Toyotomi Laser 60AT User manual

VENTED HEATER
SERVICE MANUAL
Laser 60AT

LASER HEATING SYSTEMS
Table of Contents
1- 1 Introduction
1- 2 Physical Specifications
1- 3 Description of Functions
1- 4 Description
1- 5 Combustion System
1- 6 Heat Chamber
1- 7 Burner
1- 8 Burner Ring Assembly
1- 9 Burner Coating
1-10 Flame Rod Sensor
1-11 Igniter
1-12 Forced Flue Venting System
1-13 Flue Pipe
1-14 Blower Motor Assembly
1-15 Air Circulation Fan
1-16 Fuel Delivery System
1-17 External Fuel Tank
1-18 Fusible Link Valve
1-19
Fuel Sump (Fuel Constant Level Valve)
1-20 Fuel Pump
1-21 Electrical System
1-22 Control Circuit Board
1-23 Room Temperature Sensor
(Thermistor)
1-24 Safety Mechanisms
1-25 Power Failure Recovery System
1-26 Cloth Covered Exhaust Pipe
1-27 Air Circulation Fan Cover
1-28 Fuse
1-29 Overheat Protector Switch
1-30 Igniter Cleaning System
2- 1 Introduction
2- 2 Physical Placement of Heater
2- 3 Drilling Requirements
2- 4 Power Requirements
2- 5 Fuel Tank Requirements
2- 6 Room Temperature Sensor Wiring
Requirements
2- 7 Building Codes
2- 8 Unpacking
2- 9 Heater Installation
2-10 Installing Ceramic Log
2-11 Installing an Extension kit
2-12 Typical Fuel Lifter
Pump Installation
2-13 Fuel Tank Installation
2-14 For High Altitude Use
3- 1 Introduction
3- 2 Operating Specifications
3- 3 Operating Controls and Indicators
3- 4 Pre-Operation Check List
3- 5 Before Operation
3- 6 Operation
3- 7 Manual Operation
3- 8 Automatic Operation
3- 9 Reprogramming the Laser Heater
3-10 Room Temperature Sensor
(Thermistor)
3-11 Turning Heater Off
3-12 Manual Combustion System for
Testing Purposes
3-13 Power Failure Recovery System
3-14 Recovery from Overheat Condition
Description
Page 1-6
Page 7-15
Page 16-22
Installation
Operation
Section 1
Section 2
Section 3

LASER HEATING SYSTEMS
Table of Contents
4- 1 Introduction
4- 2 Routine Maintenance
4- 3 Inspect Intake/Exhaust Air Lines
4- 4 Verify Igniter Operation
4- 5 Clean Fuel Inlet Strainer
4- 6 Replacement of Fuses
4- 7 Fuel Contamination
5- 1 Introduction
5- 2
Cleaning Glass Cylinder and Burner
5- 3 Removal of Water Deposits and
Contaminants from Fuel Sump and
Fuel Lines
5- 4 Measurement of Fuel Flow Rate
5- 5 Cleaning Blower Motor
5- 6 Cleaning Fuel Filter or Water Block
Filter
5- 7 Error Message
6- 1 Electrical System
6- 2 Schematic Wiring Diagram
6- 3 Resistor/Capacitor Value
6- 4 Control Circuit Board Time Chart
6- 5 Trouble Shooting Guide
6- 6 Parts Description
Page 23-26
Page 27-30
Page 31-40
Maintenance
Servicing
Trouble Shooting
Section 4
Section 5
Section 6

