Shizuoka Seiki VAL6 MPX5 User manual

Contents
7.
8.
Safety Devices
Specifications
Wiring Diagam
Standard resistance & Voltage
5.
Sequence Time Chart
2.
3.
2
3
4
4
6
6.
1.
4.
Names of components
5
13
Check & Repair
15
2014.08
Troubleshooting
Service Manual

1
Names of components
★ Burner Section
2

2
Safety Devices
When the flame is extinguished, turn『OFF』the operating switch. Then
turn『ON』the operating switch again after the problem is solved.
★ Switch Section
3

110CFM
Safety Systems
Tip-over Switch
Flame Monitor
Electrical System Protection
Overheat Prevention
Anomaly detection system for fan motor
Airflow
3
Specifications
Type
Radiated/Direct-fired
High : 59.4dB
Low : 57.8dB
Ignition System
Fuel
High intensity discharge
#1DIESEL(KEROSENE)
High : 0.48GAL/h , 1.55kg/h
High : 1.8L/h , 1.55kg/h
Low : 0.42GAL/h , 1.38kg/h
Low : 1.6L/h , 1.38kg/h
Fuel Consumption
High : 62,500BTU , 18kW
High : 15,800kcal/h , 18kW
Dry Weight
Low : 55,500BTU , 16kW
Low : 14,000kcal/h , 16kW
Heat Output
Tank Capacity
6.6 gallons
25liter
Nozzle Wrench
Power Supply
AC120V 60Hz
AC230V 50Hz
When ignitiong : 100W
Continuous Operating Time
Low : 15.7hours
High : 13.7hours
When burning : 120W
When burning : 112W
4
Wiring Diagram
Electric Fuse
3A
1.6A
720(H)×520(W)×675(D)
70.5Lbs , 32kg
Accessory
Nozzle
Filter Element
Operating Noise Level
When ignitiong : 100W
Power Consumption
Model Type
VAL6MPX5
VAL6MPX1
Dimensions
inch
mm
28.4(H)×20.5(W)×26.6(D)
4

Blower Fan
Solenoid Valve
Fuel pre-heater
Plug
IN
Switch
ON
5
Operation Switch
Fan Motor
Igniter
Fuel Pump
Flame Monitor
5sec
within
10sec
10sec
pump delay
※Fuel pre-heater ： Operating when the temperature in the inside of burner cover falls below 41 degrees Fahrenheit
(5 degrees Celsius) and stopping when it reach over 68 degrees Fahrenheit (20 degrees Celsius).
Sequence Time Chart
post ignition
Switch
OFF
200sec
post purge
Ignition
5

Phenomenon page
12
Fuel pump does not operate at all
About 5 seconds after turning on
No fuel or a little fuel is pumped up
Combustion is not stable
Smoke comes out
Odor comes out
7
8
9
10
11
9
8
7
6
5
When the switch is turned on
When the plug is put into the socket
Fuse blows out
Fuel leaks
4
3
2
Misfire lamp is lit
Misfire lamp is lit
Sequence of operation is normal, but it doesn't ignite
Igniter does not spark. [Igniter does not operate]
1
6
Troubleshooting
Combustion stop during the operation
Misfire within 10 seconds after ignition
The heater does not ignite
(though the heater is working)
The heater does not start
Misfire lamp is lit
Operation lamp is lit
The lamp does not light on
6

Phenomenon Possible Cause How to check Result Remedy
1．The heater does
not start.
The lamp does not
light on.
No power source supplied
Measure voltage of AC outlet.
Standard:
MPX5 - AC120V
MPX1 - AC230V
If circuit tester indicates 0V, power
source is disconnected
Connect power source
Fuse blowout
Take fuse out from fuse box, and then
check each lead with circuit tester
If multimeter reads ∞Ω, fuse blows
out
Find a cause of blown fuse and
replace with a new one
Disconnection of power cable
Take power source connector (CN 1)
out from burner controller, and then
check each lead with multimeter
If either of the lead is broken, power
cable is broken
Make sure the power cable 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 in 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 in contact
Plug in connector (CN 7) firmly
Failure of transformer
Measure voltage at output side of
transformer connector (CN 7)
If multimeter reads normal voltage
at input side, and reads 0V at output
side, transformer fails
Replace transformer
Standard (purple-purple):
about AC15V
Loose connection of operating
switch connector
Plug in operation switch connector
(CN 8) again, and then turn on
If it works normally, operation
switch connector fails in contact
Plug in connector (CN 8) firmly
Failure of operating switch
Take operating switch connector (CN
8) out, and then check lead with
If it doesn't conduct when turned on,
operating switch fails
Replace operating switch
Standard: Conducting (0Ω) when
turned on
Failure of burner controller
Measure voltage at input side of
transformer connector (CN 7)
Standard (white-red):
MPX5 - AC120V
MPX1 - AC230V
If power source is normal and
multimeter reads 0V at input side,
burner controller fails
Replace burner controller
Run lamp is lit
Loose connection between
thermostat connector and cap
Attach the cap firmly
If it works normally, the cap fails in
contact with thermostat connector
Attach the cap firmly
Misfire lamp is lit.
Flame monitor lens is perplexed
by direct sunlight
It starts to operate
Avoid direct sunlight on radiation
disk
Failure of burner controller It doesn't start to operate Replace burner controller
VAL6 MPX5/MPX1 Troubleshooting
Unplug flame monitor connector (CN
11), and then start operation
7

