Shizuoka Seiki VAL6 User manual

VAL6 Infrared Heater
Maintenance Manual
KBE5S & KBE5L
(2-step)
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■
Wiring Diagram of Burner Control
●
KBE5S
●
KBE5L 2-step
■
Sequence Time Chart
Operation
Switch
Solenoid
Pump
Fan
Igniter
ON OFF
180 sec.
5 sec.
within
10 sec.
10 sec.
(post ignition)
ignition
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PAGE# 1
Operation Flowchart
MODEL:
KBE5S, KBE5L(2-step)
Remedy
No.
NO
YES
●
Drain packing and/or bolt is damaged 1
●
There is too much fuel in the tank 2
NO
YES
●
Transformer coil is short-circuited
3
●
Surge absorber(SA1) on control board is
4
short-circuited
NO
YES
at the time of turning
●
Fan motor is short-circuited
5
on switch
●
Ignition transformer is short-circuited
6
about 5 seconds after
●
Fuel pump is short-circuited
7
turning on the switch
YES
NO
YES
NO
●
Power source is not supplied
8
●
Fuse blows out
9
●
Power cord is disconnected
10
●
Power sorce connector is loose connection
11
●
Transformer connector is loose connection
12
●
Transformer is defective
13
●
Operation switch connector is loose connection
14
●
Operation switch is defective
15
●
Circuit board (burner control) is defective
16
Possible Cause
Put fuel into the tank
Fuel is leaking
Fuse blows out
Plug into the power supply
Turn on the operation switch
Fuse blows out
Operation lamp is lit
The heater can start to operate
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PAGE# 2
Operation Flowchart
MODEL:
KBE5S, KBE5L(2-step)
Remedy
No.
Possible Cause
YES
NO
●
Terminals of control device is uncoupled
17
YES NO
●
Direct sunlight hits flame monitor
18
●
Circuit board (burner control) is defective
19
all three lamps are lit
●
Overvoltage is being detected
20
YES
NO
●
Combustion fan connector is loose connection
21
●
Combustion fan motor is clogged
22
●
Combustion fan and/or circuit board (burner
23
control) is defective
YES
NO
●
Ignition transformer connector or high-voltage
24
cord is loose connection
●
Electrode is defective
25
●
Ignition transformer is defective
26
（
crack in high-voltage cord
）
●
Circuit board (Burner control) is defective
27
YES
NO
YES
NO
●
Fuel pump connector is loose connection
28
●
Fuel pump is defective
29
●
Circuit board (Burner control) is defective
30
*1 KBE5S manufacturered from 2006 to
2013(Serial# J-04 to D-05)
Combustion fan is running
Overvoltage lamp is lit
Misfire lamp is lit
Electrode is sparking
The heater ignites
Fuel pump does not turn on
(for KBE5L)
(for KBE5S)*1
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PAGE# 3
Operation Flowchart
MODEL:
KBE5S, KBE5L(2-step)
Remedy
No.
Possible Cause
NO
YES
●
Fuel pump is inhaling remaining air in fuel line
31
(especially brand-new heater or after refueling)
●
Pump is inhaling air from the fittings of fuel line
32
between tank and fuel pump
YES
NO
●
Fuel line is clogged
33
●
Fuel filter (element) is clogged
34
●
Nozzle is clogged
35
●
Fuel pump is clogged or defective
36
●
Fuel filter and/or nozzle is clogged by thick fuel
37
●
Nozzle is clogged
38
●
Fuel is contaminated with water
39
NO
YES
NO
YES
●
Lens of flame monitor is dirty or dusty
40
●
Poor lighting is detected by flame monitor
41
●
Flame monitor connector is loose connection
42
●
Flame monitor is defective
43
YES
NO
●
Run out of fuel
44
●
Nozzle is clogged
45
●
Fuel filter is clogged
46
●
Air intake of fuel gauge is clogged
47
Overvoltage lamp is lit
●
Overvoltage is being detected
48
Fuel is sprayed normally from
Combustion stops during the operation
(fuel drips down from the
disk or does not come out
at all)
Overvoltage lamp is not lit
Fuel pump is idling with
Misfire in about 25 seconds
(Fuel is sprayed normally from the nozzle)
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PAGE# 4
Operation Flowchart
MODEL:
KBE5S, KBE5L(2-step)
Remedy
No.
