Toyotomi OPT-91UL Montageanleitung

INSTALLATION AND OPERATION INSTRUCTIONS

FUEL LIFTER PUMP

MODEL OPT

91UL

IMPORTANT:

READ AND UNDERSTAND INSTRUCTIONS CAREFULLY BEFORE INSTALLING

OR USING LIFTER. RETAIN INSTRUCTIONS FOR FUTURE REFERENCE AND

CHECK LOCAL CODES AND ORDINANCES FOR PERMITTED USE.



CONTENTS

PAGE TITLE

3 SAFETY TIPS

3 Fuel

3 Installation

3 Operation

4 SPECIFICATIONS

4 ELECTRICAL CIRCUIT DIAGRAM

5 COMPONENT PARTS

5 Indication panel

6 SAFETY MECHANISM

6 OPERATION

8 MAINTENANCE

9 STORAGE

10 TROUBLESHOOTING

11 INSTALLATION

11 Unpacking lifter carton

12 Selecting location

12 Safety tips for installation

13 Installation of lifter

15 PIPING

15 Precautions

15 Piping precautions

16 Flaring of pipes

16 Connection of copper pipes

17 Permanent wiring installation

17 Lifting characteristics chart

18 External fuel supply installation kit

19 PARTS LIST

SAFETY TIPS

Before operating your lifter pump, please review these safety tips.

FUEL

WARNING: Never use any fuel other than clear or red dyed

ASTM D3699 1-K Kerosene or ASTM D396

No.1 or No.2 Fuel Oil. NEVER USE GASOLINE

or other flammable liquid! Use of gasoline can

cause a fire.

OPERATION

1. The maximum lifting height is 26 feet (8 m). (Fig. 1)

2. The height (A)between the lifter and the heater

should be the height specified for the heating appliance.

(16 in. Min., 8 ft.Max.)(

Fig. 1)

3. Never close the main tank valve while heater is in

use. If the valve is closed during the lifter operation,

it may cause a pump lock, etc. (Fig. 1)

4. To prevent air locks in fuel pipe, fuel line should be

smooth with no U-shaped or sharp bends. (Fig. 1)

5.Never use the lifter for the purpose other than

supplying fuel to the heaters.

6. This lifter is intended to refuel the heater by means

of gravity pressure difference; therefore, it cannot be

used for a heater which do not have an oil level

control such as oil leveller or solenoid valve.

In the event that the lifter is connected to the sub fuel

tank of a wick fed type heater by mistake, it will

cause an overflow of the fuel on the heater. (Fig. 2)

RIGHT WRONG

GAS

Air lock

Heater

Less than

26 ft. (8 m)

Check-valve should be installed

at lowest point of intake line.

Main

fuel tank

Open

Main tank valve-Open

KEROSENE

Fig. 1

Heater

÷Wick fed type kerosene heater

÷Wickless fan heater

Fig. 2

INSTALLATION

Note : This lifter pump must be installed in accordance with National Fire Protection Association

Code NFPA 31.

This lifter is for indoor installation only. Electrical components are not waterproof.

Also, when used in a cold area, condensation may occur inside the lifter, possibly causing

problems. To avoid such trouble, it is recommended not to install the lifter outdoors or on cool area.

The lifter must be installed in accordance with the National Electrical Code (NFPA 70)

and all other codes that are applicable to the local jurisdiction.

IMPORTANT

This lifter is designed and tested for use with Oil Miser, Toyostove and Toyotomi products.

No.1 & No.2

SPECIFICATIONS

ELECTRICAL CIRCUIT DIAGRAM

PUMP TYPE

LIFTING HEIGHT (MAX.)

MAXIMUM HORIZONTAL DISTANCE

OUTLET FLOW RATING

INLET PIPE SIZE

POWER SUPPLY

POWER CONSUMPTION

SUMP TANK CAPACITY

DIMENSIONS

WEIGHT

FUEL TYPE

Suction (Head or fall type)

26 ft. (8 m)

131 ft.

4 gal./h (15 L/H)at 20 ft. (6 m)

3/8" O.D.

