Toyotomi Oil Miser OM-180 Instruction Manual

Instantaneous Oil-Fired Water Heater
Operation and Maintenance Instructions
MODEL OM-180
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
Control Panel 5
Dimensional Outline 5
Construction 6
Wiring Diagram 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
Operation Control by Timer (Option) 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

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. 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 sanitizing
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

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

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. High Limit Thermistor
In order to prevent burns, the high limit thermistor 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. 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.
4. Power Failure Recovery System
If power fails during water heater operation the unit will turn off. When power resumes the unit will
automatically reignite.
5. Fully Vented System
Flue pipe system provides outside air for combustion and vents all combustion products to the out-
doors.
6. 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.
7. Fuel Strainer
Special strainer catches any dirt or impurities present in the fuel before it is sent to the burner.
8. Temperature Fuse
When the air around the heat exchanger rises to an abnormal level, the temperature fuse will turn the
unit 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

SPECIFICATIONS
Model: OM-180
Type: Combustion Type Pressure Vapor
Flue Pipe Forced Flue
Heating Supply System On Demand
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: 90% (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: 81 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: Igniter safety device, high limit thermistor,
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, 7A
(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

DIMENSIONAL OUTLINE
5
22-1/2” (570mm)
6-1/4”
(160mm)
8-1/2”
(215mm)
3/16”
(5mm)
12-5/8” (320mm)
Access Cover
Air Intake Inlet
ø2-3/4”(ø70mm)
Exhaust Outlet
ø2-3/4”(ø70mm)
19-1/4”(488mm)
4”
(101mm)
Fuel Line
Junction Box
27-3/4”(705mm)
Front Panel
Hot Water Outlet or
T&P Relief Valve
(NPT 1-1/4”Male)
Cold Water Inlet or
Drain Outlet
(NPT 1-1/4” Male)
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-180
ON/OFF
POWER
THERMOSTAT
B
HOT
A
COLD
VERY HOT
130° F
WARNINGBURNEROPERATION
CONTROL PANEL

CONSTRUCTION
WIRING DIAGRAM
6
Main Circuit Board
High Limit Thermistor
Fuel Pump
Flame Sensor
Fusible Link Valve
Air Pressure Switch
Blower Motor
Burner
Heat Exchanger Bi-Metal Switch
Ignition Transformer
Strainer
Thernistor
ON
ON
ON
OFF
OFF
OFF
ON
3618
3.6
2
1
3
2
1
3
HIGH LIMIT
SWITCH
(P)
41
THERMISTOR
(A)
FUSE2
FUSE1
3
1
7
1
GN
BK
WT
PRINTED CIRCUIT BOARD
GROUND
TRANSFORMER
ON/OFF
SWITCH
SECONDARY
TRANSFORMER
(J2)
PRIMARY
TRANSFORMER
(J1)
VOLUME
OPERATION LAMP
BURNER LAMP
WARNING LAMP
AIR
PRESSURE
SWITCH
FUEL
PUMP
(F)
REMOTE CONTROLLER
FLAME
DETECTOR
(D)
THERMISTOR
(T)
TEMPERATURE
FUSE
(Q)
IGNITION
TRANSFORMER
(H)
FG
JUNCTION BOX
POWER SOURCE
60Hz,AC120V
(E) BLOWER MOTOR
(G)
TIMER SHORT CIRCUIT
(L)
HGH LIMIT
SW1 (DIFFERENTIAL SWITCH)
BL IG
FP
5A
7A
OUTPUT
60HZ, AC120V
(FOR CIRCULATION PUMP)
(K)
SW1
DIFF (˚F)

The OM-180 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

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. 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.
7. Do not operate the unit without water in the heat exchenger. The heat exchanger may be damaged. In
case of using the unit for heating, be sure there is a sufficient amount of water in the heat exchanger
regularly.
8
SECTION D:
OPERATION