Possible Cause
YES
NO
●
Nozzle is clogged
49
●
Fuel pump is clogged or defective
50
YES
NO
●
Change-over switch connector is loose connection
51
●
Change-over switch is defective
52
NO
YES
YES NO
●
Fuel viscosity is increasing
53
Black White
●
Fuel viscosity is increasing
54
●
Nozzle is clogged
55
YES NO
gives off black
●
Combustion air is insufficient
56
smoke
●
57
Oxygen for combustion is low because of high
altitude
Combustion is stable
Smoke comes out
Smoke is continuous
Which color is the smoke?
Heater is using in high altitude
Combustion level can switch into High/Low
(for KBE5L 2-step only)
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PAGE# 5
Operation Flowchart
MODEL:
KBE5S, KBE5L(2-step)
Remedy
No.
Possible Cause
NO
YES
●
Quantity of combustion air is too much
58
●
Nozzle is clogged
59
●
Fuel filter is clogged
60
●
The nozzle is incorrect
61
NO
YES
YES
NO
●
Combustion air is insufficient
62
●
Oxygen for combustion is low because of high
63
Normal Operation
Smell of fuel comes out
Flame bounces out from the disk
The unburnt component may come out under the temperature of
combustion chamber is low right after ignition. This unburnt component
causes odor.
However this may stop within 3 minutes because the temperature of
combustion chamber will increase.
Operating in high altitude
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1
VAL6 KBE5S & KBE5L Trouble Shooting
No. Possible Cause How to check Result Remedy
1Drain packing and/or
bolt is defective Remove fuel from tank and take out a drain bolt.
Then check whether the
packing and bolt are
damaged
Fuel leaks because of
broken packing and/or
bolt
Replace a drain
packing and/or bolt
2Too much fuel in the
tank
Check the fuel level Drain excess fuel
3Transformer coil is
short-circuited Disconnect transformer connector (CN 7) from
circuit board, then
measure coil resistance
values of two leads
If either lead shows ∞Ω,
the transformer is short-
circuited
Replace a
transformer
・
Without circuit tester
Disconnect transformer
connector (CN 7) from
circuit board, then put
plug into AC outlet
If the fuse is intact, the
transformer is short-
circuited
Replace a
transformer
4Surge absorber(SA1)
on control board is
short-circuited
Measure resistance at
surge absorber (SA1) If resistance value is ∞ Ω, surge absorber is
short-circuited
Replace a circuit
board (burner
control)
Fuel is leaking
Fuse blows out
At the time of pluging into the power supply
Standard: about 350Ω(white-red)
Standard: about 9Ω(purple-purple)
SA1
1
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2
VAL6 KBE5S & KBE5L Trouble Shooting
No. Possible Cause How to check Result Remedy
5Fan motor is short-
circuited Disconnect fan connector (CN 3) from circuit
board, then measure
resistance between
terminals
If value leads ∞Ω, the
fan coil is short-circuited Replace a fan motor
・
Without circuit tester
Unplug fan connector
(CN 3), and then start
operation
If the fuse is intact, the
fan coil is short-circuited Replace a fan motor
6Ignition transformer is
short-circuited Disconnect ignition connector(CN 4) from
circuit board, then
measure resistance
between terminals
If the value shows ∞Ω,
the ignition coils is short-
circuited
Replace an ignition
transformer
・
Without circuit tester
Disconnect ignition
connector (CN 4), and
then start operation
If the fuse is intact, the
ignition coils is short-
circuited
Replace an ignition
transformer
7Fuel pump is short-
circuited Disconnect fuel pump connector (CN 6) from
circuit board, then
measure resistance
between terminals
If the value shows ∞Ω,
the fuel pump coil is
short-circuited
Replace a fuel pump
・
Without circuit tester
Disconnect fuel pump
connector (CN 6), then
turn on
If fuse is intact, the fuel
pump coil is short-
circuited
Replace a fuel pump
At the time of turning on operation switch
About 5 seconds after turning on operation switch
2
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3
VAL6 KBE5S & KBE5L Trouble Shooting
No. Possible Cause How to check Result Remedy
8Power source is not
supplied Measure voltage of AC outlet.
