Shizuoka Seiki VAL6 KBE5S User manual

VAL6
Service manual

S
p
ecifications
Type VAL6 KBE5S
Heat Output 111,000BTU/h
Fuel Kerosene, Diesel
Tank Capacity 9 gallons
Fuel Consumption 0.85gallon/h
Power Source 120V, 60Hz single phase
Power Consumption 80W (in burning), 100W (in igniting)
Ignition System High Intensity Discharge
EXTERNAL DIMENSION (L/W/H) 27.4/27.9/36.2(in) [695/708/918(mm)]
Safety Device Photocell Flame Monitor
Overload Check Device 3A Fuse
Dry Weight 83.8lbs
Names of Com
p
onents
1
2

Wirin
g
Dia
g
ram of Burner Control
3
PS : Power Source
SW1 : Operating Switch
TH : Thermostat (Short)
FE : Flame Monitor
FG : Frame Ground
ＨＴ : Pre Heater
FM : Fan Motor
CM : (Open)
IG : Igniter
SP : Solenoid Pump
SV : (Open)
RL : Running Lamp
AL : Misfire Lamp
KA : Control Relay
F : Line Fuse
Z : Surge Absorber
ES : Emergency (Short)
RUN MISFIRE
CN1 CN5CN4 CN3CN2 CN6
CN9 CN8
CN7
CN10CN11
CN12
CN13
Connector No.
CN1 Power Source
CN2 -
CN3 Fan Motor
CN4 Igniter
CN5 -
CN6 Solenoid Pump
CN7 Tran
CN8 Operating Switch
CN9 Thermostat (Short)
CN10 -
CN11 Flame Monitor
CN12 Running Lamp,
Misfire Lamp
CN13 -
Operation
Switch
Solenoid
Pump
Fan
Igniter
ON OFF
180 sec.
5 sec.
within
10 sec.
10 sec.
(post ignition)
ignition
Sequence Time Chart

VAL6 KBE5S Troubleshooting
Phenomenon page
1The heater does not start The lamp does not light on 1
Misfire lamp is lit
2The heater does not ignite
Fuel pump does not operate at all
3
No fuel or a little fuel is pumped up
Igniter does not spark. [Igniter does not operate]
Sequence of operation is normal, but it doesn't ignite
3Misfire within 25 seconds after ignition Misfire lamp is lit 5
4Combustion stop during the operation Misfire lamp is lit 6
5Odor comes out 7
6Smoke comes out 8
7Combustion is not stable 9
8Fuel leaks
9Fuse blows out
When the plug is put into the socket
10
When the switch is turned on
About 5 seconds after turning on

VAL6 KBE5S Trouble Shooting
Possible Cause How to check Result Remedy Reference
1．The heater
does not start. The lamp does not light
on.
No power source
supplied
Measure voltage of AC
outlet.
If circuit tester indicates
0V, power source is
disconnected
Connect power
source
Standard: AC120V
Fuse blowout Take fuse out from fuse
box, and then check
each lead with circuit
tester
If circuit tester reads ∞
Ω, fuse blows out
Find a cause of
blown fuse and
replace with a new
one
Picture 8
Picture 9
Disconnection of
power cord
Take power source
connector (CN 1) out
from burner control, and
then check each lead
with circuit tester
If either of the lead is
broken, power cord is
broken
Make sure the
power cord is
connected, or
replace it
Loose connection
of power source
connector
Plug in power source
connector (CN 1) again,
and then turn on
If it works normally,
power source connector
fails on contact
Plug in connector
(CN 1) firmly
Loose connection
of transformer
connector
Plug in transformer
connector (CN 7) again,
and then turn on
If it works normally,
transformer connector
fails on contact
Plug in connector
(CN 7) firmly
Failure of
transformer
Measure voltage at
output side of
transformer connector
(CN 7)
If tester reads normal
voltage at input side, and
reads 0V at output side,
transformer fails
Replace
transformer
Standard: about AC15V
(purple-purple)
Phenomenon
1