OPERATION
CAUTION: ¡High water 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: ¡High water 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.
NOTE: ¡Seasonal change of water temperature from the main water source results in a different hot
water temperature supplied. Use hot water supply faucet to control hot water temperature,
or readjust temperature setting.
¡The hot-cold mixing faucet is recommended to ensure safe and comfortable use of the water
heater. Choose a mixing faucet which can provide a comfortable water temperature with less
temperature fluctuation.
¡After installing the mixing faucet, set the temperature selector knob at the position of "VERY
HOT" and then gradually adjust the water temperature by adding cold water to your prefer-
able level. Sufficient care must be taken not to misoperate this adjustment, which may result
in scalding your hands.
9
Position of Temperature Selector Knob
VERY HOT
B
HOT
A
COLD
Hot Water Temperature
around 176°F
around 158°F
around 122°F
around 95°F
around 68°F
CAUTION
HOTTER WATER INCREASES THE
RISK OF SCALD INJURY.
BEFORE CHANGING TEMPERATURE
SETTING SEE INSTRUCTION
MANUAL.
OM-180
ON/OFF
POWER
THERMOSTAT
B
HOT
A
COLD
VERY HOT
130° F
WARNINGBURNEROPERATION

FLOW RATE AND WATER TEMPERATURE
NOTE: Whenever high temperature water is required for continuous demand, lessen the flow rate.
Whenever low temperature water is required, the flow rate may be increased.
The flow rates are calculated under the conditions of standard installation and normal usage so
that they will vary according to installation, usage and temperature.
TURNING UNIT OFF
1. Press "POWER SWITCH" to ''OFF'' position. All lamps will go out.
2. Close the fuel tank valve.
OPERATION CONTROL BY TIMER (OPTION)
¡This unit is equipped with a timer connection terminal.
¡Leave the power switch “ON” for automatic operation by the timer.
[When the timer is ON]
When the timer connection terminal receives a no-voltage contact signal “ON”, the unit operates and the
operation lamp lights up. Then, according to the temperature of the heat exchanger, automatic operation
is carried out. When the burner starts burning, the burner lamp lights up.
[When the timer is OFF]
When the no-voltage contact signal on the timer connection terminal is turned “OFF”, the unit enters a
stand-by condition and the operation lamp blinks. When the timer connection terminal receives no-volt-
age contact signal “ON” again, the unit automatically operates as stated above.
NOTE: Even when the timer connection terminal receives no-voltage contact signal “ON”, the water
heater won’t operate when the power switch is “OFF”.
PREVENTING FREEZE UP
In order to prevent any kind of damage or leaks caused by freezing, keep the pipes heated at all times, as
specified below.
CAUTION: In order to prevent the water heater from freezing or develop a leak, regardless of being used in
a cold region or in a warm or hot region, the water supply piping, hot water supply piping,
drain pipe, check valve, valves, expansion tank, and temperature & pressure relief valve are to
be protected with sufficient insulation materials (by wrapping with heat insulation or by equip-
ping an freeze prevention heater).
1. OPERATING AT HIGH TEMPERATURE
CAUTION: Risk of scald injury. Before changing temperature setting make sure that the water heater is
not being used by any of your family at any place in the house.
Set the Thermostat to the ''VERY HOT'' position, and press "POWER SWITCH" to ''ON'' position.
NOTE: Since this method cannot prevent the water inside of the piping from freezing, sufficient insulation
measures are to be given according to the requirements mentioned in the above cautions.
10
CAUTION
HOTTER WATER INCREASES THE
RISK OF SCALD INJURY.
BEFORE CHANGING TEMPERATURE
SETTING SEE INSTRUCTION
MANUAL.
OM-180
ON/OFF
POWER
THERMOSTAT
B
HOT
A
COLD
VERY HOT
130° F
WARNINGBURNEROPERATION
SUMMER
SPRING & FALL
WINTER
SEASON
INCOMING WATER TEMP HOT WATER TEMP FLOW RATE
80°F
60°F
40°F
120°F (40°F RISE)
120°F (60°F RISE)
120°F (80°F RISE)
6.2 GPM
4.1 GPM
3.1 GPM

