Toyotomi Oil Miser OM-148 (Type D) Troubleshooting guide

Instantaneous Oil-Fired Water Heater
Operation and Maintenance Instructions
MODEL OM-148
(Type B)
CONTENTS
IMPORTANT
READ AND UNDERSTAND INSTRUCTIONS BEFORE INSTALLING OR USING THIS WATER HEATER.
RETAIN INSTRUCTIONS FOR FUTURE REFERENCE. CHECK LOCAL CODES AND ORDINANCES FOR
PERMITTED USE.
CAUTION
THIS WATER HEATER SHALL NOT BE USED FOR COMMERCIAL USE OR FOR ANY PURPOSES OTHER
THAN HOT WATER SUPPLY USES. OTHER USAGE MAY CAUSE A MALFUNCTION OR SHORTEN ITS
SERVICE LIFE. DO NOT REMOVE THE RATING PLATE AND LABELS FROM THE WATER HEATER UNIT.
SECTION A:
Safety Tips ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 1
Safety Features ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 3
SECTION B:
Specifications⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 4
Dimensional Outline⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 5
Control Panel ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 6
Construction ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 6
SECTION C:
Fuel Guide ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 7
SECTION D:
Operation
Fueling ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 8
Inspection Before Operation ⋯⋯⋯⋯⋯⋯⋯⋯ 8
Operation ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 9
Adjusting Water Temperature ⋯⋯⋯⋯⋯⋯⋯ 9
Flow Rate and Water Temperature ⋯⋯⋯⋯ 10
Turning Unit Off ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 10
Preventing Freeze Up ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 10
Long Term Inactivity ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 11
SECTION E:
Routine Maintenance
Inspection and Maintenance ⋯⋯⋯⋯⋯⋯⋯ 12
Inspection and Maintenance Items ⋯⋯⋯⋯ 12
SECTION F:
Troubleshooting ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯ 13
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BE SURE TO FOLLOW THE FOLLOWING INSTRUCTIONS.
The instructions which are contained in this manual are classified into the following two types, which are
"WARNING" and "CAUTION". These instructions are intended to provide important information for safe
operation.
"WARNING" indicates the possibility of causing the user a fatal accident or serious injury if the water heater
is incorrectly operated.
"CAUTION" indicates the possibility of causing the user injuries or material damages if the water heater is
incorrectly operated.
WARNING
1. Never use any fuel other than ASTM D3699 1-K Kerosene, ASTM D396 No.1 or No.2 Fuel Oil.
NEVER USE GASOLINE! Use of such fuels can result in an explosion and/or fire and cause injury.
2. Never store flammable liquids or materials such as gasoline near the unit.
3. This unit should be installed by a licensed, authorized person(s) due to the necessity of making electri-
cal, water and fuel connections.
4. RISK OF BACKFIRE AND INDOOR AIR POLLUTION. Before operation make sure flue pipe is free of snow,
icing, leaves, bird's nest or strong drafts.
5. RISK OF INDOOR AIR POLLUTION AND FIRE. Be sure the exhaust pipe is properly installed and connect-
ed. Aluminum tape may be used for sealing exhaust pipe connections.
6. RISK OF INJURY FROM MOVING PARTS AND ELECTRICAL SHOCK. Disconnect power cord before ser-
vicing unit.
7. This water heater is designed to be used no more than 4,922 FY. (1,500 m) above sea level. Burner
adjustments are required when: (1) water heater is installed with flue pipe (#20476401) above 4,992 ft.
(1,500 m); (2) water heat is installed with chimney kit (#20476430) above 3,280 ft, (1,000 m). Failure to
make appropriate adjustments may cause combustion failure. Contact your local dealer.
The water heater may have a failure of combustion at a high altitude
CAUTION
1. HOTTER WATER INCREASES THE RISK OF SCALD INJURY. Water heaters are intended to produce hot
water. Water heated to a temperature which will satisfy clothes washing, dish washing, and other sani-
tizing needs can scald and permanently injure you upon contact. Before changing temperature setting
make sure nobody is using a shower. High temperature setting increases the risk of scald injury.
Temperature has been set at factory to about 130°F.
2. RISK OF SCALD INJURY. When using a shower, feel the temperature of the water with your hand before
getting under the water.
3. RISK OF SCALD INJURY. Do not touch hot water flowing from temperature and pressure relief valve.
4. RISK OF BURN INJURY. Do not touch flue pipe top and exhaust pipe. The insulated material provided
should be installed around the exhaust pipe. Due to high surface temperature, keep children away from
the unit.
