CSS Coolant Small System

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					                      CSS
              Coolant Small System


       Installation & Operation Manual




216211-001 rev 3
        KIM HOTSTART Mfg., Co., Inc.
                P.O. Box 11245
            Spokane WA 99211-0245


       Customer Support: (509) 536-8660


                 NOTICE
When ordering replacement parts for your heating
system, always reference the heating system’s
Model Number and Serial Number.
                  CAUTION
ALL CONNECTIONS IN THE JUNCTION BOX SHOULD BE CHECKED
PRIOR TO INSTALLATION. VIBRATION DURING SHIPMENT CAN CAUSE
SCREWS TO LOOSEN. ALL CONNECTIONS IN THE JUNCTION BOX
SHOULD BE CHECKED AT REGULAR INTERVALS. EXCESSIVE
VIBRATION WILL EVENTUALLY CAUSE CONNECTIONS TO LOOSEN
OVER TIME.

WIRING TO HEATING SYSTEM TO BE PERFORMED BY A QUALIFIED
ELECTRICIAN AND CONFORM TO ALL NATIONAL, STATE AND LOCAL
ELECTRICAL CODES.


                     KIM HOTSTART MANUFACTURING COMPANY

                     EAST 5723 ALKI AVENUE • P.O. BOX 11245
                     SPOKANE, WASHINGTON • 99211-0245 • USA
                     Phone: (509) 534-6171 • Fax: (509) 534-4216
                                       Notices
This manual was prepared to assist you with the installation, operation and maintenance of the
Kim Hotstart CSS Heating System. We encourage you to use this material and the enclosed
illustrations as your primary source of information about the heating system. For additional
information, contact:

                           Kim Hotstart Manufacturing Company
                                     P.O. Box 11245
                                Spokane, WA 99211-0245
                                Telephone: (509) 536-8660
                                   Fax: (509) 534-4216

This instructional material and the corresponding illustrations are based on a typical Kim
Hotstart heating system with standard components and the most frequently requested options.
Your particular heating system configuration may vary from the heating system described. For
your reference, available replacement parts and component options are listed in this manual.




           Identifying Your “CSS” System
The CSS Heating System is a compact coolant heating system designed for use in marine
propulsion, diesel-powered generator sets, or any large engine applications. The model is
pre-wired, pre-plumbed, and assembled on a steel plate. Each CSS heating system has an
identification plate usually located on the front of the control box. An example of the
identification plate is shown on the following page.


NOTE: When ordering replacement parts, be sure to reference your heating system’s model and
      serial numbers found on the identification plate.

       Model numbers ending in other than –000 are custom systems. Reference the drawings
       included with your system for parts specific to your system.




                                                                                                 i
ii
                                      Table Of Contents
THE CSS SYSTEM ...................................................................................................... 1-1


   System Overview.................................................................................................................... 1-1


   Basic System Operation......................................................................................................... 1-1


INSTALLATION AND SYSTEM START-UP ............................................................... 2-1


   System Mounting Requirements .......................................................................................... 2-1


   System Installation................................................................................................................. 2-3
      Coolant Supply Line ............................................................................................................ 2-3
      Coolant Discharge Line ....................................................................................................... 2-3
      Main Power Wiring.............................................................................................................. 2-5
      24 VDC System Shutdown .................................................................................................. 2-5


   Electrical Grounding Requirements .................................................................................... 2-6


   Coolant Requirements ........................................................................................................... 2-7


   System Start-Up ..................................................................................................................... 2-8
      Coolant Heating System Start-Up........................................................................................ 2-8

   24 Volt DC Connection.......................................................................................................... 2-9




                                                                                                                                         iii
SYSTEM COMPONENTS............................................................................................ 3-1

  Control Box............................................................................................................................. 3-1
     Fuses .................................................................................................................................... 3-2
     Transformer.......................................................................................................................... 3-2
     Coolant System Temperature Setting Adjustments ............................................................. 3-6

  Coolant Heating Tank Assembly.......................................................................................... 3-3

  Heating Element Replacement ............................................................................................. 3-4

  Set Temperature Table.......................................................................................................... 3-7


SYSTEM MAINTENANCE & TROUBLESHOOTING .................................................. 4-1

  System Maintenance .............................................................................................................. 4-1
     Control Box.......................................................................................................................... 4-1
     Plumbing Connections ......................................................................................................... 4-1
     Electrical Connections ......................................................................................................... 4-1
     Heating Tank........................................................................................................................ 4-2
     System Mounting ................................................................................................................. 4-2