2. DRAINING WATER
When you do not plan to use the unit for an extended period, the following procedures are recommend-
ed.
1. Turn the unit off.
2. Disconnect the power supply cord.
3. Close the fuel tank valve securely.
4. After closing the main water supply valve, open up all the faucets.
5. Open the drain valve on the bottom of the unit.
6. Pull up the lever of the temperature and pressure relief valve.
NOTE: If the water heater is not used in the winter season or in a cold region where the water supply
is frozen, or if it is not used for a long period of time, the water heater should be drained and
related piping system shut off completely.
When re-supplying water in the water heater and system:
1. Close the air exit valve, if it is provided for the piping.
2. Close the drain valve.
3. Pull down the lever of the temperature and pressure relief valve.
4. Close all the hot and cold mixing faucets.
5. Fully open the main water supply valve.
6. First slowly open the valve for the hot and cold mixing faucet which is located in the farthest posi-
tion and gradually increase the flow rate as water starts flowing continuously.
NOTE: Since the water heater and piping system still have much air left after they are drained, a flash
flow of water may be caused by such air pressure when re-supplying water through them. First
open the valve carefully and gradually increase its opening to "Full Open" when the water flow
becomes stable. When air bubbles disappear in the water, fully open the valve for hot and cold
mixing faucet.
7. Also flow water through other hot and cold mixing faucets by the procedure of item 6 above.
8. Fully open the feed fuel valve of the fuel tank.
9. Connect the power supply cord.
10. Press the the "POWER SWITCH" to "ON" position.
11. Next open the valve for hot and cold mixing faucet, so hot water will flow out.
Operation start of the water heater in a cold region:
Before starting the water heater, open a valve for a hot and cold mixing faucet to make sure that water flows
out. If there is no water flow on a slow flow, the water heater and piping system may be frozen. If this hap-
pens, wait until such frozen water is melted and re-start the operation of the water heater when water flows
properly.
LONG TERM INACTIVITY
When leaving the unit unused over a long period of time, drain the heat exchanger and pipes thoroughly
and disconnect the electrical cord.
11

INSPECTION AND MAINTENANCE
WARNING: RISK OF INJURY FROM MOVING PARTS AND ELECTRICAL SHOCK.
RISK OF INJURY FROM MOVING PARTS AND ELECTRICAL SHOCK. Disconnect the power sup
ply cord before inspecting and servicing unit.All repairs should be left to professionals. RISK OF
BACKFIRE AND INDOOR POLLUTION. Before operation make sure the flue pipe is free of snow,
icing, leaves, bird's nest or strong drafts.
CAUTION: RISK OF BURN INJURY. Do not touch the flue pipe top and the exhaust pipe.
Annual maintenance is recommended for most efficient operation.
When inspecting, ALWAYS do the following.
a. Press the Power Switch to OFF position.
b. Disconnect the power plug from the receptacle.
c. Close the fuel feed valve.
When inspecting, NEVER do the following.
a. Do not remove the thermistor.
b. Do not adjust the pressure of the fuel pump.
INSPECTION AND MAINTENANCE ITEMS
1. FLAMMABLE IN THE ENVIRONMENT (REGULARLY)
Remove all flammable material from the area.
2. FUEL LEAKS (REGULARLY)
Always check for oil leaks. Clean off spilled fuel thoroughly. If a leak is found, shut down the unit until
the problem is corrected.
3. FUEL FEED LINE INSPECTION (REGULARLY)
Check for fuel leaks from the fuel feed line. Replace it if any cracks or leaks are found.
4. WATER LEAKS (REGULARLY)
Check the heat exchanger for water leaks. Always correct if found.
5. ODOR OR SOOT (REGULARLY)
If you notice soot at exhaust pipe fittings, exhaust gas may be leaking from the pipe joints. Consult your
dealer.
6. DUST (ONCE A MONTH)
Check for dust inside of the unit and the bottom (base).
7. WATER INSIDE THE FUEL TANK (ONCE A MONTH)
Remove any water or waste particles that accumulate inside the fuel tank.
8. FUEL STRAINER / FUEL FILTER (ONCE A MONTH)
Vibration, noise, ignition and combustion failure could be caused by water or waste particles in the fuel
strainer and the fuel filter. Clean the strainer and filter once a month.
9. FLUE PIPE (ONCE A MONTH)
A clogged flue pipe will cause improper combustion.
Inspection for any clogging or soot accumulation should
be done at least once every year. Make sure not to place
combustibles in the flue pipe area.
Make sure that exhaust gas is not leaking from the flue pipe.
Also check whether there are leaks from pipe joints.
12
SECTION E:
ROUTINE MAINTENANCE

