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Section 4Thermostat ControlsPressure SwitchMagnetic ContactorsJunction BoxesComplete ControlSystems – for manualand automatic startengines33

TemperatureControlsFixed Setting1”NPT x 1”NPTWeathertightNOTE: When using athermostat above 277 voltor on3 phase applications,select the proper controlbox with transformer andcontactor as shown onpages 37 or 38.CONDUIT TYPE ENCLOSURE1" NPT1" NPT4.57PartNumberTemp.SettingOn4.71OffTFTC6-1NPT 60 F 80 FTFTC8-1NPT 80 F 100 FTFTC10-1NPT 100 F 120 FTFTC12-1NPT 120 F 140 FTFTC14-1NPT 140 F 160 F3.62Maximum CapacityRatings120/240Volt 277 Volt25 amps25 amps25 amps25 amps25 amps22 amps22 amps22 amps22 amps22 amps1”NPT x 1” HOSE BARB4.62CONDUIT TYPE ENCLOSURE1 3/8" Hex1" NPT1" Hose Barb1/2 ConduitKnockout (4X)PartNumberTemp.SettingOnOffMaximum CapacityRatings120/240Volt 277 Volt4.96TFTC6-1HB 60 F 80 FTFTC8-1HB 80 F 100 FTFTC10-1HB 100 F 120 FTFTC12-1HB 120 F 140 FTFTC14-1HB 140 F 160 F3.6225 amps25 amps25 amps25 amps25 amps22 amps22 amps22 amps22 amps22 amps1”NPT x 3/4” HOSE BARB1 3/8" HexCONDUIT TYPE ENCLOSURE1" NPT4.623/4" Hose Barb1/2" ConduitKnockout (4X)PartNumber4.96Temp.SettingOnOffTFTC6-3HB 60 F 80 FTFTC8-3HB 80 F 100 FTFTC10-3HB 100 F 120 FTFTC12-3HB 120 F 140 FTFTC14-3HB 140 F 160 FMaximum CapacityRatings120/240Volt 277 Volt25 amps25 amps25 amps25 amps25 amps22 amps22 amps22 amps22 amps22 amps3.62CLASS 1, GROUP DCONDUIT TYPE ENCLOSURE1/2" NPTConduitOpening3.0PartNumber5.01.01" NPT Inlet1.252.2534HOTSTART Engine HeatingTFT6ERTFT8ERTFT10ERTFT12ERTFT14ERP.O. Box 11245Temp.SettingOnOff60 F80 F100 F120 F140 F80 F100 F120 F140 F160 FMaximum CapacityRatings120/240Volt 277 Volt25 amps25 amps25 amps25 amps25 amps22 amps22 amps22 amps22 amps22 ampsSpokane Valley, WA 99211-0245

14-3 HPN(4 FT.)TemperatureControls1”NPT x 1”NPTCORD TYPE Maximum CapacityRatings120/240Volt 277 Volt4.71TFT6-1NPT 60 F 80 FTFT8-1NPT 80 F 100 FTFT10-1NPT 100 F 120 FTFT12-1NPT 120 F 140 FTFT14-1NPT 140 F 160 F2.5625 amps25 amps25 amps25 amps25 amps22 amps22 amps22 amps22 amps22 ampsWeathertightNOTE: When using athermostat above 277 voltor on 3 phase applications,select the proper control boxwith transformer andcontactor as shown onpages 37 or 38.14-3 HPN (4 FT.)1”NPT x 1” HOSE BARBCORD TYPE ENCLOSURE1 3/8" HEX1" NPT1" B 60 F 80 FTFT8-1HB 80 F 100 FTFT10-1HB 100 F 120 FTFT12-1HB 120 F 140 FTFT14-1HB 140 F 160 F2.6314-3 HPN (4 FT.)Maximum CapacityRatings120/240Volt 277 Volt25 amps25 amps25 amps25 amps25 amps22 amps22 amps22 amps22 amps22 amps1”NPT x 3/4” HOSE BARBCORD TYPE ENCLOSURE1 3/8" HEX3/4"Hosebarb1" NPTPartNumber3.78Temp.SettingOn4.96TFT6-3HB 60 F 80 FTFT8-3HB 80 F 100 FTFT10-3HB 100 F 120 FTFT12-3HB 120 F 140 FTFT14-3HB 140 F 160 F2.63Adjustable Range65 F to 250 (Open or Off Setting)Differential 7 F (Close or On Setting).078Dia.AT6525Maximum Capacity Ratings120/240 Volt – 25 Amps277 Volt – 22 Amps125 155 1855 25021LOCustomer Support: (509) 536-866022 amps22 amps22 amps22 amps22 ampsPartNumber5.061.0325 amps25 amps25 amps25 amps25 ampsWith 60’’ Capillary Probe3.3660120/240Volt 277 m CapacityRatings95ATWAluminumProtectiveWell forAT6525Toll-Free FAX: (800) 224-5550.5 inchNPTwww.hotstart.com35