1SERVICE MANUAL
LASER HEATING SYSTEMS
Description
The Laser Heating System is a completely new type of
sophisticated and fuel-efficient vented system featuring
its own housing, combustion and air circulation systems
and a micro computer control system.
In addition to superior design and technology, rigorous
testing for quality and safety have made the Laser
Heating System unmatched for efficiency, convenience,
economy and flexibility. Plus, the Laser is easy to
maintain and requires minimal service.
The following section outlines the Laser Heater and its
various components.
Listed below, are the physical specifications that apply
to the Laser:
Laser 60AT
W × D × H (inches): 30"× 24" × 19"
(760 × 608 × 483 mm)
Weight: 77 lbs. (35kg)
Flue Pipe Hole: 2-3/4" to 3" diameter
(70 to 75 mm)
See Fig. 1-1.
The heating cycle begins with a purge of any existing
fuel vapors along with a pre-heat period. The fuel and air
are then delivered to the heated burner, resulting in
ignition.
After several minutes of low and medium mode
combustion, the circulation fan starts to blow air through the
heat exchanger and automatically maintains the proper
burn rate. An easy to use selector allows for regulation of
room temperature while the indicator panel allows
monitoring of the Laser’s heating condition. When the room
temp. increaces sufficiently, the heater shuts down and
goes through a post-purge mode for approx. 3 minutes.
Laser 60AT is equipped with a programmable set-back
timer which allows for fully automatic operation 24 hours
a day. The heater will run at four stages "HIGH",
"MEDIUM", "LOW" and "OFF" cycle to maintain the
desired temperature setting.
The Laser 60AT is composed of the following:
• A drip tray
• A cabinet
• A forced flue venting system
• A combustion system
• An air circulation system
• A fuel delivery system
• Electrical and electronics systems
• A variety of safety mechanisms
In the combustion system a mixture of fuel and air is
burned to produce heat. Air is drawn from outside the
dwelling to the burner. At the same time, fuel is metered
from a storage tank into this same burner. Within the
burner, the air/fuel mixture is ignited to produce heat.
The Laser combustion systems are safeguarded by an
overheat protector switch that will shut down the heater
(to protect it from damage) in the event of excessive
heat build-up. The error code "EE-6" or "EE-2" will be
displayed on the digital indicator at this time. The
overheat protector switch will be reset after the cooling
down period. Turn the ON/OFF switch to "ON" again to
restart.
Section 1
1-1 INTRODUCTION
SHUTDOWN
OFF
HEATING
POST-PURGE
COMBUSTION
IGNITION
Figure 1-1 SIMPLIFIED OPERATIVE CYCLE
1-2 PHYSICAL SPECIFICATIONS
1-3 DESCRIPTION OF FUNCTIONS
1-4 DESCRIPTION
1-5 COMBUSTION SYSTEM