VAL6 KBE5S Trouble Shooting
Possible Cause How to check Result Remedy Reference
Phenomenon
Loose connection
of operation
switch connector
Plug in operation switch
connector (CN 8) again,
and then turn on
If it works normally,
operation switch
connector fails on
contact
Plug in connector
(CN 8) firmly
Failure of
operation switch
Take operation switch
connector (CN 8) out,
then check lead with
circuit tester
If it doesn't conduct
when turned on,
operation switch fails
Replace operation
switch
Standard: Conducting (0
Ω) when turned on
Failure of burner
control
Measure voltage at input
side of transformer
connector (CN 7)
If power source is
normal and tester reads
0V at input side, burner
control fails
Replace burner
control
Standard: AC120V
(white-red)
Run lamp is
lit Loose terminals
on control device
Firmly connect terminals
for control device
If it works normally,
terminals for control
device are loose
Firmly connect
terminals on
control device Picture 6
Misfire lamp
is lit. Flame monitor
sensor
malfunctions
It starts to operate Avoid direct
sunlight on
radiation disk
Failure of burner
control
It doesn't start to operate Replace burner
control
Unplug flame monitor
connector (CN 11), and
then start operation
2

VAL6 KBE5S Trouble Shooting
Possible Cause How to check Result Remedy Reference
Phenomenon
2．The heater
does not ignite. Fuel pump does not
operate at all.
Loose connection
of fuel pump
connector
Plug in fuel pump
connector (CN 6) again,
and turn on
If it works normally,
fuel pump connector
fails in contact
Plug in connector
(CN 6) firmly
Loose connection
of joint connectors
for fuel pump
Plug in joint connectors
for fuel pump again, and
then turn on
If it works normally,
connectors on fuel pump
fails in contact
Plug in Joint
connectors firmly
Failure of fuel
pump
Measure voltage at
output side of fuel pump
connector on burner
control
If voltage is normal, fuel
pump fails
Replace fuel pump
Failure of burner
control
Standard: AC60～96V
(red-blue)
If tester reads 0V, burner
control fails
Replace burner
control
No fuel or a
little fuel is
pumped up.
Fuel line is
clogged
Disconnect each fuel
line, and then clean up
each of them
If it ignites after
cleaning, fuel flow
decreases because of
clogged in fuel lines
・Clean fuel lines
・Clean and rinse
the tank with
kerosene, alcohol
or acetone
Filter is clogged Check condition of filter If filter is dirty, amount
of fuel flow decreases
because of clogged filter
・Replace filter
・Clean and rinse
the tank with
kerosene, alcohol
or acetone
Nozzle is clogged Replace nozzle If it ignites, nozzle is
clogged
・Replace nozzle
・Clean and rinse
the tank with
kerosene, alcohol
or acetone
3

VAL6 KBE5S Trouble Shooting
Possible Cause How to check Result Remedy Reference
Phenomenon
Loose joint of fuel
lines
Check looseness of each
joint
If heater ignites by
tightening joints, air leak
is the problem
Tighten joints
Fuel pump is
clogged, or failure
Remove burner cover
and fuel outlet line, and
then turn on the switch
No fuel is pumped up,
fuel pump is clogged or
failure
Replace fuel pump
Picture 4
Loose connection
of igniter
connector
Plug in igniter connector
(CN 4) again, and then
turn on the switch
If it works normally,
loose connection of
igniter connector
Plug in connector
(CN 4) surely
Failure of igniter Measure voltage at
igniter connector (CN4)
on burner control
If voltage is normal,
igniter fails
Replace igniter
Failure of burner
control
Standard:AC120V
(black-black)
If tester reads 0V, burner
control fails
Replace burner
control
Electrode is out of
alignment
Measure the alignment
of electrode
Refer to Picture 5 Replace electrode
(adjust the
position)
Picture 5
Improper amount
of combustion air
Check gate opening of
fan motor
Find adequate amount of
air flow for better
combustion
Adjust gate
opening.
Normal scale: 3
Igniter does
not spark.
[Igniter does
not operate.]
Sequence of
operation is
normal, but it
doesn't ignite
4