Standard: AC120V
(or plug in another power
tool and see if it works)
If the value shows ∞V,
power cable is not
receiving electricity. (or
if under 100V, could be
power shortage)
Plug into a working
outlet
9Fuse blows out Take fuse out from fuse
box, and then check each
conduction with circuit
tester
If circuit tester reads ∞
Ω, fuse blows out Find a cause(s) of blown fuse and solve
it,(refer to #3-7),
then replace with a
new one
10 Power cord is
disconnected Take power source connector (CN 1) out
from circuit board, then
check each conduction
with circuit tester
If either of the lead is
broken, power cord is
defective
Make sure the
power cord is
connected, or
replace it
11 Power sorce connector
is loose connection Plug in power source connector (CN 1) again,
then turn on
If it works normally,
power source connector
fails on contact
Plug in connector
(CN 1) firmly
12 Transformer connector
is loose connection 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
13 Transformer is
defective 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 is defective
Replace a
transformer
14 Operation switch
connector is loose
connection
Plug in operation switch
connector (CN 8) again,
then turn on switch
If it works normally,
operation switch
connector fails in contact
Plug in connector
(CN 8) firmly
15 Operation switch is
defective Take operation switch connector (CN 8) out,
then check conduction
with circuit tester
If it does't conduct when
turned on switch,
operation switch is
defective
Replace an operation
switch
Heater cannot start up
（
heater does not operate at all with switching on)
Operation lamp is not lit (No lamp is lit)
Standard:
input - AC120V (white-red)
output - AC15V (purple-purple)
Standard: Conducting (0Ω) when turned on switch
3
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4
VAL6 KBE5S & KBE5L Trouble Shooting
No. Possible Cause How to check Result Remedy
16 Circuit board (Burner
control) is defective Measure voltage at input side of transformer
connector (CN 7)
If power source is
normal and tester reads
0V at input side, circuit
board is defective
Replace circuit
board (burner
control)
17 Terminals of control
device is uncoupled Check whether the terminals for control
device are connected
firmly
Firmly connect
terminals on control
device
18 Direct sunlight hits
flame monitor If it starts, sunlight is detected by flame
monitor
Move disk away
from direct sunlight
or bright light source
19 Circuit board (Burner
control) is defective
If it doesn't start, circuit
board is defective
Replace a circuit
board
20 Over voltage is being
detected Change the power source or confirm whether the
voltage of power source
or generator is correct
Find a cause of over
voltage and take
away them
21 Combustion fan
connector is loose
connection
Plug combustion fan
connector (CN 13) again,
and then turn on
If it works normally,
combustion fan
connector fails on contact
Plug connector
(CN13) firmly
22 Combustion fan motor
is clogged Try to rotate a vane by hand (*Be sure to plug
off beforehand)
If a vane isn't rotated
smoothly or completely,
the combustion fan is
clogged
Replace a
combustion fan
23 Combustion fan and/or
circuit board (Burner
control) is defective
Refer to above #21 & 22 There is no cause in #21
& 22, combustion fan
and/or circuit board are
defective
Replace a
combustion fan
and/or circuit board
Overvoltage lamp is not lit (Operation lamp and misfire lamp are lit)
Unplug flame monitor
connector (CN11), then
turn on switch
All three(operation, misfire, over voltage) lamps are lit
Combustion fan does not run
Standard: AC120V (white-red)
Misfire lamp is not lit (Only operation lamp is lit)
4
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5
VAL6 KBE5S & KBE5L Trouble Shooting
No. Possible Cause How to check Result Remedy
24 Ignition transformer
connector (CN4) or
high-voltage cord is
loose connection
Connect connection
of ignition
transformer
connector (CN4) or
high-voltage cord
25
Electrode is defective
Replace an electrode
（abnormal electrode）Confirm that an electrode
or a high-voltage cord
are not wet or dirty by
grime
Clean an electrode
or a high-voltage
cord
(clearance is out of
alignment)
Refer to drawing①
26 Ignition transformer is
defective Measure voltage at ignition transformer
connector (CN4) on
If it reads 120V,
ignition transformer is
defective
Replace an ignition
transformer
27 Circuit board (Burner
control) is defective
