Hotstart CLV Engine Heater Instruction Manual

Instruction Manual for Hotstart models including: CLV Engine Heater, CLV, Engine Heater, Heater

INSTALLATION & OPERATION MANUAL CLV

CLV Engine Heater

Hotstart Thermal Management > Installation and Operation | Support

File Info : application/pdf, 27 Pages, 4.85MB

Manual-CLV-Engine-Heater-EN

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

INSTALLATION & OPERATION MANUAL | CLV HEATING SYSTEM

IDENTIFYING YOUR SYSTEM

IOM216307-000

The Hotstart heating system is designed to heat fluids 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 identification 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 identification plate and following label:

SPOKANE, WA. U.S.A.

REF. SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS

MODEL VOLTS AMPS CONTROL CIRCUIT VOLTS CONTROL CIRCUIT AMPS SERIAL NUMBER

HERTZ PHASE
MAX

R FILE NO. LR7323

THIS CERTIFICATION COVERS THE ELECTRICAL EQUIPMENT AND WIRING
SYSTEM ONLY

CETTE CERTIFICATION COUVRE UNIQUEMENT LEQUIPEMENT ELECTRIQUE ET LE CABLAGE

U.S. PATENTS 9,784,470

CAUTION
OPEN CIRCUITS BEFORE WORKING ON THIS EQUIPMENT OR REMOVING COVERS. KEEP COVERS TIGHTLY CLOSED WHILE CIRCUITS ARE ALIVE.
ATTENTION
DÉBRANCHEZ LE CIRCUIT AVANT DE TRAVAILLER SUR CET EQUIPMENT. GARDER LES COUVERTS FERMÉS QUAND LE CIRCUIT EST ACTIF

NOTE:

Typical heating system identification plate. Your identification plate may vary.

WARRANTY INFORMATION
Warranty information can be found at www.hotstart.com or by contacting our customer service department at (5 0 9 ) 5 3 6 - 8 6 6 0 . 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.

Corporate & Manufacturing Headquarters Spokane, WA, USA
509.536.8660 sales@hotstart.com

Oil & Gas Office Katy, TX, USA

Railroad Office Merrillville, IN, USA

Europe Office Koln, Germany

281.600.3700

+49.2241.12734.0 +49.2241.12734.0

oil.gas@hotstart.com railroad@hotstart.com europe@hotstart.com

United Kingdom Office Birmingham, UK
+49.2241.12734.0 UK@hotstart.com

Asia Pacific Office Tokyo, Japan
+81.3.6902.0551 apac@hotstart.com

INSTALLATION & OPERATION MANUAL | CLV HEATING SYSTEM

IMPORTANT SAFETY INFORMATION
! WARNING
Hazardous voltage: Before wiring, servicing or cleaning the heating system, turn off the power and follow your organization's lockout and tagout procedure. Failure to do so could allow others to turn on the power unexpectedly, resulting in harmful or fatal electrical shock.
Electrical hazard: All electrical work must be done by qualified 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 specified by the manufacturer, the protection provided by the equipment may be impaired. All applicable electrical safety standards defined by local jurisdictions must be followed. (Reference EU directive 2006/95/EC in EU countries.)
· Read carefully: Installers and operators of
this equipment must be thoroughly familiar with the instructions in this manual before commencing work.
· Hot surfaces: Avoid contact with the
system while it is in service. Some surfaces may remain hot even if the system is not energized.
· Proper lifting: Proper rigging and safety
equipment must be used to move this equipment. Do not lift the heating system by any cords, electrical conduit or cabling. Create a plan before attempting to move. Proper lifting locations are identified on each system; use these locations when lifting and mounting the system.
· Rotating equipment: The heating system
can start automatically and without warning. Avoid contact unless a lockout at the service panel has been installed.

· Grounding: The heater must be connected
to a suitable ground (protective earthing conductor).
· Overcurrent limiting: The power supply must
be protected by a suitable overcurrent limiting device.
· Power disconnection: A means to
disconnect the heater from the power supply is required. Hotstart recommends that a power switch or circuit breaker be located near the heater for safety and ease of use.
NOTICE
EU Countries only: Equipment rated for the conditions listed in EN 601010-1 1.4.1 Ingress protection rating IP55. (Special conditions for specific applications may apply.)

INSTALLATION & OPERATION MANUAL | CLV HEATING SYSTEM

TABLE OF CONTENTS

IMPORTANT SAFETY INFORMATION | II

TABLE OF CONTENTS | III

1
1.1 1.2
2
2.1 2.1.1 2.1.2 2.1.3 2.2 2.3 2.3.1 2.4 2.4.1 2.4.2 2.4.3
3
3.1 3.1.1 3.1.2 3.1.3 3.2 3.2.1 3.2.2 3.2.3 3.3 3.3.1

4.1 4.1.1
4.2 4.2.1 4.2.2 4.2.3 4.2.4 4.2.5 4.2.6 4.2.7 4.2.8 4.2.9 4.2.10 4.2.11 4.2.12 4.2.13
4.3
4.4
4.5
4.6 4.6.1 4.6.2 4.6.3 4.6.4 4.6.5 4.6.6 4.6.7
5
5.1 5.1.1 5.1.2

INSTALLATION & OPERATION MANUAL | CLV HEATING SYSTEM

III

(this page intentionally left blank)

INSTALLATION & OPERATION MANUAL | CLV HEATING SYSTEM

1 OVERVIEW

1.1 HEATING SYSTEM COMPONENTS
The heating system consists of the following main components: Figure 1. NOTE: Component illustrations are for reference only and are not to scale. See part drawings for dimensions
and specifications.