Description
The combustion chamber consists of two main parts;
one is the heat chamber and the other is the heat
exchanger. The heat chamber is secured to the top of
the burner. The heat chamber is made of a heatproof
glass. The exhaust vapors pass through the heat
exchanger. While exhaust vapors are moving through
the heat exchanger, the heat is extracted from the heat
exchanger by the air circulation fan. The heat exchanger
is connected to the top of the heat chamber.
The burner is positioned on the cabinet base.
The burner has a double wall construction and contains
an igniter tube, a fuel inlet fitting and a series of air holes
on the inner wall.
Connected to the burner are the igniter (located within
the burner) , a fuel line and a flame sensor. Within the
burner is the burner ring. An airway in the cabinet base
channels air from the intake fan of the combustion
blower to the base of the burner. The flame rod sensor
is mounted through the wall of the burner.
This assembly is designed to promote efficient burning.
The burner ring assembly is held by spring clips to
mounting posts within the burner.
The textured burner coating insures the even
vaporization of fuel for proper combustion.
The flame rod sensor checks the condition of the flame
for proper burning.
The flame rod sensor is mounted through the wall of the
burner.
The ceramic-type igniter is designed to pre-heat the burner
pot and to vaporize and ignite the air/fuel mixture to start
the combustion process.
The forced flue venting system channels air to and from the
heater. Outside air is drawn into the heater by the combustion
blower through the flue pipe and is blown into the bottom of the
burner. It then combines with the vaporized fuel and ignites.
As the heated air passes through the heat exchanger, a
room air circulation fan blows air past the heat exchanger
and out again into the room from the front of the heater.
Exhaust vapors are vented out of the room through the
flue pipe.
The wall thickness which the flue pipe can be installed is from
4 in. to 9 in. The extension flue pipe (option) is available for
installation in wall thickness from 9 in. to 13 in. This provides
the flexibility to meet the installation requirements of dwellings
of various wall thicknesses up to 13 inches (330 mm).
The flue pipe assembly is a “pipe-within-a-pipe”design
which consists of two concentric tubes. Outside air is drawn
through the cylindrical space between the tubes.
Combustion by-products are vented through the inner tube.
As cool air the enters the flue pipe, it is heated by the hot
air that is exiting the system.
The blower motor assembly on Laser 60AT is a dual
function fan with the intake air and exhaust air fans
mounted on a common shaft. Inside they are separated
into two compartments by a sealed plate. One side is
the intake air and the other is the exhaust air. The intake
fan draws in outside air through the flue pipe for internal
combustion. The exhaust fan, which runs on a common
shaft with the intake fan, expels all combustion by-
products through the flue pipe.
The Laser 60AT blower motor has a 2-stage, 3-speed
intake/exhaust fan. The larger diameter exhaust fan
keeps the air pressure within the combustion/exhaust
system lower than the room air. A magnetic sensor
insures proper fan speeds for each burning mode.
The blower motor will keep running for 180 seconds
after the heater is turned off to exhaust vapor in the
system and cool off the unit.
Section 1
SERVICE MANUAL 2
LASER HEATING SYSTEMS
1-6 HEAT CHAMBER
1-7 BURNER
1-8 BURNER RING ASSEMBLY
1-9 BURNER COATING
1-10FLAME ROD SENSOR
1-11 IGNITER
1-12 FORCED FLUE VENTING SYSTEM
1-13 FLUE PIPE
1-14 BLOWER MOTOR ASSEMBLY

3SERVICE MANUAL
LASER HEATING SYSTEMS
Description
The air circulation fan forces room air through the heat
exchanger, then out of the front panel to be distributed
throughout the room. The Laser 60AT circulation fan
motor has three speeds. The circulation fan will keep
running for 180 seconds after the heater shuts down.
This cools the heater.
Fuel moves by gravity from the external fuel storage
tank to the fuel sump.
Fuel must be maintained at the level corresponding to
the burn mode so that combustion can be conducted
efficiently.
The fuel pump meters the flow of fuel from the fuel sump
to the burner through a copper fuel pipe and a fuel
nozzle.
The external tank (which generally is dealer installed)
should contain at least one shutoff valve, a fuel filter and
a vent. Installation of the tank should conform to local
regulations.
The fusible link valve is mounted as a standard item.
Located inside on the base of the heater cabinet, it is
connected to the fuel sump. The fusible link valve is a
spring-loaded device that cuts off the supply of fuel to
the heater when the temperature level (at the valve)
exceeds a predefined maximum limit.
The constant level valve has an automatic shutoff safety
mechanism that prevents fuel from flooding or
overflowing from the fuel sump.
A manual reset button allows the valve to resume
operation after the heater has been moved.
Fuel enters the constant level valve through an inlet at
the bottom. As the level of fuel rises, it passes through a
fuel inlet strainer which removes most particles and
foreign matter from the fuel and then it flows up through
an open inlet valve and enters the tank. See Fig. 1-2.
The fuel pump is mounted on top of the fuel sump. The
pump assembly consists of the pump solenoid and the
control circuit.
All electronic diagrams, such as the wiring diagram, the
circuit board layout, and the electrical schematic can be
found in Section 6 of this Service Manual.
Section 1
1-15 AIR CIRCULATION FAN
1-16 FUEL DELIVERY SYSTEM
1-17 EXTERNAL FUEL TANK
1-18 FUSIBLE LINK VALVE
1-19 FUEL SUMP
(FUEL CONSTANT LEVEL VALVE)
IMPORTANT: Within the valve, a float mechanism
controls the level of fuel in the
sump. As the fuel level drops, the
float drops down to increase the
inlet valve opening to admit more
fuel into the sump. When the fuel
level reaches its maximum volume,
the float rises to shut the valve.
In the event that fuel within the
sump rises to an abnormally high
level, the float within the sump rises.
A trip magnet pulls the float up and
closes the valve to prevent fuel from
entering into the sump.
Should a foreign substance cause
the inlet valve to stick (or prevent it
from opening), the reset button is
utillized to free the mechanism and
to admit fuel to the sump.
The fuel inlet strainer should be
cleaned or replaced periodically.
Time intervals will depend on purity
and quality of fuel.
CAUTION: Care must be taken to prevent dust, dirt
or other debris from clogging or
blocking the inlet valve.
1-20 FUEL PUMP
1-21 ELECTRICAL SYSTEM