Standard: AC120V
(black-black)
If it doesn't read 120V,
circuit board is defective
Replace a circuit
board
28 Fuel pump connector
(CN6) is loose
connection
Plug fuel pump
connector (CN6) again,
and then turn on
If it works normally, fuel
pump connector fails on
contact
Plug connector
(CN6) firmly
29 Fuel pump is defective If the value shows
standard voltage, the
pump is defective
Replace a fuel pump
30 Circuit board (Burner
control) is defective If the value does NOT show standard voltage,
the circuit board is
defective
Replace a circuit
board
31 Fuel pump is inhaling
air which is remaining
in fuel line
(especially brand-new
heater or after
refueling)
Repeat start-
operation 2 or 3
times in order to
pump air out of fuel
line
＊NEVER repeat
more than 4 times in
a row as fire may
result
32 Pump is inhaling air
from the fittings of
fuel line between tank
and fuel pump
Confirm no loose fitting
in fuel line If any loose fittings, tighten it Tighten all fittings and repeat start-
operation
Fuel pump doesn't turn on (no vibration of fuel pump)
Measure voltage at
output side of fuel pump
connector on circuit
board:
Standard: AC60～96V
(red-blue)
Fuel pump is idling with clicking sound
Electrode is not sparking
The heater does not ignite
5
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6
VAL6 KBE5S & KBE5L Trouble Shooting
No. Possible Cause How to check Result Remedy
33 Fuel line is clogged Clear the clog in fuel
line
34 Fuel filter (element) is
clogged Check with eyes whether or not the fuel filter is
dirty or fouled
Replace a fuel filter
35 Nozzle is clogged Replace a nozzle
Clean and flush the
tank with kerosene,
alcohol or acetone
36 Fuel pump is clogged
or defective Loose the brass nut, then switch on and check
whether fuel comes out
(place a pan under the
pump)
If no fuel is pump up or
fuel is not flowing at
least 2" high, the fuel
pump is clogged or
defective (see exhibit
"How to restore the fuel
Replace a fuel pump
Clean and flush the
tank with kerosene,
alcohol or acetone
Fuel is not sprayed normally from the nozzle
Replacing a nozzle
unscrew three nuts and remove the burner
Replacing a fuel filter
Loose the brass nut
and switch on
(make sure that
pump turns on)
6
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7
VAL6 KBE5S & KBE5L Trouble Shooting
No. Possible Cause How to check Result Remedy
37 Fuel filter and/or
nozzle is clogged by
thick fuel
Because of low
temperature, fuel
viscosity increase and
fuel filter and/or nozzle is
clogged
Warm the fuel or
mix kerosene with
diesel.
(Replace a filter
and/or nozzle if
38 Nozzle is clogged Replace a nozzle
Clean and flush the
tank with kerosene,
alcohol or acetone
39 Fuel is contaminated
with water Because of condensation, there is the dew
condensation water in the
tank
Replace a fuel
thoroughly
40 Lens of flame monitor
is dirty or dusty Take a flame monitor out, and check whether
its lens is clear or not
If it is dirty or dustiness,
flame monitor cannot
detect flame properly
Clean the lens of
flame monitor with
soft cloth
41 Poor lighting is
detected by flame
monitor
Remove a burner and
check whether the whirl
vane and inside of draft
tube are clear or not
If they are dirty or
dustiness, flame monitor
cannot detect flame light
properly
*usually this will be
happen with above #42
at once
Clean the whirl vane
and inside of draft
tube or replace a
vane
*clean the lens of
flame monitor
42 Flame monitor
connector is loose
connection
Plug flame monitor
connector (CN11) again,
and then turn on
If it works normally,
flame monitor connector
fails on contact
Plug connector
(CN11) firmly
Misfire in about 25 seconds after ignition
(Fuel is sprayed normally form the nozzle)
Combustion stops during the operation
draft tube
whirl vane
Cleaning the whirl
vane and inside of Clean the whirl vane and
inside of draft tube
(especially behind whirl
vane) till they are shining
7
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8
VAL6 KBE5S & KBE5L Trouble Shooting
No. Possible Cause How to check Result Remedy
43 Flame monitor is
defective Disconnect flame monitor connector
(CN11) from circuit
board, then check
transition of resistance by
changing quantity of light
into flame monitor
If the valu of resistance is
nonstandard, the flame
monitor is defective
Standard: balck-black
dark: over 2MΩ
light: under 10KΩ
Replace a flame
monitor
44 Run out of fuel Check whether fuel is in
tank
Refueling