C B

D
Figure 1. CLV heating
system components.
E

F A

H N M

I
J L
K

A. Coolant on/off/prime switch B. coolant fault light C. Lift points (×3) D. Element assembly E. Check valve F. Coolant outlet (1.0 NPT standard) G. Coolant High-Limit RTD (resistance
temperature device)

H. Heating tank I. Coolant Control RTD (resistance
temperature device) (located behind heating tank)
J. Coolant pressure/temperature gauge K. Coolant pressure relief valve (0.5 NPT) L. Coolant inlet (1.0 NPT standard) M. Coolant pump/motor N. Identification plate

INSTALLATION & OPERATION MANUAL | CLV HEATING SYSTEM

1.2 OPERATION OVERVIEW
The CLV heating system is intended to maintain an engine's optimal starting temperature while the engine is shut down. The heating system may be activated locally or by optional remote control (see SECTION 2.4.3). The CLV heating system should be deactivated upon engine start-up.
During heating system operation, a centrifugal pump takes coolant from the drain area low on the engine water jacket and forces it through the heating tank and into the coolant return line. The coolant pump will continuously circulate fluid throughout the engine. To maintain consistent fluid temperature, the heating element will cycle on and off at the userselected temperature control point.
A coolant check valve (included with the CLV unit and installed at the coolant outlet) prevents backflow 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. CLV operation overview, showing coolant circulation. While the heating element cycles on and off to maintain the preset temperature, the pump circulates fluid continuously during operation.
Component illustrations are for reference only and are not to scale. See part drawings for dimensions and specifications.

INSTALLATION & OPERATION MANUAL | CLV HEATING SYSTEM

2 PLUMBING INSTALLATION
! CAUTION
Pressure hazard: Power must be turned off and locked out at the service panel when the isolation valves are in the closed position. Failure to do so may cause damage to heating system components, fluid leaks and unexpected release of heated coolant.
Overheating hazard: After completing line installation, top off the fluid levels to compensate for the fluid used to fill the lines and heating tank. Do not operate the heating system without the presence of fluid. Position the heating tank to ensure it is completely full of fluid while in operation.
Pump priming: Fill supply line with fluid. 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-flow 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 overpressure release of heated coolant occurs. Do not connect pressure relief plumbing to coolant system.
! CAUTION
Lifting hazard: Proper rigging and safety equipment must be used to move this equipment. Do not lift the heating system by any cords, electrical conduit or cabling. Create a plan before attempting to move. Proper lifting locations are identified on each system; use these locations when lifting and mounting the system.
NOTICE
Heating system damage: Engine vibration will damage the heating system; isolate the heating system from vibration. Never mount the heating system or components directly to the engine. If the heating system is installed using rigid pipe, use a section of flexible hose to the supply and return ports to isolate the heating system from engine vibration.
Improper mounting hazard: Reference heating system component drawings before mounting the system. Unless mounted properly, the heating system will be unstable.

INSTALLATION & OPERATION MANUAL | CLV HEATING SYSTEM

2.1 COOLANT PLUMBING
NOTICE
Heating system damage: Engine vibration will damage the heating system; isolate the heating system from vibration. Never mount the heating system or components directly to the engine. If the heating system is installed using rigid pipe, use a section of flexible hose to the supply and return ports to isolate the heating system from engine vibration.
The following illustrations are intended for a locomotive installation. For non-locomotive engine applications, general installation principles still apply.

Figure 3. Coolant suction port installed at main locomotive engine drain. Note suction port (A) has been installed at the same level as the drain (B), ensuring CLV pump will draw water from the cooling system's lowest point.

2.1.1 COOLANT SUPPLY

When installing the CLV coolant supply line, refer to the following Hotstart guidelines (see SECTION 5.1 for optional coolant install kit components):

· At a minimum, size the coolant supply line
per the pump inlet. NOTICE! Do not reduce the supply line inner diameter; pump seal
damage will occur.

NOTE:

To maximize flow and allow the longest possible supply line, install the largest practical inner diameter hose; for most installations, Hotstart recommends using a hose with a size larger inner diameter than the pump inlet.

· Install the coolant suction port as low as
possible on the engine's water jacket, typically
near the main water drain. See Figure 3.

· The coolant pump is a centrifugal-
type that is not self-priming. It must be

situated below the minimum liquid level of the engine cooling jacket to ensure it remains flooded and has a positive pressure at the inlet.
· To minimize flow restriction, the coolant
supply line must be as short and as straight as possible. Use elbow fittings sparingly; Hotstart recommends using sweeping bends or 45° fittings.

2.1.2 COOLANT RETURN

When installing the CLV coolant return line, refer to the following Hotstart guidelines:

· Size the coolant return line per the pump
outlet. NOTICE! Do not reduce the return line inner diameter.
· To minimize heat loss, avoid connecting the
coolant return to any location that will allow warm coolant to bypass the engine or pass through radiators or heat exchangers.
· Install the coolant discharge port as high as
possible on the engine's water jacket on the opposite end of the suction port; typically near the aftercooler water line discharge port.

NOTE:

To ensure even heat distribution, the coolant return line may be split and routed to two return ports. Size both return lines per the outlet of the heating system. For engines without an aftercooler, typical installation points are along the water line from the radiator to the engine block. See Figure 7.

Install coolant return line as follows:
1. Using appropriate fittings, install a 1 inch full-flow
ball valve at the water discharge outlet before installing any T-fittings.

2. Place a 1/2 inch T-fitting after the shutoff valve to
supply a 1/2 inch line for heating the locomotive's accessories. The line may be installed at either of the following locations:

· the locomotive's compressor (preferred)
· the locomotive's expansion tank
(if a compressor connection is not available)

3. Install fittings at the compressor or expansion
tank to accept 1/2 inch hose. See Figure 5 and Figure 6.

NOTE:

If the locomotive has wet cab heaters, install another 1 inch T-fitting after the shutoff valve to supply a 1 /2 inch branch line to the cab heater drain valve line.

4. Use appropriate fittings after the shutoff valve and
T-fittings to route a 1 inch inside diameter hose up to the ceiling inside the car body to allow trapped air to be purged from system.

INSTALLATION & OPERATION MANUAL | CLV HEATING SYSTEM

Figure 4. Coolant return hose (1/2 inch inner diameter) as installed on locomotive compressor. If a connection to the compressor cannot be made, utilize an alternative connection to the expansion tank.