TemperatureControlsAdjustableThermostatReduce engineheater cycle timein both warm andcold ambienttemperatures.HOTSTART offers an adjustable thermostatas an option on weathertight enginepreheaters and as a stand-alone unit.Control your optimum desiredtemperature with Kim Hotstart’sadjustable thermostat. Adjustable from 90 F to 130 F. Stock one thermostat to fit all needs. 5/8” hose barb or 1” NPT threadconnections allow for easy in-lineinstallations on a variety of heatingunits. Weather resistant enclosure. Rated up to 480 volts.Cord Type14-3 HPN (4 FT.)2.573.674.161.685/8" HosebarbConduit TypeModel NumberTypePlumbing ConnectionsCord TypeModel NumberTFTCA-1NPTTFTCA-5/8HB1” NPT X 1” NPT5/8” HB X 5/8” HBTFTA-1NPTTFTA-5/8HBAdjustable RangeElectrical Rating120/240 Volt — 25 Amps277 Volt — 22Amps480 Volt — 12.5 Amps90 F to 130 F (Open or Off Setting)Differential 20 F (Close or On Setting)Conduit Type6.433.663.103.781.933.341" NPT36HOTSTART Engine Heating1" NPTP.O. Box 11245Spokane Valley, WA 99211-0245

ControlComponentsOil Pressure SwitchesFor automatic cut-off of heaters when engine startsMaximum Current Capacity:120V/208V/240V/277V — 25 Amps380V/480V/575V — 15 AmpsTwo pole single throw.To prevent overheating of the heatingelement on standby equipment andautomatic start engines, HOTSTARTrecommends turning the coolant heateroff when the engine is running. A pressureswitch that senses engine oil pressure isutilized to shut the heater off on increaseof oil pressure and to turn the heater onwhen engine oil pressure drops.Kim HotstartModel NumberEnclosureTypePS252Dry LocationsPS252RDry Locations (Reverse Action)PS252WTWet LocationsPS252EPHazardous LocationsPS252Magnetic ContactorsCoilVoltageDRY LOCATIONSMC330LMC330120V240VKim HotstartModel Number60 AMPS30 AMPSKim HotstartModel NumberMC360LMC360HAZARDOUS LOCATIONS120V240V3 POLE3 POLE120V240VWET LOCATIONS120V240VJBE11-000JBE12-000MC330DRY LOCATIONSWET 12-060120V240VHAZARDOUS LOCATIONSJBE11-060JBE12-060120V240VInrush Voltamps (VA) 35 VAInrush Voltamps (VA) 92 VAHolding Voltamps (VA) 8 VAHolding Voltamps (VA) 10 VAJunction BoxesUse to simplify wiring on equipment when a variety of heaters and controls are required.All models have ten, 25 Amp terminal blocks.PartNumberNumber ofOpeningsPDB-0008*PDB-000* Box comes assembled with 4 strain relief connectors.For additional connectors, order part# PDB-1.PDB-1Customer Support: (509) 536-8660Toll-Free FAX: (800) 224-5550www.hotstart.com37