  Troubleshooting ..................................................................................................................... 4-2


REPLACEMENT PARTS AND DRAWINGS ............................................................... 5-1

  Replacement Parts ................................................................................................................. 5-1

  Control Box Components...................................................................................................... 5-2

  Model Number Breakdown................................................................................................... 5-3
     Transformer Part Number .................................................................................................... 5-3
     Contactor Part Number ........................................................................................................ 5-3

  Wiring Diagram ..................................................................................................................... 5-4




                                                                                                                                                iv
                       The Kim Hotstart System

System Overview
        Shown on the next page is the basic layout of the CSS Heating System. This circulating
        heating system consists of a coolant heating chamber, heating element, adjustable
        thermostatic control, a centrifugal pump, a control box with electro-mechanical controls
        and a mounting plate.



Basic System Operation
        Upon energizing the system, engine coolant which is taken from the coolant drain area in
        the lower section of the engine is circulated via a centrifugal pump, pulled through the
        heating chamber and back to a location on the engine furthest from the coolant suction
        line. The pump stays on and continues this circulation process even when the heating
        elements are off to provide an accurate, uniform heat to the engine. In the element
        enclosure is a thermister. This device senses the temperature of the engine coolant and
        sends a signal to a solid-state temperature controller in the control box that turns the
        element on and off as needed.

        The front panel on/off switch or a 24 VDC input for automatic operation can control
        system operation manually.




Section 1 System Overview                                                                      1-1
Section 1 System Overview   1-2
               Installation and System Start-Up
The Kim Hotstart Heating System comes pre-wired and pre-assembled for ease of installation.
This section describes proper installation of the basic Kim Hotstart Heating System. Complete
step-by-step instructions for system start-up are also included in this section. If you need
additional assistance installing or starting your particular system application, please contact:


                    Kim Hotstart Manufacturing Company Customer Support
                                       (509) 536-8660




System Mounting Requirements
The CSS Heating System can be mounted in the horizontal or vertical position. The pump shaft
must be in the horizontal position at all times for proper lubrication and cooling of shaft end
bearing.


Be sure to mount the system as low as possible in reference to the engine coolant level. The
outlet of the heating system is at the pump. Loosen the outlet flange to allow any trapped air to
escape. This allows the heating tank to completely fill at all times, eliminating potential air
pockets and thus preventing premature element failure.


Heating Systems mounted on the engine’s skid base may require vibration isolators on the base
plate to minimize excessive vibration to the system.



                    Vibration Isolator       PRP220113-000     (Qty 4 required)




Section 2 Installation and System Start-Up                                                      2-1
    NOTE:        The pump must be located at or below the water jacket level. Pump shaft must be
                 horizontal.




Section 2 Installation and System Start-Up                                                     2-2
System Installation

Coolant Supply Line
Connect a minimum 1-inch N.P.T. coolant supply hose or pipe from the main coolant drain of
the engine to the tank inlet of the heating system. Drawing coolant from a location low in the
coolant system will ensure head pressure to the pump. The supply line must remain level or
angle downwards to eliminate air pockets. When approaching a plumbing obstacle, go around
the obstacle instead of over it.


Coolant Discharge Line
Connect a minimum 1-inch N.P.T. coolant return hose or pipe from the outlet of the pump to the
highest possible location on the engine coolant system at the furthest possible location from the
suction line. This connection enables heated coolant to be circulated through the entire engine.

    NOTE:        Your system may be configured with optional, non-restrictive shut-off valves in the
                 coolant lines allowing maintenance on the heating system without draining the
                 engine coolant.

                          Isolation Valves              PRP203125-100

    NOTE:        If the heating system is plumbed with rigid pipe, use flexible lines near the heating
                 system long enough to provide freedom from vibration in all directions.


    NOTE:        After the heating system is mounted and refilled with coolant, loosen outlet flange
                 at pump to bleed the air out of the system.




Section 2 Installation and System Start-Up                                                          2-3
                                         Coolant return line to rear of engine.