Figure 6. Typical coolant discharge ports installed on a turbocharged
engine. The return line is split into two ports, installed at a welded 45° fitting to ensure majority of heated coolant is transferred to engine. Note incorrectly oriented fitting (inset). This fitting must be angled in the opposite direction to allow proper flow.

Figure 5. Coolant return hose (1/2 inch inner diameter) as installed at the locomotive's expansion tank.
h If locomotive engine is turbocharged, the
coolant return line may be split and routed to two return ports. Size both return lines per the outlet of the heating system. The water discharge flow must be directed to the upper after-cooler tubes on both sides. Fittings must be welded to the tubes at 45° angles to force most coolant toward the locomotive engine and allow some coolant to flow to the turbochargers. See Figure 7.
h If engine is supercharged, install a single return
port at the radiator Y-pipe. See Figure 8.

Figure 7. Coolant discharge port installed in non-turbocharged (supercharged) engine. Discharge port is located at radiator Y-pipe.
route to a safe area, bucket or catch-basin. CAUTION! Coolant pressure relief valve outlet must be plumbed to a safe area in case an over-pressure release of heated coolant occurs. Do not connect pressure relief plumbing to coolant system.

V-2

COMPONENT

DESCRIPTION

V-1

USER SUPPLIED FULL FLOW ISOLATION VALVE

E-1

COOLANT PUMP

E-2

COOLANT HEATING ELEMENT

V-2

PRESSURE RELIEF VALVE

V-3

CHECK (NON-RETURN) VALVE

V-4

USER SUPPLIED FULL FLOW ISOLATION VALVE

2.1.3 COOLANT PRESSURE RELIEF
To safeguard personnel and equipment, attach an appropriately sized pipe to the pressure relief valve and

V-1

E-1

E-2

V-3

V-4

Figure 8. CLV system operation. Component illustrations are for
reference only and are not to scale. See part drawings for dimensions and specifications.

INSTALLATION & OPERATION MANUAL | CLV HEATING SYSTEM

2.2 COOLANT PLUMBING ILLUSTRATION

COOLANT DISCHARGE
PORT SECTION 2.1.2

COOLANT SUCTION PORT SECTION 2.1.1
ISOLATION VALVES

COOLANT RETURN SECTION 2.1.2

COOLANT SUPPLY SECTION 2.1.1
6

PRESSURE RELIEF VALVE
SECTION 2.1.3
INSTALLATION & OPERATION MANUAL | CLV HEATING SYSTEM

2.3 MOUNTING
2.3.1 TANK AND PUMP
Mount the heater in a vertical orientation with pump motor assemblies directly below control box or in a horizontal orientation with the heating tanks directly above the control box and pumps. Reference drawings for mounting position. When installing the heating system, HOTSTART recommends 30 inches (76 cm) of clearance to remove element for maintenance. Reference part drawings for minimum clearance required for your model.

AJ
2.4

A
Figure 9. CLV 0.438 inch (11.13 mm) diameter mounting holes × 6 (A). Mount unit in either orientation shown. Do not mount at an angle or in any other orientation.
ELECTRICAL CONNECTIONS

A B

Figure 10. Underside of CLV control box, showing 0.75 NPT main power entrance (A) and 0.5 NPT customer interface wiring entrance (B).

h For three-phase applications, the terminal
blocks are labeled L1, L2 and L3.
h For single-phase applications, use the terminal
blocks labeled L1 and L2. See Figure 11 on following page.

2. Connect the main power ground wire to the ground
lug or ground block on the electrical panel located inside the electrical box.

2.4.2 MOTOR ROTATION CHECK

! WARNING

2.4.1 MAIN POWER SUPPLY

1. Connect the specified power from the user-
supplied circuit breaker to the terminal blocks located in the main control box.
NOTE: The specified power source must be within plus or minus 10% of the rated voltage.
NOTE: The circuit breaker must be near the heating system and easily accessible. Hotstart recommends connecting the heating system to a circuit breaker rated for 125% of the system's maximum load.

NOTE:

The main power supply operates the heating elements and the circulating pumps. A transformer may be used to operate the control circuit. The transformer and control circuits are overload-protected.

NOTICE
Pump rotation (three-phase only): For three-phase applications, check for proper pump rotation prior to introducing fluid to the pump. Reverse rotation while the pump is filled with fluid 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 filled with fluid may cause damage to the pump seal.

The following procedures are for three-phase applications only. Single-phase systems are prewired to ensure the pump motor rotates in the correct direction.

1. With main power connected to the heating system
motor (see SECTION 2.4.1), energize the pump while observing the rotation of the pump motor fan at the rear of the motor. Refer to rotation decal on motor for correct rotation.
h If 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.

INSTALLATION & OPERATION MANUAL | CLV HEATING SYSTEM

TERFACE 3

2
K4

TCR2

3
K1:43

TR1

MPS1
3

TB3:2

TCR1

TEMPERATURE CONTROL

TCR2

Figure 11.

MA1ain

pA2ower

HIGH LIMIT
supply and

customer interface connections

DS1

as shown in the CLV control box.

ON INDICATOR

Reference eleX1ctricXa2 l schematic

drawing for prDoSp2 er wiring locations;

the

followingX1illRusXt2rationsFAaUrLeT

INDICATOR
typical

customer interTfaR2ce locations but

may not appAl1y toAa2 ll modFAeUlLsT.SIGNAL RELAY 3

TR1

HIGH LIMIT LATCH

TCR1

NO FAULT ELEMENT

TB2:1 TB2:3 TB2:5
3 TB2:7

TR2

TB2:2 FAULT CONTACTS

TB2:4 RUN CONTACTS

3
K4

TB2:6 24V SHUTDOWN

3 TB2:8 EXTERNAL REMOTE 4
(JUMPERED FROM FACTORY)
CUSTOMER INTERFACE

PRIME OFF ON K2

SW1

MOTOR

SW1 STATE OFF
PRIME

CONTACT STATE 3-4 11-12 13-14
X X

A. Main power gTrSo1und block

E. Remote On/Off 24 V DC

X = CLOSED

B. MaTinCRp1:To1weBLUr termiBnRNal bTCloR1c:Tk2 C. Coolant fault signaBLlK TCR1:T3

shutdown
F. NExOteTrEnSa:l remote

Hotstart SPOKANE, WA. A

D. Coolant motor run signal TS2

G. F2a. uKlt4 sRiEgLAnYalWrIeRElaDyFOR NORMALLY CLOSED FROM FACTORY. TO CHANGE K4 TO NORMALLY OPEN,

F G PROPRIETARY INFORMATION
This drawing and the information shown on it are property of Hotstart, Inc.

and are for the sole purpose of doing business with us. Any copying or transmittal to others

of this information is strictly prohibited without prior written consent from Hotstart.