Phenomenon Possible Cause How to check Result Remedy
VAL6 MPX5/MPX1 Troubleshooting
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 then turn on
If it works normally, fuel pump
connector fails in contact
Plug in connector (CN 6) firmly
Loose connection of joint
connectors in fuel pump
Plug in joint connectors in 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 controller
If voltage is normal, fuel pump fails Replace fuel pump
Failure of burner controller
Standard (blue-blue)
MPX5 - AC60～96V
MPX1 - AC 115～184V
If multimeter reads 0V, burner
controller fails
Replace burner controller
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 fuel tank
with kerosene, alcohol or acetone
Filter element is clogged Check clarity of filter element
If filter is dirty, fuel flow decreases
because of clogged filter element
・Replace filter element
・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 fuel tank
with kerosene, alcohol or acetone
Loose joint in fuel lines Check looseness of each joint
If heater ignites by joints fastened
more tightly, air is absorbed into
fuel lines at loosed joints
Fasten joints more tightly
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
Failure of burner controller
Measure voltage at fuel pump
connector on burner controller
standard (blue-blue)
MPX5 - AC60~96V
MPX1 - AC115~184V
If multimeter reads power supply
voltage , burner controller fails
Replace burner controller
Loose connection of igniter
connector
Plug in igniter connector (CN 4)
again, and then turn on the operating
switch
If it works normally, loose
connection of igniter connector
Plug in connector (CN 4) firmly
Failure of igniter If voltage is normal, igniter fails Replace igniter
Failure of burner controller
If multimeter reads 0V, burner
control fails
Replace burner controller
Alignment of electrode is out of
standard
Measure the alignment of electrode
If any part is out of standard
position, out of alignment is cause
Replace electrode (adjust the
position)
Improper quantity of
combustion air
Check gate opening of fan motor
If gate opening is unusual, quantity
of combustion air is improper
Adjust gate opening.
Normal scale:
MPX5 - 2.5
MPX1 - 4.5
Sequence of
operation is normal,
but it doesn't ignite
Igniter does not
spark.
[Igniter does not
operate.]
Measure voltage at igniter connector
(CN4) on burner controller
Standard (black-black):
MPX5 - AC120V
MPX1 - AC230V
8

Phenomenon Possible Cause How to check Result Remedy
VAL6 MPX5/MPX1 Troubleshooting
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 then
check clarity of its lens
If lens of flame monitor is dirty less
sensitive.
Wipe lens of flame monitor with
soft cloth
Remove burner, and then check clarity
of burner cone and vane
If burner cone or fan is dirty, it
senses little light
Clean burner cone and whirl vane
Check extent of combustion air inlet
opening
If opening is too extensive, flame is
short because combustion air is too
much
Decrease opening to reduce
combustion air.
Normal scale:
MPX5 - 2.5
MPX1 - 4.5
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
Measure voltage at flame monitor
connector on burner controller
standard
dark - about DC5V
light - DC1.2V and under
If voltage doesn't change, flame
monitor fails
Replace flame monitor
Nozzle clogged Replace nozzle If it ignited, nozzle is clogged Replace nozzle
Filter element clogged Check clarity of filter element
If filter is dirty, fuel flow decreases
because of filter element clogged
Clean or replace the filter element
3．Misfire within 10
seconds after ignition.
9

Phenomenon Possible Cause How to check Result Remedy
VAL6 MPX5/MPX1 Troubleshooting
Misfire lamp is lit.
Absorbing air into fuel lines
from joints
Check looseness of each joint
If any joint is loose, air is absorbed
into fuel lines from loose joint
Fasten joints more tightly
Insufficient pumping of fuel
because vacuum forms in fuel
tank
Check if air intake of tank cap is
clogged with dust
If air intake of tank cap is clogged,
fuel flow is insufficient by vacuum
forming in fuel tank
Clean air intake of tank cap
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 burner cone and vane
If burner cone or whirl vane is dirty,
flame monitor detects a little of light
Clean burner cone and whirl vane
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 element clogged Check clarity of filter element
If filter is dirty, fuel flow decreases
because of clogged filter element
Clean or replace the filter element
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:
MPX5 - 2.5
MPX1 - 4.5
Nozzle clogged Replace nozzle
If it works normally, nozzle is
clogged
Replace nozzle
Filter element clogged Check clarity of filter element
If filter is dirty, fuel flow decreases
because of clogged filter element
Clean or replace the filter element
Incorrect nozzle
Check makers imprint of the nozzle if
it is correct.
Mark: 0.4USgal/h 80° H
If makers imprint is incorrect, the
nozzle is incorrect
Replace incorrect nozzle for
correct one
4．Combustion stops
during operation.
10

