WILHELM KELLER OILPRESS 180.902 User guide

The OILPRESS pressure storage vessels
type 180.902 and type 240.902 are used to
transport heating oil to EL DIN 51603 to one
or more consumer points.
The units consist of a casing with pressure
storage vessel, motor, pump and pressure
switch. During the transport process, the
heating oil is sucked in via the pump and
pressed into pressure storage vessel. The air
cushion in the storage vessel presses the oil
to the individual consumer points.
The motor is switched on by the pressure
switch at a lower working pressure of 1.6 bar,
and switched off again on reaching the upper
working pressure of 2.6 bar.
Pump Type 180.902
The planetary gear pump is driven by the
motor through a reduction gear. The pump is
characterised by its quiet running and low
wear. The pump is protected against conta-
mination by dirt by means of a circular filter
fitted to the pump body.
Pump Type 240.902
The feed pump is a planetary gear pump
driven direct by the motor. The pump is
characterised by its quiet running and low
wear. The pump is protected against conta-
mination by dirt by means of a circular filter
fitted to the pump body.
Casing
The casing is the supporting element of all
components. It houses the pump, motor,
pressure switch, pressure storage vessel,
filter, over-pressure valve and drain valve.
Two taper union connections for the connec-
tion of 8-mm pipes and the plug screw with
non-return valve are fitted to the distributor
housing on the underside of the casing.
Pressure storage vessel
Disconnect the unit from the electrical power
supply before removing the cover hood (see
“Instructions”). The lower part of the pres-
sure storage vessel is moulded into the
casing. A cylindrical diaphragm is clamped
between the lower and upper part, separa-
ting the air from the oil. An initial air pressure
of 1 bar is applied to the pressure storage
vessel through the valve located in the upper
part of the storage vessel. The air can there-
fore escape over the course of time by
Single-line removal, no return flow.
For all interlinked battery tank systems without non-return valves in the suction line,
and for individual tanks without non-return valves in the suction line
(for further details, see under: No non-return valve may be installed in the suction line).
Tested to DIN EN 12514-1.
diffusion, increasing the switching frequency
of the pump. This change is corrected by
refilling the air cushion with the aid of an air
pump. When refilling with air, take care to
ensure that the test, over-pressure and drain
valve at the side of the unit are open. The ini-
tial air pressure in the pressure storage ves-
sel is correct when the manometer on the
pressure storage vessel shows 0 bar, and the
manometer on the pressure measurement
device (air pump) shows 1 bar.
Technical data Type 180.902
Motor: 230 V ~ 88 W
Delivery capacity: 22 l/h at 0 bar pressure
Max. consumption: approx. 10 l/h
Permissible working pressure: 4.0 bar, limited by
over-pressure valve
Upper supply limit: adjustable up to 25 m,
factory set to 15 m
Suction head: 3 m
Pipe connection: Taper union 8x1 mm
Protection type: IP 34
Temperature of supply medium: max. 40°C
Weight: approx. 6 kg
Type 240.902
230 V ~ 50 W
46 l/h at 0 bar pressure
approx. 25 l/h
4.0 bar, limited by
over-pressure valve
adjustable up to 25 m,
factory set to 15 m
3 m
Taper union 8x1 mm
IP 34
max. 40°C
approx. 6 kg
Pressure Storage
Vessel Type 180.902 · Type 240.902
Installation, maintenance and usage instructions
Pressure switch
Control lamp
Suction connection
Non-return valve
(ventilation)
Filter
Air valve
Pressure storage vessel
initial pressure 1 bar
Pressure connection
Starter button
Test, over-pressure
and drain valve
245 mm
220 mm
Construction and functional
description
Wilhelm Keller
GmbH & Co. KG
Herdweg 1
72147 Nehren
DIN EN 12514-1

Type 240.902
Wiring diagram, type 180.902 Wiring diagram, type 240.902