1
SECTION A:
SAFETY TIPS
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OTHER PRECAUTIONS
1. This unit is only for indoor use. Avoid its exposure to rain or moisture.
2. Do not use for drinking or cooking until the water supply has been approved by local authorities.
3. Hot water (or cold water) left in heat exchanger or piping must not used for cooking or drinking.
4. When using a large amount of hot water the temperature may change, even though the temperature
setting has not been changed. Special caution must be taken if two faucets are open at the same time.
5. If the unit appears to be operating abnormally or in an emergency, turn off the unit and call an autho-
rized service person.
6. Avoid the use of hard water. In regions where hard water is the only source, take advantage of a water
softener.
7. Do not use a damaged unit. If repairs are needed, contact your dealer.
8. Keep the area around the unit, the fuel tank and the flue pipe clean and free of flammable materials.
9. If you plan to be away from your home for a long period of time, shut-off the fuel valve on the fuel tank.
Press "POWER SWITCH" to "OFF" position and disconnect the power supply cord.
10. If the unit is not used for a long period of time, the fuel tank may contain water cause by condensation.
Be sure to check all filters and strainers for this condition, clean or replace filter elements before using
the unit.
11. The use of the water heater with the temperature selector knob at "B", "HOT", or "COLD" may propagate
bacteria growth in the water. In order avoid this, turn the temperature selector knob to "VERY HOT" once
a week to heat the water heater and water to a high temperature for approximately one hour.
12. Before changing the temperature setting, make sure that the water heater is not being used by any of
your family at any place in the house. All family members should be aware of this "Caution."
13. Fusible Link Valve (#10005597)
¡It is most important that the valve, depending on its use, be fully opened or fully closed.
¡The top nut on the valve (below the turn handle) is sealed and should never be tightened or
removed.
¡When installing fuel lines to the valve, be sure to check for fuel leakage.
¡A LEAKING VALVE SHOULD ALWAYS BE REPLACED.
14. When No. 2 fuel oil is used in an area where the temperature becomes less than 25˚F (-4˚C), it is recom-
mended the use of an additive with the fuel to prevent congeling. Check with a fuel suppy company for
the propre additive and mix.
2
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SAFETY FEATURES
1. Ignition Safety Device (Flame Sensor)
The unit will automatically stop all operations if ignition fails or if the flame fails during combustion.
''WARNING'' lamp will light.
2. Over Heat Protector
In order to prevent burns, the over heat protector automatically stops all operations if the water in the
heat exchanger reaches abnormally high temperatures due to temperature controller malfunction. The
''WARNING'' lamp will light.
3. Power Failure Recovery System
If power fails during water heater operation the unit will turn off. When power resumes the unit will
automatically reignite.
4. Fully Vented System
Flue pipe system provides outside air for combustion and vents all combustion products to the out-
doors.
5. Fusible Link Valve
If a household fire should occur, causing the fuel line or water heater to become extremely hot, the
fusible link valve will stop the fuel supply to the burner. This will prevent the fuel supply from the exter-
nal tank from continuing to flow into the house.
6. Fuel Strainer
Special strainer catches any dirt or impurities present in the fuel before it is sent to the burner.
7. Heat Exchanger Bi-Metal Switch
If the heat exchanger temperature becomes abnormally hot because of a malfunctioning thermostat, the
burner is automatically extinguished and the ''WARNING'' lamp will light.
8. Temperature Fuse
When the air around the heat exchanger rises to an abnormal level, the temperature fuse will blow and
the unit will turn off. The "WARNING" lamp will light.
9. Air Pressure Switch
When the air flow volume reduces or the flue pipe is clogged, the burner is automatically extinguished
and the "WARNING" lamp will light up.