Complete Control SystemsFor heater protection and power savings HOTSTART recommends de-energizing the heater when engine is running. Onautomatic start engines this can be accomplished with a control system using an Oil Pressure Switch or a 24 Volt Relay.VoltsHOTSTART Model NumberMANUAL START ENGINESHOTSTART Model NumberAUTOMATIC START ENGINESAmpsVoltsSingle Ø — One Heater and Thermostat Per Engine120V208V240V277VUse thermostat only.See pages 32 through 36.VoltsManual Control 0V480VJBW11-060JBW14-060AB120V208V240V277VUse oil pressure switch(PS252) & thermostat.See pages 32-36 and page 37.25 Ampsor LessAutomatic Control SystemsWith24 Volt RelayBoxSizeWithPressure SwitchBoxSizeVolts30 V575V60 C120V480VThree Ø — One Heater and Thermostat Per 000JBW14-000JBW15-000AABBB480VJBW14-060B30 Ampsor CCCC208V240V380V480V575V60 AmpsMaximumJBW14-160BJBW14-260C480VSingle Ø — Two Heaters and Two Thermostats Per Engine120V208V240V277VUse one thermostat with each heater.See pages 32 through 3-000JBW24-000JBW25-000CCCDDD25 AmpsPerHeateror Less30 AmpsPer HeaterMaximum120V208V240V277VUse one oil pressure switch (PS252)& thermostat with each heater.See pages 32 through 36 and page 08V240V380V480V575VDDDDD208V240V380V480V575VThree Ø — Two Heaters and Two Thermostats Per 000JBW24-000JBW25-000CCDDD30 AmpsPer Heateror ll control boxes are available for Class 1 Group D hazardous locations, change prefix “JBW” to “JBE”. Consult factory for priceand availability.Box Size Code: A – 6 x 6 x 4, B – 8 x 8 x 4, C – 10 x 8 x 4, D – 12 x 10 x 538HOTSTART Engine HeatingP.O. Box 11245Spokane Valley, WA 99211-0245

All HOTSTART heaters with thermostats, designed to operate on 3-phase current (at anyvoltage), require the use of a control system with a 3-pole contactor. All Kim Hotstartheaters with thermostat designed to operate over 480 volt (1 phase or 3 phase) require acontrol system to reduce the primary voltage to 120 volts for the control circuit. Forincreased thermostat life, use a control system on all heaters above 277 volts either singleor three phase.These control systems allow for quick electrical installation of all HOTSTART enginepreheaters. They are designed as a time and labor saving component. They are especiallyuseful on installations that require two coolant heaters or combinations of a coolantheater and oil heater/hydraulic heater etc.TypicalControl BoxSystemComponentsAll control boxes on this and preceding page are NEMA 12 & 13.All control boxes are available for Class 1 Group D hazardous locations. Change prefix“JBW” to “JBE” and consult factory for price and availability.L1L2Power In480V 3PHL3Equipment Ground(must be grounded)ControlTransformer480V. PRI.H2H3H4X1MagneticContactors1A. FusesC1C1C1C2C2C2H1X2120V. 50VA1/2A. Fuse10A. l5C2Thermostat3Model JBW24-200With pressure switch2HeatingElementorModel JBW24-100With 24 volt relay2To control two 480 volt heaters at maximum 30 amps on automatic start engines.3 Phase OnlyL3Power In480V.1 or 3Ø30 AMPL1Equipment Ground(must be grounded)H1Transformer480V. PRI.50VAH3H21A. FusesH4L1MagneticContactorC1C1E1X1L2L3C1E2E3X2120V Sec.Model JBW14-000No automatic controlX11/2A. oilTo control one 480 volt heater at maximum 30 amps on manual start engine.Customer Support: (509) 536-8660Toll-Free FAX: (800) 224-5550www.hotstart.com39