45 Nozzle is clogged Replace a nozzle
Clean and flush the
tank with kerosene,
alcohol or acetone
46 Fuel filter (element) is
clogged Check with eyes whether or not the fuel filter is
dirty or fouled
Replace a fuel filter
47 Air intake of fuel
gauge is clogged Check if air intake of fuel gauge is clogged with
dust
If air intake of fuel gauge
is clogged, fuel flow is
insufficient by pressure
drop in fuel tank
Clear an air intake of
fuel gauge
48 Over voltage is being
detected Change the power source or confirm whether the
voltage of power source
or generator is correct
Find a cause of over
voltage and take
away them
Combustion is not stable
49 Nozzle is clogged Replace a nozzle
Clean and flush the
tank with kerosene,
alcohol or acetone
50 Fuel pump is clogged
or defective Loose the brass nut, then switch on and check
whether fuel comes out
(place a pan under the
pump)
If no fuel is pump up or
fuel is not flowing at
least 2" high, the fuel
pump is clogged or
defective (see Exhibit A
"How to restore the fuel
Replace a fuel pump
Clean and flush the
tank with kerosene,
alcohol or acetone
Overvoltage lamp is NOT lit
Overvoltage lamp is lit
air intake
8
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9
VAL6 KBE5S & KBE5L Trouble Shooting
No. Possible Cause How to check Result Remedy
51 Change-over switch
connector is loose
connection
Plug change-over switch
connector (CN8) again,
and then turn on
If it works normally,
change-over switch
connector fails on contact
Plug in connector
(CN8) firmly
52 Change-over switch is
defective Take change-over switch connector (CN 8) out,
then check conduction
with circuit tester
If it does't conduct when
turned on switch,
change-over switch is
defective
Replace a change-
over switch
53 Fuel viscosity is
increased by low
ambient temperature
Check whether ambient
temperature is not under
minus 4 dgree Fahrenheit
(-20℃) and make sure
winter fuel is used
If temperature is under
minus 4 degree
Fahrenheit or summer
fuel is used, fuel is not
sprayed normally from
the nozzle because fuel
viscosity is increased by
low ambient temperature
Warming up fuel,
refueling winter fuel
or mixing kerosene
with fuel in order to
decrease fuel
viscosity
54 Fuel viscosity is
increased by low
ambient temperature
Check whether ambient
temperature is not under
minus 4 dgree Fahrenheit
(-20℃) and make sure
winter fuel is used
If temperature is under
minus 4 degree
Fahrenheit or summer
fuel is used, fuel is not
sprayed normally from
the nozzle because fuel
viscosity is increased by
low ambient temperature
Warming up fuel,
refueling winter fuel
or mixing kerosene
with fuel in order to
decrease fuel
viscosity
55 Nozzle is clogged Replace a nozzle
Clean and flush the
tank with kerosene,
alcohol or acetone
Heater produces WHITE smoke
Combustion stage can switch (for KBE5L 2-step only)
Smoke comes out
Smoke is continuous for about 3 minutes
Standard: Conducting (0Ω) when making the
switch to "High"
9
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10
VAL6 KBE5S & KBE5L Trouble Shooting
No. Possible Cause How to check Result Remedy
56 Combustion air is
insufficient Check whether a combustion fan is run
(refer to #21, 22, 23)
If the combustion fan
does not run, imperfect
combustion occurs by
low oxygen
Replace a
combustion fan
and/or circuit board
Check whether vanes of
combustion fan are dusty If vanes are dusty, imperfect combustion is
occurs by low oxygen
Clean a vanes of
combustion fan
Check whether air inlet
opening for combustion
is appropriate
If opening is small,
imperfect combustion
occurs by low oxygen
Adjust a air inlet
opening
Normal scale
：
3
Check whether applied
voltage is normal
Standard: 120V±10%
If applied voltage is
lower than 108V,
imperfect combustion by
decreasing of combustion
fan rotation speed occurs
Find a cause(s) of
low voltage and
solve it
* or plug into
another outlet
57 Oxygen for
combustion is low
because of high
altitude
Check whether the heater
is opearting in an altitude
higher than 1000m
If its altitude is higher
than 1000m, imperfect
combustion occurs by
low oxygen environment
Expand an air inlet
opening gradually
until smoke is clear
away
Normal scale: 3
Heater produces BLACK smoke
Heater is using in high altitude
Adjustment of air inlet
expand an air inlet opening for combustion
fan gradually (scale should be 4 or more)
until smoke is clear away or flame doesn't
protrude from the radiation disk.
