Toyotomi OPT-91UL User manual

SERVICE MANUAL
FUEL LIFTER PUMP
MODEL OPT-91UL

SPECIFICATIONS
PUMP TYPE
Suction (Head or fall type)
LIFTING HEIGHT (MAX.)
26 ft. (8m)
MAXIMUM HORIZONTAL DISTANCE
131 ft.
SUCTION CAPACITY
4 gal./h (15 L/H) at 20 ft. (6m)
INLET PIPE SIZE
3/8” O.D.
POWER SUPPLY
A/C 115V, 60Hz
POWER CONSUMPTION
16W
SUMP TANK CAPACITY
0.24 gal. (0.9 L)
DIMENSIONS Width: 8” (202 mm)
Depth: 4-1/4” (107.5 mm)
Height: 10-7/8” (278 mm)
WEIGHT
7.1 lbs. (3.2 kg)
FUEL TYPE ASTM D3699 1-
K Kerosene or ASTM
D396 No.1 or No.2 Fuel Oil
ELECTRIC CIRCUIT DIAGRAM
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COMPONENT PARTS
REF # PART # PART NAME REF # PART # PART NAME
1 20459824 Fuel opening cap 9 20459882 Drive shaft
2 20459852 Strainer gasket 10 20459850 Fuel strainer
3 20459880 Drain packing 11 20475535 Power supply cord
4 20477546 Cover 12 20459819 Pump assembly
5 20477529 Mounting plate 13 20477576 Switch circuit
6 20459837 Motor assembly 14 20477512 Main circuit board
7 20459815 O-ring (S150) 15 20459805 Cover screw
8 20459817 Outlet valve lever 16 20459825 Funnel
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SPECIAL FEATURES
Capable of lifting fuel up to a height of 26 ft. (8 m):
Equivalent to the height of the third floor of average residences (including multistoried flats and
buildings).
Fuel sump permits fuel supply without electric power:
The fuel sump contains approximately 0.17 gal (0.66 liters) that can be used even though there
is a temporary power outage.
Automatic operation restored after power outage:
Operation is automatically restored after a power outage without manually resetting the unit.
Lifter stops automatically if without fuel supply:
The lifter is automatically stopped within a specified time after the fuel supply is disrupted. This
will prevent the pump from being damaged. This condition may also indicate that the supply
tank is empty.
Easy resumption of operation with the refueling button:
A refueling button re-establishes fuel supply to the lifter after the lifter has run out of fuel.
Therefore, refueling (priming) can be done easily (except at the initial installation).
Double protection against overflow:
An abnormal oil level detection circuit positively stops the operation of the lifter if it does not
stop at the upper limit fuel level. An overflow pipe can also be installed.
Intermittent operation:
The lifter only pumps as much fuel as is consumed. This helps reduce electric power
consumption.
Silent design to ensure minimum noise:
The design and intermittent operation of the lifter ensure that it can be installed indoors without
causing a noise disturbance.
Long service life with the rotary pump:
Use of a rotary pump ensures long service life of the lifter without malfunction.
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SAFETY AND RELIABILITY
Highly reliable parts and components, various safety devices, and other protective features
ensure safe operation of the lifter.
Abnormal fuel level prevention:
Fuel leaking from the unit is considered to be one of the most serious failures of a lifter of this
type. The following redundant safety features are used to prevent this problem with the
Toyotomi Fuel Lifter. A float switch continuously maintains the normal high and low fuel level
range. If the lifter malfunctions and the fuel amount exceeds the normal high level, a high limit
safety switch stops the motor to prevent the fuel from over-flowing. The red error lamp is also
illuminated to call attention to this problem. The lifter will not automatically restart. To reset
the unit, turn the operation switch off or disconnect the power cord and repair the malfunction
before restarting the lifter.
Motor protection:
The motor provides power for the pump and will not operate if the pump gets stuck and locked
during operation. To prevent damage to the motor a safety device shuts-off the motor after 30
minutes of continuous operation. Also, in the event that the motor becomes excessively hot, a
high-temperature sensing device (a temperature fuse in the motor) terminates electric power
to the motor.
Float switch:
A float switch consisting of three glass-enclosed reed switches provides highly reliable
performance in adverse conditions such as moisture, dust, or harmful gas.
Lightning surge protection:
A varistor protects the lifter from damage due to abnormally high voltage that may be caused
by lightning or from a power line surge and which would otherwise destroy the control circuits.