AC 115V, 60Hz

16W

0.24 gal. (0.9 L)

Width: 8" (202

)

Depth: 4-1/4" (107.5

)

Height:10-7/8" (278

)

7.1lbs. (3.2 kg)

ASTM D3699 1-K Kerosene or ASTM

D396 No.1 or No.2 Fuel Oil

Red

Green

Yellow

Main

control

switch

Indication lamp

①②

①③

Surge-absorber

Transformer

Main circuit board

CN2

CN3

Power source

115V, 60Hz

Fuse

3A Chassis

Motor

Gray(or Yellow)

Relay 2

Relay 1

Blue

Black

①

③

⑤

Condenser

1μF

250V AC

Main

float

switch

Sub

float

switch

COMPONENT PARTS

Control box

Cover screw

Mounting plate

Outlet valve lever

Motor

Fuel opening cap

Driving shaft

Fuel sump

Pump

Check valve

Fuel strainer

Power supply cord

Terminal block

Float switch

INDICATION PANEL

Red lamp

Green lamp

Yellow lamp

Control box

Operation switch

Cover

Funnel

SAFETY MECHANISM

1. Overflow Prevention

(a)If the lifter is tilted while in operation, the red lamp comes on and the operation

stops.

(b)If an electric part is in malfunction and the oil level exceeds the normal oil level,

the red lamp comes on and the operation stops.

2. Idle Operation Prevention

If the fuel sump is empty while in operation or if the lifter does not pump up the fuel

because of a pump malfunction, etc.,for more than 20 minutes the yellow lamp comes

on and the motor stops.

3. Continuous Operation Prevention

If the lifter is operated over for 30 minutes due to motor lock, all lamps will flash and the

operation is stopped.

OPERATION

■When Operating Lifter For The First Time After Installation:

Before operating the lifter in the following procedure, check if installation and piping are

performed in the manner as described in "INSTALLATION" (Page 11~13) and "PIPING" (Page 15~17).

1. Remove the cover screw at the upper side of the cover and remove the cover

bringing it slightly forward.

2. Set the outlet valve lever to CLOSE by pulling up and rotating the lever, turn the operation

switch to OFF position (Fig. 3), and put the power supply cord into the electrical outlet. The

yellow lamp will flash to indicate insufficient oil in the fuel sump.

3. Pour about 0.12 gallons (450 cc) of fuel into

the fuel opening by using the attached funnel.

When the fuel sump is filled sufficiently, the green

lamp will flash to indicate the normal oil level. (Fig. 3)

CAUTION:

Use clear or red colored kerosene or

No.1 or No.2 Fuel Oil only!

Be sure there is no contamination

such as dirt, water or other particles.

Note:If an excessive amount of fuel is filled,

the red lamp will flash to indicate excessive

oil level. In this case, set the outlet valve

lever to OPEN and supply fuel to the heater

until it reaches normal oil level. (Fig. 3)

4. Turn the operation switch to ON position. The green lamp will change from flashing to continuous

and the motor will start operating.

CAUTION: Do not touch the motor fan. The motor fan will start at the same time

when turning the operation switch to ON position.

Red lamp

Green lamp

Yellow lamp

Outlet valve

lever

Control box

OPERATION

switch

OPEN

Fig. 3

OFF

Fuel opening

with rubber cap

Put the funnel

into the opening

Funnel

Note:When first started, the intake line contains air and a muted "THUMPING"

sound will be heard. Once the line is filled with fuel the sound will cease.

Note:If this does not stop until just before the motor stops, air is leaking into the

pipe. Check the pipe and all connections, especially the flares.

Note:If the lifter is installed correctly, a proper amount of fuel will be

pumped up in about 5 to 12 minutes at which time the motor will stop.

5. Turn the outlet valve lever to OPEN.

CAUTION: Be careful not to touch the motor fan when rotating the outlet valve

lever.

6. Remove the funnel from the fuel opening, and then store it in place.

7. Plug the hole of the fuel opening securely with the rubber cap.

8. Replace the cover and attach with cover screw. At this point, the lifter is ready

to perform automatic operation to supply fuel to the heater.

■When Restarting The Lifter In The Next Season:

1. Remove the cover screw and remove the cover.

2. Turn the outlet valve lever to CLOSE, turn the operation switch to OFF, and put the

power supply cord into the electrical outlet.

3. Turn the operation switch to ON.

Note:If the red lamp comes on or flashes when the operation switch is OFF position, the

motor does not rotate when turning the operation switch to ON.

(a)If the outlet pipe is longer than 33 ft. (10 m),

turn the outlet valve lever to OPEN and CLOSE

repeatedly several times. When the motor starts,

set the outlet valve lever to CLOSE, and when

the motor stops, set it to OPEN. (Fig. 4)

(b)Before turning the outlet valve lever to OPEN,

quickly repeat the procedure of holding up

the lever fully and turning it to CLOSE four or

five times. To prevent air lock which may

occur in the pipe.

(c)Be sure that fuel is not leaking from any

part of the lifter as well as from the inlet/outlet

pipes and all joints.