Description
Section 1
SERVICE MANUAL 4
LASER HEATING SYSTEMS
The control circuit board provides safety timings,
controls relays and provides clock and thermostat
functions for the Laser Heater. A componet layout of the
printed circuit boad is found in this Service Manual.
The room temperature sensor, which is capable of
sensing room temperature within range of 50°F (10°C)
to 90°F (32°C), can be wall mounted.
Approx. 8 feet (2.5 m) of wire is supplied with the sensor
to facilitate wall mounting is a favorable location. You
can also use radio wire or speaker wire to extend the
mounting location up to 20 feet (6m).
Figure 1-2 FUEL SUMP (FUEL CONSTANT LEVEL VALVE) (Part #20478534)
1-22 CONTROL CIRCUIT BOARD 1-23 ROOM TEMPERATURE SENSOR
(THERMISTOR)

5SERVICE MANUAL
LASER HEATING SYSTEMS
Description
Several safety mechanisms have been built into the
Laser Heating System. These devices protect the user
against personal injury, protect the heater against
damage, shut down the heater and display an error code
on the digital indicator if a malfunction occurs.
When an electric power failure occurs while the heater is
in operation, the heater will automatically re-start and
run in “NORMAL”mode after the power is restored.
Insulating cloth covers are to be placed over all metal
surfaces of the exhaust line during installation. Since
combustion by-products are vented at elevated
temperatures, the exhaust pipe will become hot during
operation. The insulating cloth covers protect the user from
accidental contact burn with these heated metal surfaces.
This fan cover is an integral part of the fan assembly
and protects the user against physical injury which could
occur from accidental contact with the revolving metal
fan blade.
In the event of a power surge or an internal wiring
hazard, the fuses will open and power to the heater will
be cut off. The fuses are rated at 125 V AC, 10-amps
and 125 V AC, 3-amps.
The electrical outlet into which the heater connected
should be protected by at least a 15-amp. fuse or circuit
breaker.
Overheat protector switch is rated at 195°F (90°C).
Should a heater overheat (internal temperature rises
beyond 195°F (90°C)), the overheat protector switch
(also called a high limit switch) will open to shut off the
heater. Error code “EE12”will be displayed on the digital
indicator at this time. The overheat protector switch will
automatically reset after the heater has cooled down.
Once the heater has cooled to 150°F (65°C), the system
can be restarted manually as follows:
1. Press ON/OFF switch to “OFF”.
2. Allow heater to cool down.
3. Resolve the cause of the overheat.
4. Press ON/OFF switch to “ON”to start.
The heater will start with normal operation.
Automatic igniter cleaning system
The heater will automatically turn to the “OFF”cycle at
2:00 AM everyday and the igniter will be on for self-
cleaning for ten (10) minutes. “CL:10”will be shown on
the digital indicator at this time.
Manual igniter cleaning system
you can clean the igniter manually for ten (10) minutes
as follows:
1. Press both the “HOUR”button and “MINUTE”button
at the same time for more than three (3) seconds
when ON/OFF switch is “OFF”.
2. “CL:10”will be shown on the digital indicator.
Cleaning will begin and end without any additional
input.
3. Disconnect the heater from power source during the
off season.
Section 1
1-24 SAFETY MECHANISMS
1-25 POWER FAILURE RECOVERY
SYSTEM
1-26 CLOTH COVERED EXHAUST PIPE
IMPORTANT: Do not operate the heater without
the insulating covers. During
installation make sure that all
exhaust lines are tightly connected.
1-28 FUSE
1-29 OVERHEAT PROTECTOR SWITCH
1-30 IGNITER CLEANING SYSTEM
IMPORTANT: Cleaning the igniter is important to
prolong igniter life. It is recom-
mended that the igniter be cleaned
at least once a week.
1-27 AIR CIRCULATION FAN COVER
IMPORTANT: The digital clock on the heater
must be set to the correct time.