Technical Information & Heater Installation InstructionsOPERATING PRINCIPLEThe HOTSTART engine heater operates on the principle of a thermosiphon. As the temperature of the coolant in the heatertank increases, it’s density decreases causing it to rise through the outlet of the tank to the engine. The coolant leaving theheater tank is replaced with coolant drawn from the engine and the cycle is repeated. A flow-through thermostat is availablefor the inlet of the engine heater that keeps coolant within the preset temperature range.CAUTIONPrior to heater installation, check the cooling system. Poor coolant conditionswill interfere with proper function of the heater and can also cause elementfailure. If there is sediment or foreign matter present or the coolant does notmeet the engine manufacturer’s specifications, the system should be drained,cleaned, flushed and refilled with a 50/50 mixture of low silicate antifreeze,deionized water, and low silicate supplemental coolant additives. Do not exceeda concentration of more than 60% antifreeze, as element failure may result. Acooling system containing anti-leak additives can cause premature elementfailure.MOUNTINGMount the tank heater in a horizontal position with the outlet neck pointed up.The heater can also be mounted vertically with the inlet neck as the low point(see figure 1).Bolt the heater to the truck frame or skid frame on a generator package withthe mounting straps provided. See Figure 2. The heater must be mounted belowthe lowest level of the engine water jacket to ensure a good gravity flow ofcoolant to the heater.Outlet NeckOutlet NeckInletInletVERTICAL MOUNTHORIZONTAL MOUNTFIGURE 1CAUTIONYESDO NOT mount the heater to the engine. Engine vibration can damage theheater and void the warranty.Connect the heater intake to the lowest accessible point of the water jacket. If aconnection point is unavailable in the water jacket area, connect heater intakeline to lower radiator hose. This hose should run down to heater intake.Connect heater outlet to the highest accessible point in the engine’s waterjacket area at the furthest point from the engine’s thermostat. The heater outletmust be connected at a higher point on the engine than the intake. See Figure3.NOLowest level of water jacketFIGURE 2YESNOCAUTIONDO NOT route outlet hose above engine block connection, or loop or kink hoses.This will cause air locks in the hose and block circulation of the coolant by theheater. See Figure 3.To eliminate air locks in the heater and hoses, refill the engine with the heateroutlet line disconnected at the engine until outlet line is full of coolant. SeeFigure 4-1. Then connect the outlet line to the engine and finish filling theengine. See Figure 4-2.Before energizing heater, all air must be bled out of the system by running theengine. If not, air could be trapped in the block causing the heater to fail.FIGURE 3YES1NO2NOCAUTIONThe bi-directional ball check valve located in the inlet of the heater allows areduced amount of coolant to reverse flow through the heater when the engineis running. This will maintain a full coolant level in the tank at all times toprotect the element from overheating. This is a safety device only. Kim Hotstartrecommends NOT running the engine with the engine heater energized.On standby and automatic start engines, heaters should be de-energized whenengine starts. This requires an oil pressure switch or other automatic cut-off.These systems are often operated at voltages above the 277 Volt rating of theKim Hotstart thermostat and are also often 3 Phase. All heaters above 277 Voltshould be used in conjunction with a contactor and control transformer. Allthree phase heaters must be used with a contactor. See pages 37, 38, and 39.40HOTSTART Engine HeatingFIGURE 4Coolant FlowNote: It is recommended for “V” engines larger than eight cylinders or over 1000C.I.D. that 2 heaters of equal wattage be used. One heater installed on each bankof the “V”.Example: To adequately heat a 1000 cubic inch “V” engine for ambient temperatureabove -20 F use (2) 2000 watt heaters — total 4000 watts.For the most efficient heating of this size engine and electrical savings, see theforced circulatiing heating system on pages 16 & 17.P.O. Box 11245Spokane Valley, WA 99211-0245

HOTSTART offers an adjustable thermostat as an option on weathertight engine preheaters and as a stand-alone unit. Control your optimum desired temperature with Kim Hotstart’s adjustable thermostat. † Adjustable from 90 F to 130 F. † Stock one thermostat to fit all needs. † 5/8” hose barb or 1” NPT thread connections allow for .

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