B C
D
E
FA
Fuse
Control lamp
Push button
Motor
Earth
Condenser
(suppressor
element)
Fuse
Condenser
Control lamp
Push button
Motor
Earth
Condenser
(suppressor
element)

Spare parts list
Hydraulic diagram
Piping diagram
Best.-Nr. Description
X X 511.422 Replacement cylindrical diaphragm set
X X 413.422 Pressure switch complete
X X 005.422 Switch plate
X X 079.422 Filter group complete
X X 076.422 Over-pressure valve complete
X X 077.422 Non-return valve complete
X X 096.422 Protection conductor parts
X X 016.252 Upper casing
X X 097.422 Screw set for upper casing
X X 019.252 Return screw
X X 098.422 Cable with cable clamp
X X 027.232 Screw-in stub connection
X X 010.202 O-ring 10 x 2.2 mm
X X 081.422 Connection components
X X 030.232 Control lamp
X080.422 Assembly plate complete
X075.422 Assembly plate complete
X X 025.252 Distance piece
X X 020.232 Hood
X X 099.422 Screw set for hood
X X 100.422 Cover with screws
X X 002.412 Pumpe
X X 030.422 Spare parts for pump
X 002.422 Pump complete
X017.232 Gear wheel
X X 012.252 Lug screw
X X 003.232 Manometer
X X 110.422 Push button with connecting wires
X 003.412 Motor complete
X 063.202 Fan
X198.422 Motor complete
X445.422 Intermediate flange complete
X113.202 Terminal rail
X072.312 Cylinder screw M3 x 15
X446.422 Clamp with screw
X174.312 Cylinder screw M4 x 90
X447.422 Condenser complete
X X 005.202 Fine fuse
X357.252 Carrier
X X 096.212 suppressor element
XX800.912 Leak detection system LS 1
XX754.912 Pressure relief valve DV 1
180.902
240.902
Supply line
Shut-off valve Suction line
Supply lineOil pressure regulator
Hose
Suction line
Return line
D
E
F
A
B
C
Accessory
Oil feed unit
Supply pipe
Suction pipe
Leak sensor
Oil collecting trough

WILHELM KELLER GmbH & Co. KG
Herdweg 1 · D-72147 Nehren · phone: [phone] · fax: [phone]
E-Mail: [email protected] · www.oilpress-keller.de
Test, over-pressure and
drain valve
The test, over-pressure and drain valve is the
cut-off point between the supply line and
suction line. When opened, it connects the
pressure and suction areas. No non-return
valve may therefore be installed in the
suction line. The over-pressure valve comes
into operation when the maximum set pres-
sure of 4 bar is exceeded. The proper
operation of the valve can be checked by
actuating it manually. It also enables the
pressure to be relieved in the complete
piping system and the storage vessel, and
the draining of the unit via the suction line.
Non-return valve
The non-return valve is fitted by means of
the plug screw. This prevents return flow or
loss of pressure in the oil already pumped
into the pressure storage vessel and the
supply line. To ventilate the unit, the plug
screw is removed complete with the non-
return valve.
Pressure switch
The pressure switch switches the motor on
at a lower working pressure of approx. 1.6
bar, and switches it off again on reaching the
upper working pressure of approx. 2.6 bar.
The pressure range can be regulated upward
in the case of supply heights of over 15 m.
This is done by screwing in the pressure set-
ting screw, using a small screwdriver or
small pin of max. 1.5 mm diameter in the
four slots of the pressure setting screw. The
safety cut-off must in this case be adjusted
to the lower working pressure of minus 0.1
bar. The pressure for the safety cut-off is
reduced by screwing the cross-head screw
in, and increased by screwing it out. In the
event of a drop in pressure to below the set
pressure as a result of a power failure, lack
of oil or break in the line, the safety cut-off
switches to “fault”, and the control lamp
lights up.
The installation, connection and testing of
heating oil supply systems must be carried
out in accordance with DIN 4755 Part 2. The
unit can be installed up to 1.5 m below the
upper tank level. The maximum suction head
of 3 m must not be exceeded. About 1.0 m
of suction head must be deducted for every
10 m of horizontal suction distance.