3
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SPECIFICATIONS
Model: OM-148 (Type B)
Type: Combustion Type Pressure Vapor
Flue Pipe Forced Flue
Heating Supply System Instantaneous
Source of Water Direct Connection to Main Supply
Ignition: High Voltage Discharge Spark
Fuel: ASTM D3699 1-K Kerosene,
ASTM D396 No.1 or No.2 Fuel Oil
Efficiency: 88% (1)
Hot Water Input: 148‚000 BTU/h
Fuel Consumption: 1.05 gal/h
Capacity of Heat Exchanger: 5.10 gal
Fuel system: External tank (2)
Dimensions (W x H x D): 12-5/8'' x 27-3/4'' x 22-1/2''
Weight: 86 lbs. Empty
Vent Pipe Hole: 4-3/4 diameter
Maximum Length of Vent Pipe System: 10 ft., 3 bends or less
Electrical Rating: 120 Volts AC, 60 Hz
Ignition - 120W
Burning - 98W
Required Accessories: Fuel filter, Temp & pressure relief valve
Safety Device: Over-heat protector, Ignition safety device,
Heat exchanger bi-metal switch,
Temperature fuse, Fusible link valve
Exhaust Air Temperature: less than 500°F
Nozzle: Quantity of Vapor 0.85 GPH
Spraying Angle 60°
Spray Pattern Delavan Type XA
Temperature Fuse: 282°F
Electric Current Fuse: 5 A
(1) Heat and vaporized water are produced by the combustion process of this water heater. This rating
does not take into account heat loss due to condensation of water vapor.
(2) External tank to be purchased from local suppliers.
4
SECTION B:
SPECIFICATIONS
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DIMENSIONAL OUTLINE
5
Temperature and
Pressure Relief Valve
Installation Mouth
(NPT 3/4) Female
Exhaust Outlet
ø2-3/4"(ø70mm)
Drain Outlet
(NPT 1/2) Male
Air Intake Inlet
ø2-3/4"(ø70mm)
Access Cover
Water Supply
Inlet
(NPT 3/4) Male
Hot water Supply
Outlet
(NPT 3/4) Male
Junction Box
Front Panel
5-1/8"
(130mm)
5-1/8"
(130mm)
3/16"
(5mm)
22-1/2"(570mm)
6/1/4"
(160mm)
8-1/2"
(215mm)
5-1/8"
(130mm)
5-1/8"
(130mm)
27-3/4"(705mm)
3/4"
(19mm)
23"(585mm)
12-5/8"(320mm)
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CONTROL PANEL
CONSTRUCTION
6
Temp Selector Knob Power Switch
Operation Lamp
Burner Lamp
Warning Lamp
CAUTION
HOTTER WATER INCREASES THE
RISK OF SCALD INJURY.
BEFORE CHANGING TEMPERATURE
SETTING SEE INSTRUCTION
MANUAL.
OM-148
ON/OFF
POWER
THERMOSTAT
B
HOT
A
COLD
VERY HOT
130°F
WARNINGBURNEROPERATION
Main Circuit Board
Thermistor
Fuel Pump Ignition Transformer
Fusible Link Valve
Heat Exchanger
Air Pressure Switch
Inteke Air Duct
Blower Motor
Igniter
Burner
Heat Exchanger Bi-Metal Switch
Flame Sensor
Strainer
OM-148(OP/E) 06.9.19 1:12 PM ページ 6

The OM-148 is designed for use with ASTM D3699 1-K Kerosene, ASTM D396 No.1 or No.2 Fuel Oil only.
Use of low-quality oil will cause burner performance to drop, leading to abnormal combustion and reduced
the unit life.
Purchase only ASTM D3699 1-K Kerosene, ASTM D396 No.1 or No.2 Fuel Oil in non-red cans reserved exclu-
sively for fuel and marked accordingly with the word "KEROSENE", "NO.1 FUEL Oil" or ''NO.2 FUEL OIL''.
To avoid accidented use of gasoline or other high volatile liquids, always store your fuel in a separate area.
What to Buy...
ALWAYS: Clean and high-quality ASTM D3699 1-K Kerosene, ASTM D396
No.1 or No.2 Fuel Oil.
ALWAYS: Fuel free of contaminants, water or cloudiness.
NEVER: Gasoline, alcohol, white gas, camp stove fuel or additives.
NEVER: Yellow or sour-smelling fuel.
How to Store It...
ALWAYS: Store in a clean container, non-red in color, clearly marked
"KEROSENE", "NO.1 FUEL OIL" or ''NO.2 FUEL OIL''.
ALWAYS: Store away from direct sunlight, heat sources or extreme tem-
perature changes.
NEVER: In a glass container, or one that has been used for other fuels.
NEVER: For longer than six months.
NEVER: In the living space.
Why It is Important...
Pure, clean oil is essential for safe and efficient water heater operation. Poor
quality or contaminated fuel can cause:
¡Excess tar deposits in the burner and flue pipe
¡Incomplete combustion
¡Reduced unit life
Use of a highly volatile flammable fuel such as gasoline can produce uncon-
trollable flames, creating a severe fire hazard.