10. TEMPERATURE AND PRESSURE RELIEF VALVE (ONCE A MONTH)
The temperature and pressure relief valve may become immovable at times due to corrosion of
pipes or mineral deposits In the pipes. Pull up the lever of the temperature and pressure relief
valve every month and make sure the valve is movable.
11. PLUG AND RECEPTACLE (ONCE A MONTH)
Make sure the plug is free of dust. Be sure plug fits receptacle securely.
12. BURNER INSPECTION (ONCE SIX MONTH)
Check the burner and combustion area for soot. Clean if found.
13. GASKETS AND WASHERS (ONCE SIX MONTH)
Check for water leaks caused by improper sealing of the water pipe. If there are leaks, gaskets
or sealant must be replaced.
14. FLAME SENSOR (PHOTOELECTRIC CELL) (ONCE SIX MONTH)
a. Take out the ignition transformer by removing the two (2) bolts and
remove the four (4) screws from the blower bracket C-assembly.
b. Take out the flame sensor which is located to the right upper part of the
burner inside the cabinet.
c. If the beam receiving surface of the flame sensor becomes dirty or cont-
aminated, the unit will not operate properly. The beam receiving sur-
face should be wiped with a soft cloth every 6 months.
d. To install, make the protruding section at the side of the flame sensor
agree with the slot on the bracket and insert the flame sensor firmly up
to the bottom. (For easy installation, use pliers with long tapered noses
to grip and install the flame sensor.)
15. BLOWER MOTOR (ONCE SIX MONTH)
Make sure there is no dust on the blower motor fan.
16. HEAT EXCHANGER (ONCE A YEAR)
Open the drain valve at least once a year to drain the heat exchanger. Pull
up the lever of the temperature and pressure relief valve to allow air to
enter the heat exchanger.
WARNING: RISK OF INJURY FROM MOVING PARTS AND ELECTRIC SHOCK.
Disconnect the power supply cord before servicing unit. All repairs should be left to
professionals.
WARNING: Do not re-use the unit until the cause of the problems have been determined.
CAUTION: RISK OF BURN INJURY. Do not touch the unit and the heat exchanger while in hot.
If there Is any abnormality, determine for the causes from the list below and perform the specified measure.
Consult your dealer if problems cannot be corrected from this chart.
13
SECTION F:
TROUBLESHOOTING
WARNING

14
PROBLEM
POWER LAMP FAILS
TO TURN ON
WARNING LAMP
LIGHTS AFTER
TURNING ON.
EXTINGUISHED
AFTER IGNITION
NOISE FROM FUEL
PUMP
NOISY COMBUS-
TION
HOT WATER TEMP
TOO LOW
SOOT ACCUMULA-
TION
WATER LEAKAGE
FUEL LEAKAGE
FROM FUEL PIPE
Disconnected power supply cord
Abnormal location and adjust-
ment of electrode
Igniter malfunction.
Abnormal lowering of electrical
voltage
Out of fuel
Air pocket in fuel line
Clogged fuel strainer
Stained light-intercepting surface
of flame sensor
Flame sensor dirty
Flame sensor malfunction
Fuel restriction
Combustion air restriction
Fuel nozzle failure
Bi-metal switch activated
High limit thermistor activated
Air lock in fuel line
Clogged intake line and pump
Fuel flow too much
Fuel flow too little
Fuel nozzle failure
Improper installation of flue pipe
Thermistor malfunction
Hot water supply beyond capacity
Dusty blower motor fan
Improper installation of flue pipe
Fuel flow too much
Fuel nozzle failure
Water leakage from heat
exchanger (Heat exchanger
malfunction)
Gasket malfunction
Loose connection of fuel pipes
Connect power supply cord.
Consult your dealer.
Consult your dealer.
Consult your dealer.
Consult your dealer.
Consult your dealer.
Contact electricians.
Check fuel gauge on fuel tank; refuel.
Remove air pocket.
Clean strainer.
Consult your dealer.
Consult your dealer.
Replace it.
Consult your dealer.
Clean flame sensor.
Replace it.
Remove air.
Consult your dealer.
Replace it.
Consult your dealer.
Consult your dealer.
Remove air.
Consult your dealer.
Consult your dealer.
Consult your dealer.
Replace it.
Re-install properly.
Consult your dealer.
Close hot water faucet partially.
Consult your dealer.
Re-install properly.
Consult your dealer.
Replace it.
Consult your dealer.
Replace it.
OPERATION LAMP
BLINKS
Connecr the short-circuit terminal correctly.
Normal.
Consult your dealer.
CAUSE SOLUTION
1
2
3
4
5
6
7
8
9
10
11
The short-circuit terminal of timer
connection “L” on the
circuit board is disconnected.
Or the unit is under stand-by
state by automatic operation
of the timer.
Flame sensor malfunction
Light on Flame Sensor
Thermistor malfunction
BLOWER MOTOR
OPERATES, NO
IGNITION
Bi-metal switch activated
Air pressure switch open