VAL6 KBE5S Trouble Shooting
Possible Cause How to check Result Remedy Reference
Phenomenon
Misfire lamp
is lit. Loose flame
monitor
Open burner cover, and
check if the flame
monitor is in
If flame monitor comes
off, it doesn't work
Put in flame
monitor firmly
Shortage of light
sensed from flame
Take flame monitor out,
and check condition of
its lens
If photorecepter is dirty,
sensor becomes less
sensitive.
Clean the sensor
with soft cloth
Remove burner, and
then check clarity of
draft tube and vane
If draft tube or fan is
dirty, it senses little light
Clean draft tube
and whirl vane
Picture 8
Check extent of
combustion air inlet
opening
If opening is too wide,
flame is short because
combustion air is too
much
Decrease opening
to reduce
combustion air.
Normal scale: 3
Loose connection
of flame monitor
Plug flame monitor
connector (CN 11)
again, and then turn on
If it works normally,
flame monitor connector
fails on contact
Plug connector
(CN 11) firmly
Failure of flame
monitor
Unplug flame monitor
connector (CN 11), and
then check transition of
resistance by changing
quantity of light into
flame monitor
If resistance doesn't
change, flame monitor
fails
Replace flame
monitor
Nozzle clogged Replace nozzle If it ignited, nozzle is
clogged
Replace nozzle
Filter clogged Check clarity of filter If filter is dirty, fuel
flow decreases because
of filter clogged
Replace filter
3．Misfire
within 25
seconds after
ignition.
5

VAL6 KBE5S Trouble Shooting
Possible Cause How to check Result Remedy Reference
Phenomenon
4．
Combustion
stops during
Misfire lamp
is lit. Air leak Check looseness of each
joint
If heater ignites by
tightening joints, air leak
is the problem
Fasten joints more
tightly
Insufficient
amount of
pumping fuel
because vacuum
forms in tank
Check if air intake of
fuel gauge is clogged
with dust
If air intake of fuel
gauge is clogged,
amount of fuel flow
becomes insufficient
because of vacuum
Clean air intake of
fuel gauge
Picture 10
Shortage of light
detected by flame
monitor
Take flame monitor out,
and then check clarity of
its lens
If lens of flame monitor
is dirty, it detects a little
light
Wipe lens of
flame monitor
with soft cloth
Remove burner, and
then check clarity of
draft tube and vane
If draft tube or whirl
vane is dirty, flame
monitor detects little
Clean draft tube
and whirl vane
Picture 7
Flame monitor
connector is loose
connection
Plug flame monitor
connector (CN 11)
again, and then turn on
If it works normally,
flame monitor connector
fails on contact
Plug connector
(CN 11) firmly
Failure of flame
monitor
Unplug flame monitor
connector (CN 11), and
then check transition of
resistance by changing
quantity of light into
flame monitor
If resistance doesn't
change, flame monitor
fails
Replace flame
monitor
Nozzle clogged Replace nozzle If it works normally,
nozzle was clogged
Replace nozzle
Filter clogged Check clarity of filter If filter is dirty, fuel
flow decreases because
of clogged filter
Clean or replace
filter
6

VAL6 KBE5S Trouble Shooting
Possible Cause How to check Result Remedy Reference
Phenomenon
5．Smell of
fuel comes out. Quantity of
combustion air is
too much
Check gate opening of
combustion air inlet
If opening is too
extensive, it burns
imperfectly
Decrease gate
opening of
combustion air
inlet.
Normal scale: 3
Nozzle clogged Replace nozzle If it works normally,
nozzle is clogged
Replace nozzle
Filter clogged Check condition of filter If filter is dirty, amount
of fuel flow decreases
because of clogged filter
Replace filter
Wrong nozzle Check makers imprint of
the nozzle
Mark: 0.85USgal/h 60°
H
If makers imprint is
incorrect, the nozzle is
should not be used
Replace to a
correct nozzle
7