7
SECTION C:
FUEL GUIDE
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FUELING
WARNING: Use ASTM D3699 1-K Kerosene, ASTM D396 No.1 or No.2 Fuel Oil only. Never use gasoline,
thinner, benzene, light oil or waste oil, or any other high volatile liquids.
CAUTION: Make sure that the fuel is clean and free from dirt and water. Water and dirt may cause com-
bustion failure and shorten the life of components such as the fuel pump.Be sure to refuel
before the tank runs out. Avoid having the fuel tank and fuel line run empty.
REMOVING AIR TRAP
When operating for the first time or when refueling an empty tank, air may be trapped in the fuel line, mak-
ing ignition difficult. In this situation, after removing the trapped air thoroughly from the fuel filter at the fuel
tank outlet, follow the procedures below:
1. Press "POWER SWITCH" to "OFF" position. Disconnect the power supply
cord.
2. Release the two (2) screws from the front panel and remove the front
panel.
3. To catch the fuel which will drain out, put a small container under the
strainer.
4. Loosen the screw on top of the strainer. Immediately wipe off any spilled
fuel.
5. Remove the trapped air thoroughly. Failure to remove all the air will cause improper ignition and may
extinguish the unit.
6. Tighten the screw after removing trapped air.
7. Reconnect the power supply cord. Press "POWER SWITCH" to "ON" position.
Note: In the event of an ignition failure, press "POWER SWITCH" to "OFF" position and after
10 seconds press "POWER SWITCH" to "ON" position once again.
INSPECTION BEFORE OPERATION
1. Before turning on the POWER SWITCH, make sure that the water supply inlet is open and that water
runs out properly by opening a hot water faucet. If not, check the drain valve to see if it has been left
open.
2. Check for water leaks in the pipes.
3. Be sure there is a sufficient amount of fuel in the tank and that there are no leaks in the pipe line.
4. Be sure the power supply is properly connected and grounded to the unit.
5. Be sure the area around the water heater is clear of flammable materials such as gasoline, thinner or
flammable vapors.
6. Be sure the exhaust and flue pipes are securely connected and that there are no leaks.
8
SECTION D:
OPERATION
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OPERATION
CAUTION: ¡Hotter water or high temperature setting increases the risk of scald injury.
¡Thermostat has been set at factory to about 130°F.
¡Risk of scald injury. When using a shower, feel the temperature of the water with your hand
before getting under the water.
¡When using a large amount of hot water the temperature may change, even though the tem-
perature setting has not been changed. Special caution must be taken if two faucets are open
at the same time.
1. Open the fuel tank valve.
2. Press "POWER SWITCH" to ''ON''. "OPERATION" lamp will come on. Automatic operation is based upon
the temperature of water inside the heat exchanger. ''BURNER'' lamp is lit when the burner is in its
operation mode.
NOTE: When operating for the first time or after running out of fuel, ignition may not occur because of
air in the fuel line. In that case, remove air as described in the previous section.
ADJUSTING WATER TEMPERATURE
CAUTION: ¡Hotter water or high temperature setting increases the risk of scald injury.
¡Thermostat has been set at factory to about 130°F.
¡Risk of scald injury. When using a shower, feel the temperature of the water with your hand
before getting under the water.
¡Risk of scald injury. Before changing the temperature setting, make sure that the water
heater is not being used by any of your family at any place in the house.
¡When using a large amount of hot water the temperature may change, even though the tem-
perature setting has not been changed. Special caution must be taken if two faucets are
open at the same time.
¡The use of the water heater with the temperature selector knob at "B", "HOT", or "COLD" may
propagate bacteria growth in the water. In order avoid this, turn the temperature selector
knob to "VERY HOT" once a week to heat the water heater and water at high temperature for
approximately one hour.
To increase the hot water temperature, turn the temperature selector knob clockwise. To decrease the hot
water temperature, turn the temperature selector knob counterclockwise.
9
Position of Temperature Selector Knob
VERY HOT
B
HOT
A
COLD
Hot Water Temperature
around 155°F
around 147°F
around 112°F
around 88°F
around 69°F
CAUTION
HOTTER WATER INCREASES THE
RISK OF SCALD INJURY.
BEFORE CHANGING TEMPERATURE
SETTING SEE INSTRUCTION
MANUAL.
OM-148
ON/OFF
POWER
THERMOSTAT
B
HOT
A
COLD
VERY HOT
130°F
WARNINGBURNEROPERATION
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