NOTE: The 24 V DC shutdown connection is TCR2:T1 BLU

BRN TCR2:T2 BLK TCR2:T3

2.4.T3he folCClowUOinSNgTcNOusEtMoCmETeRrIOinItNNerfTSacEeRcoFnAneCctEions are wftahiceretohdreyNa;tCainpg(pnlsoyyrinsmtgeam2ll4y. SVceloDesCseyBdws)tielflrmoshmwutitrhdineogwn 7

MOVE WIRE FROM K4:12 TO K4:14 AND REPLACE WIRE LABEL. 4 3. REMOVE BLACK JUMPER LINKING TB2:7 & TB2:8 TO USE AN EXTERNAL SWITCH OR RELAY.

TITLE
CLV 3-PHASE WIRING SCHEMATIC

APPROVALS
DRAWN BY
DG
APPROVED BY
MA

DATE
08/12/2014 01/28/2015

THIRD ANGLE PROJECTION

UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES [mm]

TOLERANCES (Except as noted)

.XX .XXX

N/A ANGULAR

N/A

DO NOT SCALE DRAWING

DWG. NO.

SIZE

ORIGIN

SCALE

A-7978-3

CO8384

1:1

SHEET 2 OF 2

REV.
04

available for remote control and monitoring:

schematic for directions to switch to NO

· Coolant Fault Signal

(normally open) operation.

TB2:1/TB2:2 (C)

· External Remote

The fault signal will indicate a coolant

TB2:7/TB2:8 (F)

heating system shutdown, triggered by either the high-limit temperature control relay or the motor protection switch (see SECTION 4.1.1).

The external remote connections allow a remote switch or relay to control the heating
system when the ON/OFF/PRIME switch is
in the ON position. The system will run when

· Coolant Motor Run Signal
TB2:3/TB2:4 (D) A motor run signal indicates the coolant pump motor is running. If no signal is present, the pump motor is not running.
· Remote On/Off 24 V DC shutdown (E)
TB2:5/TB2:6 When activated, the remote on/off connection shuts down the heating system. When deactivated, normal heating will resume. Use this connection for remote
operation of the heater when the ON/OFF/
PRIME switch is turned to ON.

there is continuity between TB2:7 and TB2:8, and will shut down when continuity is broken. These connections are jumpered from the factory, and the jumper must be removed to use this feature. This can be used together with the 24V DC remote feature, but neither will override the other. Refer to system nameplate for control voltage/amperage when selecting and wiring an external switch or relay.
· Fault Signal Relay
TR2 (G) The Fault Signal Relay introduces a small time delay to prevent a false fault signal when

the system is switched off or starting up. This

is set for a minimum delay from the factory,

but the delay may be increased to up to 10

seconds if desired.

INSTALLATION & OPERATION MANUAL | CLV HEATING SYSTEM

CLV control and high-limit TCRs (above). The standard setting for TCR1 control dial (A) is 122 °F (50 °C). The standard setting for TCR2 high-limit dial (B) is 194 °F (90 °C).

CLV motor protection switch (right), showing stop/off (C) and reset/on (D) buttons. To reset the MPS, the heating system must be switched off and the MPS reset/on button must be pressed.

3 SYSTEM COMPONENTS AND OPERATION

NOTICE! Decreasing the hysteresis below 10% may increase the cycle rate of the element contactor, shortening the contactor's expected life and potentially overheating the contactor.

3.1 SYSTEM COMPONENTS
3.1.1 MOTOR PROTECTION SWITCH (MPS)
The motor protection switch (MPS) protects the pump motor from overloads. See Figure 12. The MPS will be set at the full load amperage of the motor when shipped
from the factory. To reset the MPS, the ON/OFF/PRIME
switch must be switched to OFF and the operator must press the MPS reset/on button. See SECTION 4.1.1.
3.1.2 CONTROL TCR (TEMPERATURE CONTROL RELAY)
The control TCR (TCR1) is used to control the temperature of the fluid. The control TCR uses a resistance temperature device (RTD) to sense the temperature of the fluid as it enters the heating tank. The standard setting for the coolant control temperature relay (TCR1) is 122 °F (50 °C) at 10% hysteresis. See Figure 12.
The TCR will turn the heating element off at 122°F (50°C) and back on at 113°F (45°C) with these set points.

3.1.3 HIGH-LIMIT TCR (TEMPERATURE CONTROL RELAY)
The high-limit TCR (TCR2) is a protection device to prevent fluid overheating. The high-limit TCR uses a resistance temperature device (RTD) located near the tank outlet. The default setting for the coolant high-limit TCR is 194 °F (90 °C) at 0% hysteresis and should always be at least 18 °F (10 °C) higher than the control TCR set point. The high-limit TCR hysteresis is not used in the high-limit control. See Figure 12.

3.2 INTERFACE COMPONENTS
The following is an operation description for the standard parts located in the system.
NOTE: Parts in the control box may vary depending on the particular system configuration purchased.