Example:
Calculating the suction head
Tank floor - unit = 1.5 m W1.5 m vertical
Horizontal = 2.0 m W0.2 m vertical
suction distance
Calculated suction head 1.7 m
The unit is mounted horizontally against the
wall. The unit is easy to adjust by means of
the movable assembly plates.
The leak detection system LS 1 (Art. No.
800.912) with collecting trough must be
mounted under the device.
If the pressure storage vessel is operated
with a double-walled safety tank or a GFK
tank, the pressure relief valve DV 1 (Art. No.
754.912) must be installed in conjunction
with leak detection system LS 1.
Suction line
The installation of a filter in the suction line is
not necessary, since a filter of adequate
capacity with a mesh size of 0.1 mm is already
built into the unit. The suction line should ter-
minate at least 5 cm above the tank floor.
No non-return valve may be
installed in the suction line.
The tank connection 041.912 for individual
tanks fulfils this requirement. In the case of
normal suction lines for plastic PE and PA
battery tanks, the rocker-lever non-return
valves must be replaced by rocker-lever
shut-off valves. In the case of OILPRESS
suction lines, rocker-lever shut-off valve can
be ordered under article no. 594.912.
Supply line
OILPRESS pressure storage units allow the
use of a single-line supply system (see
Piping diagram). The line can be laid in any
way required. Oil pressure regulators must
be installed so that the permissible pressure
range of the oil regulator of 125 mm – 3000
mm of oil is not exceeded at the combustion
point. The line from the oil pressure regulator
to the oil regulator should be laid at an
incline. When used for the supply of atomis-
ing burners, the user must check whether a
pressure regulator should also be installed.
178.822/07/15
The installation and maintenance instructions
are intended only for qualified technicians!
1. Open all valves in the system, including
the inlet valve at the oil regulator.
2. Insert the plug into the socket. The control
lamp will light up.
3. Unscrew the plug screw with the complete
non-return valve .
4. Press down the push button on the
underside of the unit until oil flows without
air bubbles.
5. Refit the plug screw with the complete
non-return valve .
6. Press down the push button until the
pointer of the manometer has reached the
green area (this may take up to 10 min.).
The unit then starts to operate automatical-
ly. On reaching the upper cut-off pressure
(approx. 2.6 bar), the unit switches off.
7. For testing purposes, the button of the
over-pressure valve is now slightly
withdrawn until the motor starts again.
Note the starting pressure, which should
be approx. 1.6 bar.
following lack of oil or power failure
Check whether the manometer is still
showing any pressure, and if so, press the
starter button until the motor continues to
run automatically. If the manometer shows
no pressure, restart as described under
“Starting and ventilation”.
The installation and electrical connection of
the unit, commissioning and maintenance,
must be carried out by a qualified technician.
In the event of maintenance work, and before
removing the cover hood, the unit must be
disconnected from the power supply by
removing the plug, and the pressure in the
pressure storage vessel must be relieved.
The operating instructions must be kept in
the vicinity of the system following installation.
An essential requirement for smooth opera-
tion of the pressure storage units is proper
installation in accordance with the technical
rules applicable to the planning, installation
and operation of the complete system.
The pressure storage units and the corre-
sponding pipes must be installed so that
they are protected against frost.
Heating oil is a material harmful to water.
Spilt or leaked heating oil must be disposed
of properly. All components which have
come into contact with heating oil must be
disposed of properly in accordance with
applicable disposal regulations.
This device is not intended for use by people
(incl. children) with restricted physical, sen-
sory or intellectual abilities or lack of expe-
rience and/or lack of knowledge, unless they
are supervised by a person responsible for
their saftey or received, from this person,
instructions about how to use the device.
Children should be supervised to ensure that
they do not play with the device.
If the device’s power cable is damaged it
must be replaced by the manufacturer or the
manufacturer’s customer service or a simi-
larly qualified specialist.
Pressure setting
screw
Cross-head screw
E
F
B
Installation Starting and ventilation
F
F
E
Restarting
Instructions
Maintenance work
Replacing the filter
In case of contamination and during mainte-
nance work, the filter should be replaced, in
order to ensure trouble-free operation.
D