                                                                          Engine




Optional Shut-Off Valve

 Optional Check Valve


                                             Coolant
                                             Inlet
                Coolant
                Outlet


                            CSS System
                                                                                   engcool.eps




Section 2 Installation and System Start-Up                                                       2-4
Main Power Wiring
Connect the specified voltage and phase to the terminal blocks located in the main control box of
the Heating System. A user-supplied circuit breaker should be used rated at the appropriate
amperage. For 3 phase applications, the terminal blocks are labeled L1, L2 and L3. For single
phase applications, use terminal blocks labeled L1 and L3.When a power transformer is required,
the main power supplies the primary side of the transformer and heating element. The
transformer, used to operate the control circuit, drops the main supply voltage to 120V and
operates the coolant pump. The transformer, control circuit and pump are overload protected
with fuses.


24 VDC Shutdown
Connect an engine-supplied source of 24 VDC electricity to the terminal blocks labeled A and B
in the control box. When present, this 24 VDC shutdown signal will disable the heating system
to prevent operation while the engine is running.




Section 2 Installation and System Start-Up                                                    2-5
Electrical Grounding Requirements
Proper equipment grounding to the Kim Hotstart Heating System protects against electrolytic
corrosion and coolant system damage caused by electrical current. It is essential that you check
for voltage potential in the cooling system; 0.5 volts will destroy a cast iron engine. For testing,
you will need a voltmeter capable of reading A.C. and D.C. voltage in tenths of a volt. Meter
leads must be long enough to reach between the ground side of the battery and the coolant
system. To test voltage potential in the cooling system, follow these steps:

        Step 1       Turn the Kim Hotstart Heating System OFF.

        Step 2       Attach the proper meter lead to the ground side of the battery.

        Step 3       Install the second lead in the coolant. Be sure the lead touches the coolant
                     only.

        Step 4       Read the A.C. and D.C. voltage with all systems turned OFF.

        Step 5       Turn the Kim Hotstart Heating System ON and take an A.C. and D.C. voltage
                     reading.

        Step 6       Read the A.C. and D.C. voltage with the electrical starter engaged.

        Step 7       Take voltage readings with the engine running and all associated electrical
                     systems turned ON.

        Step 8       Remove the test lead from the coolant. Rest the lead against the outside of the
                     engine block. Repeat steps 4 through 7.

        Step 9       If you detect a voltage in the engine coolant system, change the coolant.
                     Electrical current destroys the iron protective chemical in a properly inhibited
                     coolant.

        Step 10      Correct the source of stray voltage by use of proper grounding.




Section 2 Installation and System Start-Up                                                          2-6
Coolant Requirements
Upon an initial coolant fill and each subsequent replacement, check the quality of the source
water. Proper coolant management procedures can eliminate engine and heating system
problems. Use these guidelines:


                                         Basic Water Quality
                                Chlorides          50 PPM Max
                                Sulfates           50 PPM Max
                                Total Hardness     100 PPM Max
                                Total Solids       250 PPM Max
                                pH                 7,5 to 10.5


To achieve the level of quality required, it may be necessary to use distilled water (not
deionized). Distilled water is corrosive without proper inhibitors. Kim Hotstart Manufacturing
also recommends use of a well-inhibited ethylene glycol cooling solution at 30% to 60% ratio.
Glycol based inhibitors provide superior corrosion protection, inhibition, a lower freeze point
and an increased boiling point.

For heavy duty engines, use a low silicate coolant formula inhibitor composition with a silicate
level of no more than 230 PPM. This coolant fill is supplemented with an inhibitor additive
package to provide specific inhibition for wet sleeve cylinder liners, cavitation, pitting and
erosion.


        NOTE:       The use of glycol still requires non-corrosive water, periodic re-
                    inhibition and inhibitor monitoring.


Kim Hotstart Manufacturing recommends use of "Fleetguard DCA4" (or equivalent), a high
quality inhibitor package that provides excellent steel, aluminum, copper and other cooling
system metals protection for the pre-heating system and engine. DCA4 formula consists of a
balanced combination of phosphate, molybdate and nitrite inhibitor, and is packaged in units for
easy calculation of coolant amounts.




Section 2 Installation and System Start-Up                                                        2-7
System Start-Up
After system installation has been completed, follow these steps for proper Coolant Heating
System start-up.



Coolant Heating System Start-Up

    CAUTION:         DO NOT START THE PUMP BEFORE FILLING THE SYSTEM WITH
                     COOLANT AND NEVER OPERATE THE PUMP DRY.

        Step 1       Check and tighten all electrical and plumbing connections.