10
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11
VAL6 KBE5S & KBE5L Trouble Shooting
No. Possible Cause How to check Result Remedy
58 Combustion air is too
much Check whether air inlet opening for combustion
is appropriate
If air inlet opening if too
much, imperfect
combustion occurs
Narrow an air inlet
opening
Normal scale: 3
59 Nozzle is clogged Replace a nozzle
Clean and flush the
tank with kerosene,
alcohol or acetone
60 Fuel filter (element) is
clogged Check with eyes whether or not the fuel filter is
dirty or fouled
Replace a fuel filter
61 Nozzle is incorrect Check whether correct
nozzle is used
Mark: 0.85USgal/h 60°H
Replace a correct
nozzle
62 Combustion air is
insufficient Check whether a combustion fan is run
(refer to #21, 22, 23)
If the combustion fan
does not run, imperfect
combustion occurs by
low oxygen
Replace a
combustion fan
and/or circuit board
Check whether vanes of
combustion fan are dusty If vanes are dusty, imperfect combustion is
occurs by low oxygen
Clean a vanes of
combustion fan
Check whether air inlet
opening for combustion
is appropriate
If opening is small,
imperfect combustion
occurs by low oxygen
Adjust a air inlet
opening
Normal scale
：
3
Check whether applied
voltage is normal
Standard: 120V±10%
If applied voltage is
lower than 108V,
imperfect combustion by
decreasing of combustion
fan rotation speed occurs
Find a cause(s) of
low voltage and
solve it
* or plug into
another outlet
63 Oxygen for
combustion is low
because of high
altitude
Check whether the heater
is opearting in an altitude
higher than 1000m
If its altitude is higher
than 1000m, imperfect
combustion occurs by
low oxygen environment
Expand an air inlet
opening gradually
until smoke is clear
away
Normal scale: 3
Smell of fuel comes out
Flame bounces out from the disk
Heater is using in high altitude
11
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12
VAL6 KBE5S & KBE5L Trouble Shooting
No. Possible Cause How to check Result Remedy
10 ±0.5mm
8
±0.5mm
2.4 ±0.5mm
Electrode
Nozzle
Electrode
Drawing
12
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How to restore the fuel flow
1
2
Procedure
After a few tries, fuel should squirt out of #3. It
should shoot out about 12". If you only get a
trickle, or no fuel, there may be several factors
contributing to the clogging. Please replace a fuel
If you have a good flow at #3, reconnect the flat
head screw and turn on the switch. The fuel will
flow at #2 and if it is a constant flow with a
minimum of 2" in height, turn off the switch and
reconnect the fitting #1.
Note: Insufficient amounts of fuel at the nozzle may cause the unit not to ignite and the raw fuel
that drips on the insulator will cause the black smoke when the heater does ignite.
If the heater produces a lot of black smoke, is difficult to fire or never ignites; please perform
the following procedures before replacing the pump and/or nozzle.
Make sure that the pump turns on (you can feel and hear the vibration). This will occur
approximately 5 seconds after the switch has been turned on.
Make sure that the electrode is sparking. You will hear the sparking and can see it
through the front disk right after turning on the heater. (Take the heater to a dimly lit
area for this spark check).
If the above items all check out properly and the unit is still not firing, place a pan under the
pump to collect fuel during the next procedure. (If either 1 or 2 is the problem, please refer to
the troubleshooting).
Unscrew the brass fitting #1 completely and push it
aside, so that the fuel outlet nipple #2 is visible.
Turn on switch and look for fuel coming out of #2.
The fuel flow must be at least 2" high. If the
required fuel height is met, only the nozzle should
be replaced and clean and flush the tank with
kerosene, alcohol or acetone.
If no fuel is coming out or there is only a trickle,
remove the #3 flat head screw, and turn on the
switch.
#1
#2
#3
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