VAL6 KBE5S Trouble Shooting
Possible Cause How to check Result Remedy Reference
Phenomenon
6．Smoke
comes out. Shortage of
combustion air
Check extent of
combustion air inlet
opening
If combustion air inlet is
too small, it burns in
short of oxygen
Extend
combustion air
inlet opening.
Normal scale: 3
Decrease of air
brought from fan
Check if fan is dusty If fan is dusty, it is short
of air
Clean fan
Decrease
revolutions of the
fan
Measure voltage at
power source connector
If voltage at power
source is lower than
standard, combustion air
is decreased because of
low voltage
Check voltage
(Power source
voltage is
insufficient)
Standard: AC120V
Nozzle clogged Replace nozzle If it works normally,
nozzle was clogged
Replace nozzle
Using at high
altitude area (Low
oxygen
concentration)
Know the altitude If using at higher than
the altitude of 3300ft,
heater burns imperfectly
because of lack of
oxygen
Extend
combustion air
inlet opening.
Normal scale: 3
Wrong nozzle Check makers imprint of
the nozzle
Mark: 0.85USgal/h 60°
H
If makers imprint is
incorrect, the nozzle is
should not be used
Replace to a
correct nozzle
8

VAL6 KBE5S Trouble Shooting
Possible Cause How to check Result Remedy Reference
Phenomenon
7．
Combustion is
not stable.
Loose joints in
fuel line
Check looseness of each
joint
If any joints are loose,
air is absorbed into fuel
lines from loose joint
Tighten joints
8．Fuel leaks. Loose joints in
fuel line
Check looseness of each
joint
If any joint is loose, fuel
is leaking
Tighten joints
Failure of drain
gasket
Remove drain bolt after
removing fuel from
tank, and then check that
gasket isn't broken
Fuel leaks because of
broken gasket
Replace drain
gasket
Amount of fuel in
the tank is too
much
Check the fuel level Fuel overflows because
quantity of fuel in the
tank is too much
Drain excess fuel
9

VAL6 KBE5S Trouble Shooting
Possible Cause How to check Result Remedy Reference
Phenomenon
9．Fuse blows
out When the plug is put
into the
outlet.
Short circuit of
transformer coil
Unplug transformer
connector (CN 7) from
burner controller, then
measure coil resistance
values of two leads
If either of the values is
0Ω, transformer is short-
circuited
Replace a
transformer
Standard: about 350Ω
(white-red)
Standard: about 9Ω
(purple-purple)
・Without tester
Unplug transformer
connector (CN 7) from
burner controller, then
put plug into AC outlet
If fuse doesn't blow out,
transformer is short-
circuited
Replace
transformer
When the
switch is
turned on.
Short circuit of fan
coil
Unplug fan connector
(CN 3) from burner
controller, then measure
resistance between
terminals
If resistance value is 0Ω,
fan coil is short-circuited
Replace fan
・Without tester
Unplug fan connector
(CN 3), and then start
operation
If fuse doesn't blow out,
fan coil is short-circuited
Replace fan
10

VAL6 KBE5S Trouble Shooting
Possible Cause How to check Result Remedy Reference
Phenomenon
Short circuit of
igniter
Unplug igniter
connector(CN 4) from
burner controller, then
measure resistance
between terminals
If resistance value is 0Ω,
primary side of igniter is
short-circuited
Replace igniter
・Without tester
Unplug connector (CN
4) from igniter, and then
start operation
If fuse doesn't blow out,
igniter is short-circuited
Replace igniter
About 5
seconds after
turning on
Short circuit of
pump coil
Unplug fuel pump
connector (CN 6) from
burner controller, then
measure resistance
between terminals
If resistance value is 0Ω,
pump coil is short-
circuited
Replace fuel pump
・Without tester
Unplug fuel pump
connector (CN 6), then
turn on
If fuse doesn't blow out,
pump coil is short-
circuited
Replace fuel pump
11