Outlet valve lever

Before setting the outlet valve

lever to OPEN,quickly

repeat the procedure of

holding up the lever

fully and setting it to

CLOSE four or

five times.

Hold it up fully.

Set it to CLOSE.

OPEN

OPENOPEN

CLOSECLOSE

Fig. 4

Note:If the yellow lamp or green lamp flashes when

the operation switch is OFF position, the green

lamp will flash and the motor will start rotating

to perform lifting for about 5 to 12 minutes

when turming the operation switch to ON.

(Fig. 5)

4. Turn the outlet valve lever to OPEN to supply

fuel to heater.

5. Replace the cover and attatch it with the cover

screws securely.

MAINTENANCE

CAUTION: Be sure to turn the operation switch to OFF and disconnect the power

supply cord from the electrical outlet before performing any checks or cleaning.

Note: Accumulated dust and water may cause problems. Check and clean the lifter before

using it.

1. Cleaning

Remove the cover and remove any dust from around the motor.

2. Clean fuel strainer

If the fuel strainer is clogged, clean it in the

following procedure.

(a)To catch the fuel which will drain out,

set a rag or folded paper towel below the

strainer cover. (Fig. 6)

(b)Loosen the two (2) screws from the strainer

cover and remove. (Fig. 6)

(c)Remove the fuel strainer and rinse with

clean fuel. (Fig. 7)

(d)Return the fuel strainer to its original position.

Replace the strainer cover and replace

screws.

(e)Wipe away any spilled fuel.

(f)Be sure to confirm that there is no fuel

leakage from the strainer cover.

3. Draining from fuel sump

Water can collect in the fuel sump. Drain any

water from the fuel sump prior to each season's

start up.

(a)Remove the two (2) drain screws at the

bottom of the unit. (Fig. 8)

Fuel strainer

Rag

Strainer cover

Fuel strainer

Clean kerosene

Drain screw

Fig. 6

Fig. 7

Fig. 8

Fig. 5

Red lamp

Green lamp

Yellow lamp

Outlet valve

lever Control box

OPERATION

switch

OPEN

OFF

Note: To catch the fuel and water that will drain out, set a half gallon

container under the unit.

(b)Water and fuel will be discharged together.

(c)Tighten the two (2) drain screws.

(d)Operate the lifter for a while to confirm that no fuel is leaking from the drain

screws.

STORAGE

At the end of each heating season, or when you do not plan to use the lifter for an

extended period, the following procedures are recommended.

1. Turn the operation switch to OFF position.

2. Unplug the lifter.

3. Turn the outlet valve lever to CLOSE.

TROUBLESHOOTING

Sympton

Red lamp ON.

Motor does not rotate.

Motor turns, but no

fuel pumped up.

Fuel pumped up, but

no fuel fed to heater.

All lamps go off.

Yellow lamp ON.

Cause

Too much fuel put in fuel

sump.

Lifter tilted by mistake.

Upper limit float switch

defective.

Control box malfunction.

Too much fuel in fuel

sump.

No power supplied.

Pump and/or motor lock.

Control box malfunction.

Insufficient fuel in fuel

sump for priming.

Pump height too high.

Main fuel tank empty.

Main tank valve closed.

Air leak from inlet pipe.

Driving shaft is off or

broken.

Pump valve lock.

Outlet valve closed.

Outlet pipe air lock.

Outlet pipe clogged.

No power supplied.

Control box malfunction.

Fuel consumption

larger than lifter can

pump up.

Inlet pipe clogged.

Air leak from inlet pipe.

Fuel strainer clogged.

Fuel leak from outlet

pipe.

Driving shaft is off or

broken.

Pump and/or motor lock.

Pump valve lock.

Solution

Let oil level go down, then

turn it ON.

Correct tilt. Turn operation

switch to OFF, then turn it

ON.

Replace float switch.

Check fuse then replace

the circuit board.

Let oil level go down, then

turn it ON.

Check power supply and

operation switch.

Replace pump and/or motor.

Replace the circuit board.

Add priming fuel as

instructed.

Reduce pump height to

26 ft. (8 m) or less.

Fill the main fuel tank.

Open the valve.

Repair leaks and check all

joints and connections.

Fix or replace the shaft.

Replace the pump.

Open outlet valve.

Purge air from pipes.

Clean the clogged pipe.

Check power supply and

turn the operation switch

to ON.

Check fuse on board and/or

replace circuit board.

Consumption is too much

for lifter pump add another

lifter pump.

Clean the clogged pipe.

Repair leaks.

Check and tighten fittings.

Clean the strainer.

Repair the leaks.

Fix and replace the shaft.

Replace the motor and pump.

Replace the pump.

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