Phenomenon Possible Cause How to check Result Remedy
VAL6 MPX5/MPX1 Troubleshooting
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:
MPX5 - 2.5
MPX1 - 4.5
Decrease of airflow from fan
motor
Check if fan is dusty If fan is dusty, it is short of air Clean fan
Decrease revolutions of the fan
motor
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:
MPX5 - AC120V
MPX1 - AC230V
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 lower
than the altitude of 1000m(3000ft)
If using at higher than the altitude of
1000m(3000ft), heater burns
imperfectly because of shortage of
oxygen
Extend combustion air inlet
opening.
Normal scale:
MPX5 - 2.5
MPX1 - 4.5
Incorrect nozzle
Check makers imprint of the nozzle if
it is correct.
Mark: 0.4USgal/h 80° H(danfoss)
If makers imprint is incorrect, the
nozzle is incorrect
Replace incorrect nozzle for
correct one
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
Fasten joints more tightly
8．Fuel leaks. Loose joints in fuel line Check looseness of each joint If any joint is loose, fuel is leaking Fasten joints more tightly
Failure of drain packing
Remove drain bolt after removing fuel
from fuel tank, and then check
whether packing isn't corrupted
Fuel leaks because of breach of
packing
Replace drain packing
Quantity of fuel in the fuel tank
is too much
Check the fuel level
Fuel overflows because quantity of
fuel in the fuel tank is too much
Decrease quantity of fuel in fuel
tank
11

Phenomenon Possible Cause How to check Result Remedy
VAL6 MPX5/MPX1 Troubleshooting
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:
MPX5 (white-red) - 230Ω
(purple-purple) - 6.3Ω
MPX1 (white-red) - 1.85kΩ
(purple-purple) - 6.3Ω
・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
Short circuit of surge absorber
(SA1)
Gauge resistance at surge absorber
(SA1)
If resistance value is 0Ω, surge
absorber is short-circuited
Replace burner controller
Short circuit of pre-heater
Unplug transformer connector , then
measure coil resistance values
MPX5 - about 735Ω
MPX1 - about 2700Ω
If resistance value is 0Ω, pre-heater
is short-circuited
Replace pre-heater
When the switch is
turned on.
Short circuit of fan motor 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 motor
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 igniter connector (CN 4), and
then start operation
If fuse doesn't blow out, igniter is
short-circuited
Short circuit of solenoid valve
Unplug transformer connector , then
measure coil resistance values
MPX5 - about 1.8kΩ
MPX1 - about 4.7kΩ
If resistance value is 0Ω, solenoid
valve is short-circuited
Replace solenoid valve
About 5 seconds
after turning on
Short circuit of fuel pump coil
Unplug fuel pump connector (CN 6)
from burner controller, then measure
resistance between terminals
If resistance value is 0Ω, fuel 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
About 20~30 seconds
after turning on
Short circuit of Blower motor
Unplug blower motor connector (CN
5) from burner controller, then
measure resistance between
terminals(4-5PIN)
If resistance value is 0Ω, blower
motor is short-circuited
Replace blower motor
12

★Standard resistance of functional parts
Connector Ｎｏ
Off
MPX5
MPX1
On
about 26Ω
about 227Ω
On
Black-Blue
Low
Resistance
Memo
Condition
Lead
Fuel Pump
(Switching solenoid
valve)
about 700Ω
about 3.25ｋΩ
about DC5V
Off
Black-Red
High
about 20Ω
about 125Ω
in working
White-White
（Red Line）
CN10
in working
*1 Attached to pre-heater
Operation angle: 50 －80°
yellow-yellow
-
not in working
CN11
Solenoid Valve
in working
5±5℃on
∞Ω
Parts
not in working
20±5℃off
0Ω
about 230Ω
about 1.85kΩ
input
Red-Red
(MPX5)
yellow-yellow
(MPX1)
-
about1.8kΩ
about4.7ｋΩ
Standard resistance & Standard Voltage
Purple-Purple
output
about 6.3Ω
about 6.3Ω
dark
light
DC1.2V and under
Black-Black
(bold)
output
about 4kΩ
about 2.8kΩ
not in working
-
about 89Ω
about 395Ω
input
-
-
∞Ω
0Ω
∞Ω
Blue-Blue
*１
Thermostat for pre-heater
Blue-Blue
CN4
∞Ω
CN13
1-2PIN
3-4PIN
0Ω
Transformer
Igniter
Overheat Protection
Tip-over Switch
Red-Red
Black-Black
Black-Black
(thin)
CN7
Red-White
7
0Ω
Fuel Pump
(Pump coil)
Flame Monitor
0Ω
∞Ω
Operating Switch
CN8
1-2PIN
4-5PIN
Red-Red
White-White
change-over Switch
Black-Black
-
about 16Ω
about 88Ω
Normal scale 2.5（MPX5）
Normal scale 4.5（MPX1）
Fan Motor
1-2PIN
1-3PIN
CN5
4-5PIN
Fuel pre-heater
1-3PIN
Blower Motor
CN6
2-4PIN
1-3PIN
CN3
White-Blue
in working
about 735Ω
about 2700Ω
13