Protection from short:
A fuse is used to protect the lifter from damage caused when voltage of 240V is applied or
when part of the circuitry is subjected to a short.
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INSTALLATION
SELECTING LOCATION
CAUTION: This lifter is for indoor use only. Check local codes and ordinances for
permitted uses.
1. Select a safe and solid place to install the lifter.
2. Select a place easy to inspect and maintain.
3. Do not install the lifter less than six- (6) ft. (2m)
from the heating appliance horizontally.
Do not install the lifter near the exhaust pipe
and the heat chamber of the heater.
4. Select a location away from direct sunlight and
other heat sources.
5. Maintain the shortest fuel line possible by selecting a location that is as close as possible to
the main fuel tank. If the fuel line to the main fuel tank is long, a properly located check-valve
will eliminate a long wait for fuel delivery.
TIPS FOR SAFE INSTALLATION
Follow the safety tips below when installing the lifter.
1. Establish the height of the lifter as follows.
(a) The height between the main fuel tank valve and the bottom of the lifter:
26 ft. (8m) maximum
Locate the lifter as low as possible.
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(b) Height between the floor level of the heater and the bottom of the lifter:
8-1/2 ft. (2.5m) maximum
(c) At least 16 in. higher than the heater fuel intake fitting.
2. Max. length of the pipe between the main fuel tank and the lifter:
131 ft. (40m)
If more than 50 ft. (15m), 1/2 in. fuel line is recommended instead of 3/8’’ tubing.
3. If one lifter is used to fuel to several heaters, about 1/3 of the total flow may be lost to internal
resistance. If several heaters are to be used, preferably install the lifter at a midway point
between those heaters.
4.If fuel is to be supplied from a main fuel tank by
gravity flow to a heater on the first floor and
another heater on the second floor will be supplied
by a lifter, the branch point of the fuel line should
be located as close as possible to the outlet of the
main fuel tank.
5. Fueling with a series operating lifters:
(a) This lifter is capable of pumping a maximum
head of 26-ft. (8m). More height can be
accomplished by using additional units in
series. However, please note that when two or
more lifters are connected in series, the fuel
supply line (or head) to the upper lifter(s) must
be approximately 3 1/3 ft. (1 m) longer (less)
than the fuel supply line (or head) for the unit below it. Thus if the upper unit is lifting
the maximum head of 26 feet, the lower unit must only lift approx. 23 feet.
(b) An overflow fuel pipe (return pipe) must be used when operating lifters in series. The
overflow fuel pipe must go to the main fuel tank and be installed so that there is
clearance between the outlet of the overflow fuel pipe and the maximum oil level in the
main fuel tank. A special part is also required in order to attach the overflow fuel pipe to
the lifter. (#22744901)
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6.No more than three oil meters should be used on
the outlet line from the lifter. Air inside of the oil
meter may expand due to a change in
surrounding temperature and possibly cause fuel
to flow back to the lifter.
CAUTION: If more than four meters are installed on the outline fuel line the lifter may leak
fuel and create a hazard.
INSTALLATION OF THE LIFTER
1. Check the accessories before installing.
Mounting rubber (3) Wood screw (3)
Washer (3) Flare nut (2)
2. Make three (3) small holes on the wall as per the
mounting dimension diagram.
3.Attach the three (3) mounting rubbers to the wall with
the wood screws and the washers.
Do not tighten the mounting rubbers excessively.
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4.Install the mounting plate over the mounting rubber
cushions using the holes. Slide the mounting plate
down.
5.Attach the three (3) screws securely. Be sure not to
touch the motor’s cooling fan or the control box with
the screwdriver.
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FUEL SUPPLY LINE
PRECAUTIONS
1. Use 3/8 in. (9.53 mm) outside diameter (O.D.) and not less than 0.032 in. (0.8 mm)
thickness copper tubing.
Note: some local building inspection authorities may not accept Copper tubing as fuel line.
Check local codes and ordinances for permitted use. In these instances, the fuel line
may need to be made of wrought iron or steel.
2. When cutting the copper pipe, be sure to use a tubing cutter and note the following:
(a) Do not damage any part within 5/8 in. (15mm) of the cut surface.
(b) Remove burrs from the cut surface completely.