3.2.1

ON/OFF/PRIME SWITCH
· ON The system is on. The pump will run
continuously while the heating element

INSTALLATION & OPERATION MANUAL | CLV HEATING SYSTEM

cycles on and off to maintain the coolant temperature. The 24V DC shutdown and/or external remote may be used to activate or deactivate the system.
· OFF The system is shut off.
· PRIME Turn and hold the switch to PRIME
to energize the pump motor in order to remove any air in the heating system without energizing the elements.

is not completely filled with fluid will cause damage to the pump seal. Proper heating operation: The high-limit temperature control relays (TCR2, TCR4) must be set at least 18 °F (10 °C) higher than the corresponding control temperature control relay for proper heating operation. This will prevent nuisance tripping of the high-limit circuit.
3.3.1 FIRST RUN PROCEDURE

3.2.2 PRESSURE/TEMPERATURE GAUGE
The CLV model features a temperature/pressure gauge mounted at the inlet of the heating tank. The gauge will indicate a pressure increase when the pump motor
is engaged by turning and holding the ON/OFF/PRIME
switch to PRIME or during normal operation. The gauge will also indicate the current incoming fluid temperature. NOTE: Your system's operating pressure may vary
depending on the configuration of the engine.
3.2.3 PRESSURE RELIEF VALVE
! CAUTION
Pressurized steam hazard: Coolant pressure relief valve outlet must be plumbed to a safe area in case an overpressure 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 flow to a safe area, bucket or other catch-basin.
3.3 HEATING SYSTEM START-UP
! WARNING
Hazardous voltage: Before wiring, servicing or cleaning the heating system, turn off the power and follow your organization's lockout and tagout procedure. Failure to do so could allow others to turn on the power unexpectedly, resulting in harmful or fatal electrical shock.
NOTICE
Pump damage: Do not run the motor/pump assembly dry for more than a few seconds. Running a pump that

1. Check and tighten all electrical and plumbing
connections.
2. Ensure isolation valves are open before energizing
the system.
3. Check the pump for proper rotation. NOTICE!
Do not run the motor/pump assembly dry for more than a few seconds.
h For three-phase heating systems, briefly turn and hold the ON/OFF/PRIME switch to PRIME
while observing the rotation of the pump motor fan at the rear of the motor. If the pump motor is not rotating in the correct direction, switch any two electrical leads at the main power terminal block. See SECTION 2.4.1.
h Single-phase systems are prewired to ensure the
pump motors rotate in the correct direction.

4. Bleed all trapped air from the heating system and
connecting plumbing by opening plugs or pipe
fittings as needed. Turn and hold the ON/OFF/
PRIME switch to PRIME to evacuate any remaining air in the lines.

NOTE:

When priming the pump, the pressure gauge should indicate an increase in pressure. Your system's operating pressure may vary depending on the configuration of the engine.

NOTE:

Remaining air may be evacuated from the pump using the air bleed screw on the pump housing. Unscrew the pump air bleed screw to vent trapped air. Tighten screw once coolant begins venting.

5. Turn the ON/OFF/PRIME switch to ON to energize
the heating system.

6. Once operation is satisfactory, turn the control
dial on the temperature control relay TCR1 to the desired temperature setting for engine coolant. TCR1 is set to a control temperature setting of 122 °F (50 °C) and TCR2 is set to a high-limit setting of 194 °F (90 °C) at the factory. See SECTION 3.1.2 and SECTION 3.1.3.

INSTALLATION & OPERATION MANUAL | CLV HEATING SYSTEM

4 MAINTENANCE, REPAIR AND TROUBLESHOOTING
4.1 SYSTEM FAULTS
4.1.1 COOLANT FAULTS
The coolant fault light will display if:
· The coolant pump motor protection switch is
tripped (MPS1).
· The coolant high-limit temperature is
exceeded (TCR2).
A failure in the pump motor that causes the motor protection switch (MPS1) to trip will shut down the heating system. A fault signal will be transmitted and the coolant fault light will illuminate. If this failure occurs, the
ON/OFF/PRIME switch must be switched to OFF and the
operator must press the MPS reset/on button to reset the fault. (See SECTION 3.1.1.)
If there is a failure that causes a high temperature to occur, the high-limit temperature controller (TCR2) will shut down the heating system, including the pump motor. A fault signal will be transmitted and the coolant fault light will illuminate. To restart the system,
the ON/OFF/PRIME switch must be switched to OFF
and then back to ON to resume operation once the fluid temperature drops below the high-limit preset. Restarting the system remotely will also reset a high-limit fault. (See SECTION 3.1.3.)
NOTE: A high-limit fault can only occur when the heating element is energized.
For additional troubleshooting, see SECTION 4.5.
4.2 SYSTEM MAINTENANCE
! WARNING
Hazardous voltage: Before wiring, servicing or cleaning the heating system, turn off the power and follow your organization's lockout and tagout procedure. Failure to do so could allow others to turn on the power unexpectedly, resulting in harmful or fatal electrical shock.
Instructions for the following maintenance procedures are provided to ensure trouble-free operation of your heating system. Replacement parts must meet or exceed original part requirements in order to maintain the compliance level of the original heating system.
NOTE: After maintenance is performed, refer to SECTION 3.3.1 for system start-up procedures.

4.2.1 PLUMBING CONNECTIONS
Periodically check plumbing connections for leaks and, if necessary, tighten connections. A loose connection on the suction side will cause a loss of flow and cavitation in the pump. It can also pull air into the heating tank and cause an element failure.
4.2.2 ELECTRICAL CONNECTIONS
Vibration and thermal cycling may cause terminals to loosen. After initial first run, disconnect power and tighten electrical connections (see SECTION 4.3). Check connections again in a week. Tighten all electrical connections every three months.
4.2.3 SYSTEM MOUNTING
Vibration may cause mounting bolts to loosen. Periodically check and tighten all mounting bolts.
4.2.4 MAGNETIC CONTACTORS
Magnetic contactors are used to control motors and heating elements in Hotstart heating systems. The contactor coils operate at the system's nameplate control voltage. To test for failure, check for continuity across the coil connections (A1 and A2); an open or direct-short reading indicates a failed contactor coil.
With power disconnected, verify that the mechanism of the contactor moves freely and is not stuck in an open or closed position. With the contacts held closed, check for unusually high resistance across the main poles. For contactors with screw terminals, verify that all wire connections are properly tightened.
Magnetic contactors have finite life cycles, as they contain moving parts and electrical contacts that will wear out with use. Replace contactors that develop functional problems or show obvious external signs of heat damage. Hotstart recommends that element contactors be replaced at least every five years as a preventative maintenance measure.
NOTE: Higher-current systems or systems operating in high ambient temperatures may require more frequent contactor replacement.
4.2.5 COOLANT PUMP SEAL
Coolant pump mechanical seals are controlled leakage devices and are not intended to create a zero leak seal. Some leaking from the seal is expected during normal operation. If seal becomes worn, replacement pump seals are available. To ensure pump seal longevity, ensure the supply lines do not restrict flow excessively (see SECTION 2.1.1 and SECTION 2.1.2) and run the

INSTALLATION & OPERATION MANUAL | CLV HEATING SYSTEM

heating system for 20 minutes monthly during offseason periods (see SECTION 4.4. NOTE: Instructions to replace the pump seals are
included with replacement seals.
4.2.6 COOLANT PUMP REPLACEMENT
Before installing a replacement pump, the replacement pump component will require volute adjustment for proper fit.

