine heating. If equipped with a control thermostat – the heatershould cycle on and off a maximum of 4 times per hour.20 Customer Support: (509) 536-8660 www.hotstart.com