3. Be sure to bend the copper pipe before connecting it.
PRECAUTIONS
1.Install the horizontal pipe on the inlet side as low
as possible up to the point which is in closest
proximity to the lifter and from which the vertical
pipe rises straight up to the lifter. If installing
horizontal fuel line in other cases than above,
carefully observe the following:
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(a) When installing several lifters with one main
fuel tank, install a large diameter horizontal
pipe lower than the height of the bottom of
the main fuel tank at each point at which the
branch vertical pipes are connected to their
respective lifters.
(b)If the large diameter horizontal line is
installed higher than the bottom of the main
fuel tank, the lifters will be overloaded and
require an excessive length of time for
suction or possibly cause be incapable of
suction.
2.Be careful not to have any convex or concave
bends in the line or sections of the line that
might come in contact with heat and cause
high temperature at those points.
3.The amount of fuel in the outlet fuel lines must be less than 1.3 gallons (5 liters).
Note: Fuel inside the line may expand with high ambient temperature and cause fuel to be
pushed back up to the lifter.
4.When inspecting the lines and joints for leakage, be careful not to cause any pressure rise
inside the piping. Such pressure may cause the lifter to malfunction.
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FLARING THE TUBING
1. Slide the flare nut provided onto the copper
tube.
2. Flare the pipe with a good flaring tool.
Note: Be sure the flare is “CLEAN”.
3. Push flared pipes against the joint nut and
tighten the flare nut. Fasten the nut securely,
but do not over-tighten.
CONNECTING COPPER PIPES
1. When connecting a copper tube to the main fuel tank from the top rather than from a bottom
drain, leave 2 in. (5 cm) or more between the end of the fuel line and the bottom of the tank
(so that it does not pump up water or sediment).
2. When connecting a copper tube to the lifter, use the following procedure:
(a) Cut the copper tubing to size and slip the flare nut onto the tubing.
(b) Flare the tubing by using a good flaring tool. Push the flared tubing against the joint nut
fitting and tighten nut with the torque approx. 220-lbs. in. with two wrenches.
CAUTION: Flush the fuel line briefly with fuel before connecting to the lifter and make
sure that fuel line is free from any particles from cutting the copper tubing.
OPERATION
■When operating the lifter for the first time after installing:
Before operating the lifter according to the following procedure, check the installation and fuel
lines to be sure they are done as described in “INSTALLATION” and “FUEL LINE”.
1. Remove the cover screw at the top of the cover and remove the cover by pulling it slightly
forward.
2. Set the outlet valve lever to CLOSE, turn the operation switch to OFF, and insert the power
plug into the outlet. The yellow lamp will flash to indicate insufficient oil level.
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3. Use the attached funnel to pour about 0.12
gallons (450 cc) of fuel into the fueling
mouth. When the fuel sump is filled
sufficiently, the green lamp will flash to
indicate a normal oil level.
CAUTION: Use clean fuel only! Be sure
there is no contamination such
as dirt, water or particles of
metal.
Note:If an excessive amount of fuel is
filled, the red lamp will flash to indicate excessive fuel. If this occurs set the outlet
valve lever to OPEN and supply fuel to a heater until the normal fuel level is
established.
4. Turn the operation switch to ON. 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 when the operation switch is
turned to ON.
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:When this sound does not stop until just before the motor stops, air is leaking into the
fuel line. Check the line and all connections, especially the flares.
Note:When the lifter is installed correctly, a proper amount of fuel will be pumped up in
about 5 to 12 minutes and then the motor will stop.
5. Turn the outlet valve lever to OPEN.
CAUTION: When operating the outlet valve lever, be careful not to touch the motor fan.
(a) If the outlet line is longer than 33-ft.
(10 m), open and close the outlet
valve lever several times. When the
motor starts rotating, set the outlet
valve lever to CLOSE, and when the
motor stops rotating, set it to OPEN.
(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.
This will help prevent air locks in the line.
(c) Be sure that fuel is not leaking from any part of the lifter as well as from the inlet/outlet
lines and all joints.
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6. Remove the funnel from the fueling mouth and store it in a secure place.
7. Plug the hole of the fueling mouth securely with the rubber cap.
8. Replace the cover and attach with cover screw. At this point, the lifter is ready supply fuel
automatically 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 insert the power
plug into the 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.
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.
4. Turn the outlet valve lever to OPEN to supply
fuel to heater.
5. Replace the cover and secure it with the cover
screw.
MAINTENANCE
CAUTION: Be sure to turn the operation switch to OFF and disconnect the power plug before
performing any checks or cleaning.
Note: Accumulations of 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 manner.