4.2.7 MOTOR LUBRICATION
Motors are installed with initial lubrication. If your motor has provisions for relubrication, refer to the motor manufacturer for recommended relubrication schedule intervals. For recommended lubrication type, refer to the motor nameplate.
NOTE: New motors installed on heating systems placed in extended storage for a year or longer may require relubrication. See SECTION 4.4.

Figure 12. CLV pump, motor and pump volute, showing volute screws (A). Volute will need to be rotated 90 degrees as shown prior to installation on the CLV heating system.
1. Unscrew four volute screws See Figure 12.
Remove volute.
2. Rotate volute 90 degrees as shown.
3. Reattach volute and secure using volute screws.
4. Tighten volute screws.

4.2.8 PRESSURE/TEMPERATURE GAUGE
The pressure/temperature gauge will indicate a pressure increase when the pump motor is engaged by turning
and holding the ON/OFF/PRIME switch to PRIME
or during normal heater operation. The gauge will also indicate the current temperature of the fluid. No maintenance for this parts is required.
4.2.9 VOLATILE CORROSION INHIBITOR (VCI)
A volatile corrosion inhibitor (VCI) is provided with each control box and should be replaced once a year.
NOTE: Heating systems placed in extended storage will require that the VCI is replaced at six month intervals. See SECTION 4.4.

Figure 13. CLV pump, motor and pump volute, rotated in correct installation orientation. Note that pump and motor appearance may vary depending on CLV model. Orienation of motor terminal box and pump inlet/outlet are critical.

INSTALLATION & OPERATION MANUAL | CLV HEATING SYSTEM

4.2.10 TEMPERATURE CONTROL RELAY (TCR)

! WARNING

Hazardous voltage: Before wiring, servicing or cleaning the heating system, turn off the power and follow your organization's lockout and tagout procedure. Failure to do so could allow others to turn on the power unexpectedly, resulting in harmful or fatal electrical shock.
If the CLV heating system does not maintain the desired preset control temperature or signals a high-limit temperature fault immediately upon system start-up, the TCR (temperature control relay), the RTD (resistance temperature device), or the RTD cable may require replacement. To perform this troubleshooting, you will need:
· Ohmmeter
1. De-energize the heating system. Verify fluid
is present and flow is not restricted. Check temperature gauge to ensure the liquid in the tank is below 122 °F (50 °C).
2. Verify the control TCR is set correctly. Verify that
high-limit TCR is set at least 18 °F (10 °C) higher than the control TCR set point.
3. Using the ohmmeter, measure the resistance
between TCR terminals T1 and T2. (See Figure 14.)
h If the measured resistance is between 80 and
120 ohms continue troubleshooting. Proceed to step 4.
h If the resistance is lower than 80 ohms or
higher than 120 ohms,contact HOTSTART for further assistance.

Figure 14. Control TCR (TCR1) and high-limit TCR (TCR2) showing terminals T1, T2 and T3.

TCR TCR1 Coolant TCR2 Coolant

TYPE

RTD Position

Control 50 °C Coolant Tank Inlet

High-limit 90 °C Coolant Tank Outlet

Table 2. TCR types, default temperature settings and corresponding RTD positions.

5. Using the ohmmeter, touch the probes to RTD
pin 1 and pin 3. See Figure 15. Note the resistance. Touch the probes to RTD pin 1 and pin 4 to check for continuity:
h If 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.
h If 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. Using the ohmmeter, test for continuity between
TCR terminals T2 and T3:
h If there is continuity between TCR terminals
T2 and T3, the TCR, RTD and RTD cable are functioning correctly. Close control panel. Allow fluid 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.
h If there is no continuity between TCR terminals
T2 and T3, locate connected RTD on the heating tank. Unscrew the RTD plug from RTD. See Table 2 and Figure 14, Figure 15. on following page.

PIN 1
(BROWN WIRE)
PIN 3
(BLUE WIRE)
PIN 4
(BLACK WIRE)
Figure 15. RTD pins 1, 3 and 4. The resistance between pin 1 and pin 3 should measure between 80 and 120 ohms. There should be continuity between pin 1 and pin 4.

INSTALLATION & OPERATION MANUAL | CLV HEATING SYSTEM

4.2.11 RESISTANCE TEMPERATURE DEVICE (RTD)

! WARNING
Hazardous voltage: Before wiring, servicing or cleaning the heating system, turn off the power and follow your organization's lockout and tagout procedure. Failure to do so could allow others to turn on the power unexpectedly, resulting in harmful or fatal electrical shock.
High-limit or control resistance temperature devices (RTDs) sense temperature to either control fluid temperature or protect the system and fluid 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 fluid to cool.

2. Close isolation valves. Drain fluid from the heating

tank. Locate the RTD that requires replacement.

See Figure 16.

3. Unscrew RTD plug. Remove plug. See Figure 16.

4. Unscrew RTD from tank. See Figure 17.

5. Screw replacement RTD into tank. When tightening,
ensure plug is aligned with notch toward top of tank. See Figure 18.

6. Fit RTD plug to RTD. Ensure plug is aligned
correctly with notch. Push plug in firmly. Screw RTD plug to RTD to secure in place.