Chart１ Standard resistance of functional parts
Parts Connector Ｎｏ Lead Condition Resistance Remarks
Operation Switch ＣＮ8 Yellow－Yellow on 0Ω
of
f
∞Ω
Photo Cell ＣＮ11 Black－Black dark over 2MΩ
li
g
ht under 10KΩ
Transformer ＣＮ7 Red-White in
p
ut about 350Ω
Pur
p
le-Pur
p
le out
p
ut about 9Ω
Igniter ＣＮ4 Black－Black in
p
ut -
out
p
ut about 4.5KΩ
Solenoid Pump ＣＮ6 Red-Blue - about 130Ω
Fan motor ＣＮ3 Gray-Gra
y
－ about 10Ω
g
ate：Normal scale 3 （60Ｈz）*
When heater is used above 3,000ft sea
level, adjust air inlet on fan motor for
better combustion
Chart２ Input & Output of Burner Control
Parts Connector Ｎｏ Lead Condition Voltage
Power code ＣＮ１ Black-White － AC 120V (±10%)
Transformer ＣＮ7 Red-White in
p
ut AC 120V (±10%)
Pur
p
le-Pur
p
le out
p
ut about AC 15V
I
g
niter ＣＮ4 Black-Black in
p
ut AC 120V (±10%)
Solenoid Pump ＣＮ6 Red-Blue －AC 60～96V
Fan motor ＣＮ3 Gray-Gray 60Hz AC 120V (±10%)
50Hz -

Picture 1 How to measure resistance Picture 2 How to measure voltage
①Pull out a connector which you
will measure from burner
① Operate the heater
②Turn on the resistor and set AC
voltage range
② Turn on the resistor and set resistor range
③
Insert the lead head of resistor to
connector [lead wire side] and measure
resistance
③
Insert the lead head of resistor
to connector and measure
resistance
Picture 3 Removing a burner
Unscrew two silver nuts with holding
gold nuts and remove two fuel hoses
Unscrew two
screws and take a
burner cover off
Unscrew three nuts
a
n
dta
k
eabu
rn
e
r
o
ff
Nut
screw

Picture 4 Inspection fuel pump
Remove a pipe and check whether
fuel comes out
Standard pressure 99 psi (±4)
Picture 5 Standard position of electrode
Picture 6 Inspection terminals for control device
Check whether the terminals
for control device are coupled
firmly
Manufacturer does
not recommend to fix
electrode as they are
very sensitive to
position.

Picture 7 Inspection draft tube
and fan Picture 8 Inspection fuse①
Object Serial Number : 01S, 01R, 01Q-030000
In case of draft tube and fan
are dusty, please clean them up
Open the fuse box and check whether
the fuse blows out
Picture 9 Inspection fuse② Picture 10 Clean up fuel gauge
Object Serial Number :01Q-040000, 01P, 01N
If air intake of fuel gauge is
clogged, clean it up
Open a screw cap and
take out a fuse
draft
b
whirl
Check
whether fuse
is blown out
air
ik

Daily Maintenance
Inspection of the tank inlet filter
Remove the fuel ca
p
and
and check inlet filter is clean
If the inlet filter is dirt
y
,
clean it with fuel
Place the inlet filter back and
ti
g
hten the fuel ca
p
firml
y
Inspection of the filter and drainage of water from the fuel tank
Check if the filter element is dirt
y
If the filter element if dirt
y
re
p
lace to a new one.
Plu
g
the new filter in and ti
g
hten the metal rin
g
If dirt or water is found in the cu
p
,
clean the cu
p
throu
g
hl
y
Also clean the inside of fuel tank
Drain the dirt
y
fuel from the bottom of the tank
Drain the old fuel from the bottom Loose the drain bolt a
g
ain
of fuel tank b
y
loosin
g
the drain bolt
t
o drain the dirt
y
fuel
Place the drain bolt back Place the drain bolt and fuel
cap firmly
Pour clean kerosene or alcohol
into the fuel tank
Shake the fuel tank
Checking the filter element
Drainage of water/dirty fuel from the fuel tank
1
3
2
1
3
2
1
3
2
4
5
6