        Step 2       Ensure isolation valves are open before starting system.

        Step 3       Once the heating system is installed and the engine is filled, run the engine for
                     a short period before energizing the heater. This will purge any air from the
                     pump and heating tank. Loosen outlet flange at pump to bleed air.

        Step 4       The thermostat is set at 65° from the factory for initial start-up. Energize the
                     coolant heating system by turning the coolant switch on the control box to the
                     ON position. After flow is verified through the tank and any trapped air is
                     expelled, adjust thermostat to the desired temperature. See pages 3-7.

        NOTE:        On initial startup, it may take several attempts to achieve proper flow.

If the Coolant Heating System fails to operate correctly, contact Kim Hotstart Manufacturing at
(509) 536-8660 for further instructions.




Section 2 Installation and System Start-Up                                                         2-8
24 VDC Connection
A terminal block, labeled A and B , for the 24 VDC input signal is supplied inside the control
box of the Kim Hotstart heating system. The signal source for this connection is usually the fuel
pump or alternator. Once the signal is detected at the control circuit, the heating system will
automatically shut down during engine operation and re-energize upon engine shutdown.



                              CAUTION
    THE HEATING SYSTEM MUST NOT BE OPERATED WHILE THE ENGINE IS
    RUNNING. IF OPERATED, PREMATURE ELEMENT FAILURE MAY RESULT.




Section 2 Installation and System Start-Up                                                     2-9
                              System Components
This section describes the control box and heating tank components of the CSS Heating System.


Control Box
The control box used in the Kim Hotstart Heating System is shown. The control box contains the
electrical control components of the heating system. Parts in the control box may vary,
depending on the particular system configuration you purchased.




Section 3 System Components                                                                3-1
Fuses
There are one or two different types of fuses located in the control box depending on the heating
system:

Transformer Primary Fuses
      These fuses, located in the control box, protect the power transformer from overloading.

Transformer Secondary Fuse
      This fuse, located in the control box, protects the control circuit components of the
      control box and the pump.


Transformer
The transformer steps down the source primary voltage to 120 volts. Wiring information is listed
on the top of the transformer. This transformer is overload protected with fuses.


        NOTE:    When ordering replacement parts, be sure to reference your heating system's
                 model and serial numbers found on the identification plate.




Section 3 System Components                                                                    3-2
Coolant Heating Tank Assembly
The Kim Hotstart coolant heating tank assembly is shown below.




Following is an overview of operation and replacement instructions for the CSS heating tank
assembly and components, including the coolant heating element.




Section 3 System Components                                                                   3-3
Heating Element Replacement

The heating element heats the engine coolant. To replace the heating element, follow the steps on
the following page. Be sure to allow at least 12" of space for element removal. The wattage and
phase of the heating element are listed on the identification label found on the base of the heating
element assembly.




                             WARNING
 DISCONNECT ALL POWER AT THE SOURCE LEADING TO THE KIM HOTSTART
    HEATING SYSTEM PRIOR TO PERFORMING ANY MAINTENANCE ON THE
                          HEATING SYSTEM.




Section 3 System Components                                                                      3-4
     Step 1    Turn the Kim Hotstart Heating
               system OFF.


     Step 2    Drain the fluid from the heating
               tank.

     Step 3    Open the element enclosure and
               disconnect the following wires to the
               heating element assembly:

               • L1, L2, L3 (L1 & L3 on single
                 phase units)

               • The 2 wires from the thermister.

               • The heating element ground wire.

     Step 4    Remove the conduit connector and
               electrical wires from the element
               enclosure.

     Step 5    Remove the heating element by
               loosening the clamp from the
               heating tank as shown.

     Step 6    Replace the heating element or
               perform the necessary cleaning
               procedure.




To re-assemble the heating element and tank, follow the steps listed above in reverse order.
Make sure the green ground and black power electrical wires are properly reconnected. To order
a new heating element, refer to part number on the label of the element, or the assembly drawing
included with this manual.




Section 3 System Components                                                                  3-5
Coolant System Temperature Setting Adjustments
The system temperature setting adjustment is located inside the control box. The solid-state
adjustable thermostat provides 5° incremental settings between 65° and 140°. To adjust the
heating system's temperature, follow these steps.


                             CAUTION
    DISCONNECT ALL POWER AT THE SOURCE PRIOR TO PERFORMING ANY
                MAINTENANCE TO THIS HEATING SYSTEM.