7. To ensure proper installation and temperature
regulation, re-energize and check heating system for proper operation. Refer to SECTION 3.3.1 for system start-up procedures.

Figure 16. CLV highlimit RTD (A), control RTD (B) and RTD plug detail (C).
C
Figure 17. High-limit RTD shown removed from CLV heating tank.

Figure 18. Proper RTD orientation. Note the notch centered at the top of the RTD connection.

INSTALLATION & OPERATION MANUAL | CLV HEATING SYSTEM

Figure 19. Removing and replacing the
heating tank element. The heating system should be drained, cleaned and flushed
annually. See SECTION 4.3.

A. Element service
entrance cap
B. V-clamp
C. O-ring
D. Tank
E. Element cable
gland and element conduit cable

F. Element
G. Conduit
connector entrance
H. Element
identification plate

D C B

G H

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 for 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 19. The wattage and phase of the heating element are listed on the identification plate on the outside of the element (H). Reference this label for the replacement part number.
1. De-energize the heating system. Allow fluid to cool.
2. Close isolation valves.

7. Unscrew cable gland (E) from conduit connector
entrance (G). Remove electrical cable and wires from the heating element.
8. Loosen V-clamp nut to remove V-clamp (B) Detach
the heating element assembly from tank.
9. Replace the heating element (F) or perform the
necessary cleaning procedure. Ensure the O-ring (C) is intact and in place before securing V-clamp.

4.2.13 REASSEMBLY OF HEATING ELEMENT AND TANK

Tighten the following components:
· V-clamp nut (B) to 180 lbf-in (20 Nm) · Element terminal nuts to 14 lbf-in (1.6 Nm)

NOTE:

System heating wattage may be changed by installing a different 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.

3. Drain the fluid from the heating tank (D).
4. Remove the cap (A) from the heating element
service entrance enclosure.
5. The wire connections inside the enclosure
correspond to one of the jumper configurations shown. Note your unit's jumper configuration. See Figure 21.
NOTE: Replacement elements may be a different jumper configuration.

SINGLE-PHASE SERIES

SINGLE-PHASE PARALLEL

Figure 20. Heating element jumper configurations.
Replacement elements may be a different jumper configuration.

6. Disconnect the ground (green/yellow) and power
electrical wires from the posts inside the assembly.

THREE-PHASE WYE

THREE-PHASE DELTA

INSTALLATION & OPERATION MANUAL | CLV HEATING SYSTEM

4.3 RECOMMENDED MAINTENANCE
See part drawings for replacement parts.

INTERVAL
At initial start-up One week after initial start-up Every three months Annually
Every five years

MAINTENANCE TASK
Tighten electrical connections. See SECTION 4.2.2.
Check and tighten electrical connections. See SECTION 4.2.2.
Tighten electrical connections.
Drain, clean and flush 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. See SECTION 4.2.12.
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.
During storage, the faces of the pump seal may adhere to each other if there is no fluid in the pump. Applying power from the pump motor with stuck seal faces can damage or destroy the pump seal. For heating systems

that are new or have been in storage, remove the pump shaft guards and rotate the shaft by and to ensure the seal faces move freely before energizing the motor.
During the offseason, or during periods in which the heating system is not active for a month or longer, Hotstart recommends running the heating system for a minimum of 20 minutes each month. Circulating and heating fluid at regular intervals will reduce pump seal wear and promote pump seal longevity.

INSTALLATION & OPERATION MANUAL | CLV HEATING SYSTEM

4.5 TROUBLESHOOTING

SYMPTOM

POSSIBLE CAUSES

Heating system fault

Pump not primed properly

Isolation valves may be closed Hose kinked or crushed Leak in suction line Pump motor turning backwards

Fluid temperature too low

Control TCR failure: closed Motor failure Motor contactor failure Motor protection switch tripped RTD failure RTD cable failure Motor failure Heating element failed Element breaker tripped Element contactor failed Motor contactor failed Control TCR failure: open Control TCR set point too low RTD failure RTD cable failure

SOLUTION
Bleed all trapped air from lines. Restart system.
Open valves. Restart system.
Remove obstruction. Restart system.
Repair leak. Bleed and restart system.
Reverse any two leads on power (for three-phase systems). Restart system. See SECTION 2.4.2. For single-phase systems, contact Hotstart.
Check and replace if necessary. See SECTION 4.2.10.
Check and replace if necessary. Restart system.
Check contacts and replace if needed. Restart system.
Check and reset switch. If problem occurs again, check motor. Restart system.
Check TCR and RTD. See SECTION 4.2.10.
Check TCR and RTD. See SECTION 4.2.10.
Check motor. Replace if necessary.
Check elements for continuity. Replace element if necessary.
Check for element short to ground. If no short, reset breaker.
Check contacts and coil. Replace if necessary.
Check contacts and coil. Replace if necessary.
Check and replace if necessary. See SECTION 4.2.10.
Adjust set point for control TCR. See SECTION 3.1.2.
Check TCR and RTD. See SECTION 4.2.10.
Check TCR and RTD. See SECTION 4.2.10.

INSTALLATION & OPERATION MANUAL | CLV HEATING SYSTEM

4.6 REPLACEMENT PARTS LIST

4.6.1

ALL MODELS
DESCRIPTION Pump, Coolant Circulating Pump, Coolant Circulating: Seal Kit Relay, Temperature Control Resistance Temperature Device (RTD) RTD Cable