TOYOTOMI U.S.A., INC.("TOYOTOMI") warrants each product and any parts thereof sold by it to be free from defects in
materials or workmanship under normal use and service for TWELVE (12) MONTHS* from the date of delivery to the original
purchaser at retail subject to the following terms and conditions :
WHAT IS COVERED : Product or any parts thereof which are defective in materials of workmanship.
WHAT IS NOT COVERED :
(1) This warranty does not extend to any defect due to the negligence of others: failure to install, operate, or maintain unit in
accordance with instructions (Installation and Operation instructions are furnished with each new unit); unreasonable use;
accidents; alteration, use of unauthorized or non-standardized TOYOTOMI parts and accessories; electrical malfunction, i.e.,
as resulting from large power surges, short circuit, etc.; incorrect installation; use of any fuel other than that specified in
owner's manuals; or repair by anyone other than a service facility specified by TOYOTOMI.
(2) Normal wear and tear of parts, including hoses, wires, burner mats, fuel nozzles, filters and accessories.
(3) This warranty does not cover shipping costs.
WHO IS COVERED : The original purchaser at retail.
WHAT WE WILL DO : TOYOTOMI will either repair or replace, at its option, all defective parts free of charge that are covered
by this limited warranty on a carry-in basis, to your nearest authorized dealer or distributor of TOYOTOMI.
WHAT YOU MUST DO FOR WARRANTY SERVICE : You must return the defective Product or part to any authorized dealer or
distributor of TOYOTOMI with this LIMITED WARRANTY and a copy of your bill of sale or credit card charge receipt or other
documents evidencing the date of the Product's delivery, if service is not available locally, please contact our CUSTOMER
RELATIONS DEPARTMENT at :
TOYOTOMI U.S.A., INC.
604 Federal Road, Brookfield, CT 06804
[phone]
THE FOREGOING EXPRESSES ALL OF TOYOTOMI'S OBLIGATIONS AND LIABILITIES WITH RESPECT TO THE QUALITY OF
PRODUCT FURNISHED BY IT. ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING THE WARRANTIES OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE DISCLAIMED. TOYOTOMI SHALL NOT BE LIABLE
FOR THE LOSS OF USE OF THE PRODUCT, INCONVENIENCE, LOSS OR ANY OTHER DAMAGES, DIRECT OR
CONSEQUENTIAL ARISING OUT OF, THE USE OF, OR INABILITY TO USE, THE PRODUCT OR DAMAGES RESULTING FROM
OR ATTRIBUTABLE TO DEFECTS IN THE PRODUCT.
No one other than TOYOTOMI has authority to extend or modify the terms of this Limited Warranty in any manner whatsoever.
Some states or provinces do not allow the exclusion or limitation of incidental or consequential damages or limitations on how
long an implied warranty lasts, so these limitations or exclusions may not apply to you. This Limited Warranty gives you
specific legal rights and you may also have other rights that vary from state to state, or province to province.
* In addition to the warranty period stated above, an extended two (2) year warranty (3 years from date of purchase) is on for
the following parts. :
1.Vented Heater :
A. Burner Pot
B. Heat Chamber (Excluding Glass Cylinder)
C. Heat Exchanger
2.Hot Water Heater :
A. Burner Top
B. Heat Exchanger
NOTE : THE EXTENDED WARRANTY POLICY IS APPLICABLE ONLY FOR THE REPLACEMENT OF THE ORIGINAL FACTORY-
INSTALLED PARTS THAT HAVE FAILED WITHIN THE TIME LIMITATIONS AS INDICATED. REPLACEMENT PARTS ARE
WARRANTED FOR THE REMAINDER OF THE ORIGINAL PART WARRANTY PERIOD. LABOR IS NOT COVERED ON
THE EXTENDED WARRANTY.
LIMITED WARRANTY
New 7/05 Printed in Japan
4788003051
TOYOTOMI U.S.A., INC.
604 Federal Road, Brookfield, CT 06804
www.toyotomiusa.com
This manual supersedes earlier editions. PART No.20476795