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(a) To catch the fuel that will drain out, place
a rag or folded paper towel below the
strainer cover.
(b) Loosen the two (2) screws from the
strainer cover and remove it.
(c) Remove the fuel strainer and rinse with
clean fuel.
(d) Return the fuel strainer to its original
position. Replace the strainer cover and
replace the screws.
(e) Wipe away any spilled fuel.
(f) Be sure to confirm that there is no fuel
leakage from the strainer cover.
3. Draining the 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.
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
Preservation of the lifter:
-Use the following procedure to prepare the lifter for storage during the off season if
it is to remain installed.
1. Disconnect the power supply plug from the receptacle.
2. Turn the outlet valve lever to “CLOSE”.
- If the lifter will be stored disassembled:
1. Disconnect the power source plug from the receptacle.
2. Remove fuel from the unit in the procedures referred to “Draining the fuel sump”. (See
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Page 15.)
3. Mark the pipe joints and the nuts and then take them apart.
4. The lifter unit and relevant fuel lines should be covered with a piece of plastic to prevent
dust or insects from entering.
When using the lifter in the next season:
- If the lifter has been stored as installed:
Restart the lifter in accordance with the procedures mentioned in the instruction of “When
restarting lifter in the next season.” (See Page 14.)
- If the lifter has been stored disassembled:
1. Securely reconnect the inlet and outlet fuel lines so that they will not leak.
2. The nuts that were marked when disconnected for storage should be fastened
approximately 1/6 turn tighter.
3. Restart the lifter in accordance with the procedures that are mentioned in the “When
operating lifter for the first time after installing.” (See Pages 12, 13 & 14.)
Service information:
Any operational or functional trouble should be referred to your local dealer or distributor.
TROUBLESHOOTING
The following points should be checked before proceeding with detailed inspection.
1. Make sure that the power supply plug is securely connected to the receptacle and that
AC115V is supplied.
2. Make sure that the main tank is filled with a sufficient amount of fuel and that the outlet
valve is open.
3. Make sure that each fuel line connection is secure and without looseness or leakage.
4. Make sure that the lifter has been installed within specifications (a fuel supply line length of
less than 40 meters, a head of less than 26 ft. (8 m), and a height difference of 20 in. (0.5
m) to 8-1/2 ft. (2.5 m) between the lifter and the supply level).
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When installing:
Red LED lamp
is illuminated.
Operation Yes Drain the priming oil until green
switch OFF. lamp flashes and next turn
operation switch ON.
No
Lifter Yes Turn operation switch OFF.
is not level. After returning the pump to
its vertical position, turn
No operation switch ON.
Control box Replace the control box.
malfunction
Motor does not
work.
Operation Yes Turn operation switch ON.
switch OFF.
No
1
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1
[Note 1]
Excessive Yes Operation switch to be turned ON after
priming oil turning operation switch is turned OFF
and fuel is removed until green
No LED lamp flashes.
Motor connector Yes Operation switch is turned OFF.
disconnected Operation switch to be turned ON
after connector is inserted.
No
Broken Yes Unplug from receptacle and
fuse. then replace the fuse.
No
[Note 2]
Motor fan will not Yes Motor Yes Replace
spin by hand. malfunction motor
No No
Pump Replace
malfunction pump assy.
Control box Replace
malfunction control box
Note 1: If operation switch is turned OFF, but red LED lamp flashes or lights up,
fuel has been fed excessively.
Note 2: Be sure to disconnect power source before turning motor fan by hand.
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Motor drives, but no
fuel is pumped.
Flow-out valve Yes Turn operation switch OFF to close
left open flow-out valve, next repeat oil-priming
again, and then turn operation
No switch ON.
Priming oil Yes Turn operation switch OFF, repeat oil-
not sufficient priming again, and then turn
operation switch ON.
No
[Note 3]
Inlet fuel line Yes Securely fasten the connection of
defective connection inlet side fuel line.
No
Inlet side piping Yes Clean the piping by removing
plugged stuck substances.
No
Strainer Yes
plugged Clean strainer.
No
Note 3: A large amount of air bubbles
2 occur in this situation.
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2
Drive shaft
dislodged Align drive shaft to
or broken. its position, or replace it.
Pump malfunction Replace pump assy.
Fuel pumped,
but not fed to
the heater.
Flow-out valve Flow-out valve to
left closed. be opened.
Valve of the
heater left Valve of the heater to
closed. be opened.
3
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