PART NUMBER PRP228083-000 PRP203256-000
PRP224146-000 PRP224308-001
PRP224307-000

4.6.7

CLV MODEL: CLV33004-00

DESCRIPTION

PART NUMBER

Element Motor, Coolant Pump Switch, Motor Protection

E30043E-C0NV-00 PRP236272-000 PRP232071-002

4.6.2

CLV MODEL: CLV11102-00

DESCRIPTION Element Motor, Coolant Pump Switch, Motor Protection

PART NUMBER E11021E-C0NV-00 PRP236275-001 PRP232071-000

4.6.3

CLV MODEL: CLV31802-00

DESCRIPTION

PART NUMBER

Element Motor, Coolant Pump Switch, Motor Protection

E18023E-C0NV-00 PRP236276-000 PRP232071-003

4.6.4

CLV MODEL: CLV31804-00

DESCRIPTION Element Motor, Coolant Pump Switch, Motor Protection

PART NUMBER E24043E-C0NV-00 PRP236272-000 PRP232071-002

4.6.5

CLV MODEL: CLV31800-00

DESCRIPTION Element Motor, Coolant Pump Switch, Motor Protection

PART NUMBER E24043E-C0NV-00 PRP236276-000 PRP232071-002

4.6.6

CLV MODEL: CLV32404-00

DESCRIPTION

PART NUMBER

Element Motor, Coolant Pump Switch, Motor Protection

E24043E-C0NV-00 PRP236272-000 PRP232071-002

INSTALLATION & OPERATION MANUAL | CLV HEATING SYSTEM

5 APPENDIX
The following section contains additional product documentation intended for installation and operation. See part drawings for dimensions and specifications. Documentation includes:
5.1 INSTALLATION KITS
The following kits are available for CLV installation: 5.1.1 CLV Installation Kit (Optional)
This optional kit includes suitable hoses and fittings for most typical CLV coolant plumbing installations. Contact Hotstart with questions concerning special installations. See page 20.
5.1.2 CLV Installation Kit Parts List This list contains all parts for the optional CLV installation kit. See page 21.

INSTALLATION & OPERATION MANUAL | CLV HEATING SYSTEM

5.1.1 COOLANT INSTALL KIT (OPTIONAL)

8 D

11 17

19 25

32 28

26 19 30
22 B
18

17 13 10 12 10 A 10 11
CLV-IK KIT INSTALL CLV PART NUMBER DESCRIPTION
8

16 15

27
14 15 33 1

16 1

24 23 34 1

14 1

27 1

NOTE:
1. INCLUDE MANUAL WITH PLUMBING KIT

REVISIONS

REV. ECO

DATE

DESCRIPTION

AUTH. DR.

ZONE

218499-000 WAS 218425-000, DELETED ONE OF 218001-501, ADDED ONE OF 218001-501, ADDED 1 9921 11/05/2020 ONE OF 127020-000, ADDED ONE OF 218153-000, JTB ADDED TWO OF 218117-000, ADDED ONE OF 218024-000, ADDED ONE OF 218001-301

KP A5, A6, D4

53 2 1

Hotstart SPOKANE, WA.

A PROPRIETARY INFORMATION
This drawing and the information shown on it are property of Hotstart, Inc. and are for the sole purpose of doing business with us. Any copying or transmittal to others
of this information is strictly prohibited without prior written consent from Hotstart.
TITLE
COOLANT PIPING INSTALLATION KIT

APPROVALS
DRAWN BY
ALS
APPROVED BY
BNE

DATE
01/19/2016 01/25/2016

THIRD ANGLE PROJECTION

UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES [mm]

TOLERANCES (Except as noted)

.XX .XXX

N/A ANGULAR

N/A

DO NOT SCALE DRAWING

DWG. NO.

SIZE
B

ORIGIN SCALE

A-8223-0
CO8775
1:10 SHEET 1 OF 1 1

REV.
01

INSTALLATION & OPERATION MANUAL | CLV HEATING SYSTEM

5.1.2 CLV INSTALLATION KIT PARTS LIST

ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 -

PART NUMBER 218020-000 218001-601 203011-001 218115-000 218115-001 127019-002 218150-000 218499-000 218115-003 218001-502 218031-002 203011-000 218022-000 218117-000 218117-003 127020-000 218117-001 127018-006 218042-000 218001-504 218023-000 218117-002 218001-401 218027-000 218042-001 218152-000 218153-000 218003-600 127018-007 215175-000 215175-002 220011-906 218024-000 218001-301 216061-056 216307-000

REPLACEMENT PARTS
DESCRIPTION TEE, 1.25 BLACK NIPPLE, 1.25 X CLOSE BLACK VALVE, BALL 1.25 NPT NIBCO #NIT5857 ADAPTER, ST 1.25MPT X #24 MJIC ADAPTER, 90 1.25MPT X #24 MJIC HOSE, #24 FJIC X 228 OAL #24 HOSE X #24 FJIC SWIVEL PARKER ELBOW 90DEG 24JIC MALE X 1.0NPT MALE ADAPTER, ST 1.0MPT X #24 MJIC PLATED NIPPLE 1.0 NPT CLOSE SCHED 40 STAINLESS WELDED ELBOW 1FNPT 90 DEGREE BLACK IRON VALVE, BALL 1NPT TEE, 1 X 1 X .50 BLK ADAPTER ST .5MPT X 10MJIC PARKER # ADAPTER 90 .5MPT X 10MJIC 90 HOSE, #10 FJIC X 144 OAL ADAPTER ST 1MPT X 20MJIC HOSE, #20 FJIC X 360 OAL COUPLING, 1 STEEL (BLK) KELLER HAS NIPPLE, 1.0 X 2.0 BLACK TEE, 1.0 BLACK ADAPTER 90 1MPT X 20MJIC NIPPLE, .75 X CLOSE BLACK TEE, .75 X .75 X .50 BLK COUPLING,1 STEEL COPED 45DEG TO FIT #20 HOSE #20 FJIC SWIVEL PARKER 206 #10 HOSE #10 FJIC SWIVEL PARKER 206 NIPPLE, 1 X 12 BLK HOSE, #20 FJIC X 36 OAL APU BASE HOSE CLAMP APU CLAMP #24 HOSE NUT 5/16-18 ZN KEP TEE, .50 BLACK NIPPLE, .50 X CLOSE BLK INSTRUCTIONS, HOSE ASM. COR, DDHS, OPERATION MANUAL - CLV - ENGLISH

QTY. 1 1 1 1 1 1 1 1 1 3 4 1 1 3 2 2 3 1 2 1 1 3 1 1 2 3 2 4 2 6 6 6 1 1 1 1

INSTALLATION & OPERATION MANUAL | CLV HEATING SYSTEM

References

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