       Step 1    Open the control box.

       Step 2    Inside the control box, locate the thermostat control with four dip switches.

       Step 3    The system's temperature setting is factory preset at 65°F for initial start-up.
                 After flow is achieved a setting of 100° under normal conditions is sufficient for
                 normal operation. If a higher or lower temperature is required, reset the dip
                 switches to desired temperature.


                            CAUTION
  SEE SET-TEMPERATURE TABLE ON PAGE 3-8 FOR ORIENTATION OF THE
 COMBINED SWITCHES THAT ARE NUMBERED 1, 2, 4 AND 8 LOCATED ON TOP
                  OF THE SOLID-STATE CONTROL.




After the desired temperature is achieved, close the control box and re-energize the heating
system. A few seconds will pass before the thermostat control begins to energize the element.




Section 3 System Components                                                                      3-6
                         Set Temperature Table




Section 3 System Components                      3-7
      System Maintenance & Troubleshooting
This section describes maintenance procedures for the Kim Hotstart Small Capacity Heating
System and provides tips for troubleshooting.


System Maintenance
The following maintenance procedures are provided to ensure trouble-free operation of your
heating system:

        • Control Box                                           •   Plumbing Connections
        • Electrical Connections                                •   Heating Tank
                                       • System Mounting

                                 WARNING
            DISCONNECT ALL POWER PRIOR TO PERFORMING ANY SYSTEM
                               MAINTENANCE.


Control Box
             Periodically check O-rings and gaskets for proper seals.

             Check the control box for moisture (if necessary, add desiccant packets).


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.


Electrical Connections
             Excessive vibration will eventually cause terminals to loosen. Periodically tighten all
             electrical connections. Ensure that all connectors to the circuit board are firmly seated.

             At least once every six months, spray the inside of the main control box with a moisture
             repellent for electrical connections.




Section 4                                                                                            4-1
Heating Tank
              At least once per year, clean the interior of the heating tank and the heating element
              with a wire brush and/or damp cloth. Periodically check the element for sediment
              build-up around the hairpins. Any scaling or build-up will shorten element life.
              Maintenance and replacement procedures for the heating element are described in
              Section 3.


System Mounting
              Excessive vibration may cause mounting bolts to loosen. Periodically check and
              tighten all mounting bolts.




Troubleshooting

            Symptoms                   Possible Causes                          Solutions

                               Air leaks in suction lines          Tighten suction line connections

                               No power                            Energize main power supply
                                                                   Replace primary and/or
                               Blown fuses
 Coolant is not heating                                            secondary fuses
                               Isolation valves are closed
                                                                   Open isolation valves
                               (user supplied)
                                                                   Adjust thermostat dip switches
                               Thermostat is not set properly
                                                                   inside control box




Section 4                                                                                              4-2
              Replacement Parts and Drawings




Replacement Parts

            Description                Part Number
            Pump                      PRP228052-001
            Tank Clamp                PRP215113-000
            Flange Pump               PRP213009-001
            O-Ring Pump               PRP203093-000

        Note: For element Part Number, add “RE” to the front of the
              System Part Number.

        Example: RECSS30604
        All Dimensions on Reference



Section 5                                                             5-1
              Replacement Parts and Drawings




Control Box Components
             Description        Part Number
            On/Off Switch      PRP231075-002
            Fuse – 600v/2amp   PRP231068-002
            Pilot Light        PRP231004-002
            Snubber            PRP224098-000
            Temp. Control      PRP224096-001
            Relay – 24v        PRP224047-001
            Transformer          See p. 5-3
            Contactor            See p. 5-3




Section 5                                      5-2
               Replacement Parts and Drawings




Transformer Part Number
               Voltage    Transformer Part Number
                208            PRP235081-000
                240            PRP235059-000
                380            PRP235061-001
                400            PRP235061-001
                415            PRP235061-001
                480            PRP235059-000
                575            PRP235085-000


Contactor Part Number
   Voltage        Phase     Wattage       Contactor Part Number
      208             1   6kw and over         PRP232049-000
      208             3   12kw and over        PRP232049-000
      240             3   12kw and over        PRP232049-000
  All Others                                   PRP232047-000




Section 5                                                         5-3
            Replacement Parts and Drawings
Wiring Diagram




Section 5                                    5-4