★Input &Output of Burner Control
*2
Solenoid Valve
CN10
Red-Red
(MPX5)
yellow-yellow
(MPX1)
-
about AC 100V
about AC115V
Fuel pre-heater
White-Blue
in working
AC 120V (±10%)
AC 230V (±10%)
Blower Motor
Black-Black
-
AC 120V (±10%)
AC 230V (±10%)
CN5
4-5PIN
1-3PIN
Parts
Connector Ｎｏ
Lead
Condition
Voltage
about AC 15V
Memo
MPX5
MPX1
Power Cable
CN1
Black - White
(MPX5)
Brown - Light
Blue
(MPX1)
-
AC 120V (±10%)
AC 230V (±10%)
Purple - Purple
output
Transformer
CN7
Red - White
input
AC 120V (±10%)
Fuel Pump
(Pump coil)
Blue-Blue
-
AC 60-96V
AC 115-184V
*1
Black-Red
High
AC 120V (±10%)
AC 230V (±10%)
Igniter
CN4
Black - Black
(thin)
Fuel Pump
(Switching solenoid
valve)
yellow-yellow
Fan Motor
CN3
1-2PIN
1-3PIN
AC 120V (±10%)
AC 230V (±10%)
1-3PIN
-
CN6
2-4PIN
Black-Blue
Low
AC 120V (±10%)
AC 230V (±10%)
input
AC 120V (±10%)
AC 230V (±10%)
AC 230V (±10%)
*1/*2 Output voltages vary according to mesuring instrument because they are half-wave/full-
wave rectification
14

Checking a pre-heater
23
8
Check & Repair
16
16
Removing a burner unit
Removing a burner cover
Figure 2
Figure 1
19
20
Positioning a electrode
Checking a fuel pump
Replacing a fuse
Mesuring voltage
22
Adjusting an air inlet opening of fan motor
17
17
17
Checking a surge absorber (SA1)
Figure 6
Figure 12
Mesuring resistance
Cleaning a frame monitor
20
21
19
18
18
Checking a filter element
Figure 14
Figure 13
Checking a fuel tank
Checking a burner cone and whirl vane
Figure 8
Figure 5
Figure 7
Figure 9
Figure 3
Figure 4
Figure 11
Figure 10
15

Unscrew three nuts as below and take the burner unit off
Removing a burner cover
Figure 2
Removing a burner unit
Unscrew two screws and take burner cover off
Figure 1
Nuts
Burner cover
Screws
16

①①
②②
③③
※Be sure to set resistor at proper range
※
Turn on the multimeter and set
multimeter range
Figure 3
Mesuring resistance
Figure 5
Checking a surge absorber (SA1)
Observation
Unplug an intended connector from
burner controller
Operate the heater
Take out the burner controller, and point the lead head at solder part of SA1
Figure 4
Turn on the multimeter and set AC
voltage range (partially direct current
range)
Insert the lead head of multimeter to
connector [lead wire side] and
measure resistance
Insert the lead head of multimeter to
connector and measure voltage
Mesuring voltage
Be careful not to insert the lead head of resistor strongly since damage in
connector may occur
17

Checking a filter element
Check whether or not the filter element is dirt or foul
In case the filter element is dirty, replace it with a new one
Be sure to unplug the power plug then open the fuse cap and Check whether fuse is
blown out
Figure 6
Replacing a fuse
Figure 7
Fuse cap
18

Figure 9
Checking a fuel pump
Figure 8
Checking a fuel tank
Fuel outlet line
Take out a fuel outlet line then check whether or not fuel comes out
CAUTION: Fuel will squirt cheerfully
19

Figure 10
Cleaning a frame monitor
Figure 11
Positioning a electrode
Take out a burner and check each clearance as below
Tip of electrode
Manufacturer does not
recommend to fix electrode as
they are very sensitive to
position, so it is
recommended to replace it.
Observation
20