Description
Section 1
SERVICE MANUAL 6
LASER HEATING SYSTEMS
Exhaust fan
Exhaust gas
5. Flue pipe
Intake air
Blower motor
Adjustable leg
Draft pipe Burner
Drip tray
2. Fuel strainer
Fuel sump
Fuel pump
Reset button
Fuel pipe
Burner ring
Ceramic log
Glass cylinder
Intake fan
Igniter 1. Flame sensor
Heat exchanger
3. Overheat protector
Model Laser 60AT
Figure 1-3 CONSTRUCTION

7SERVICE MANUAL
LASER HEATING SYSTEMS
Installation
Installing the Laser System at the user's location can be
performed quickly and economically.
Laser 60AT is strictly an externally fueled system, is fully
vented and will need the installation of an external fuel
storage tank.
By completing each step of the easy-to-follow
installation instruction (each step should be completed in
the exact order specified), the technician is directed
through the installation process.
This section contains all relevant installation information
including:
•Installation specifications
•List of installation tools
•Alternative types of venting systems
(and installation procedures for each)
•Basic requirements for fuel tank installation
•Instructions to install the Laser System
The heater can be located almost anywhere within the
dwelling provided that electrical, fuel, and exhaust
specifications are met.
In addition to the space taken up by the heater, interior
space must also be reserved for free air circulation.
Remove all combustibles from the heating area.
Unless building or fire codes dictate otherwise, the Laser
System can be placed on any floor surface (including
carpeting or other combustible material) and provide safe
operation. Check clearances as instructed in Figure 2-1.
Through-the-wall flue pipe installation requires that a 2-
3/4" to 3" (70 to 75 mm) hole be drilled through the
dwelling wall (interior or exterior). The hole must be
pitched downward toward the outside at an approx.
angle of 2 degrees.
The appropriate wall area (in which hole will be drilled)
must contain no internal obstacles such as piping,
wiring, air ducts or studs.
RECOMMENDED TOOL KIT FOR SERVICE TECHNICIANS
1) #2 Phillips Head Screwdriver
2) Steel Tape Measure
3) Felt Tip Pen or Pencil
4) Caulking Material (exterior grade)
5) Electrical Drill (reverse capability recommended)
6)
Hole Saw, Saber (Jig) Saw or other appropriate
tool for cutting a 2-3/4" to 3" (70 to 75 mm)
diameter hole for flue pipe
7) Long Drill Bit-1/2"
8) 1/4" ×6" Standard Screwdriver
9) Adjustable Wrenches (various sizes)
10) Copper Tubing Cutter
11) Copper Tubing Flaring Tool
12) Volt, OHM, Meter with shielded probes
13) Level (small circular type)
14) Plumber's Pipe Thread Tape
15) Small Assortment of Self-Tapping Screws
16)
Assorted Pliers (Slip Joint, Needle nose, Cutting,
Lock Joint)
17) Phenolic Probe or Insulated Screwdriver
18) Floor Mat to cover carpeting
19) Quart Size Pan for draining fuel
Section 2
2-1 INTRODUCTION
IMPORTANT: Before beginning installation of the
Laser Vented Heating System
(including any electrical wiring and
fuel supply equipment), check local
building, electrical, mechanical and
fire codes. The requirements of
these codes must be followed to
insure lawful installation and use.
IMPORTANT: The heater is designed to be used
no more than 3000 FT. (1000 m)
above sea level.
If using at a altitudes higher than
3000 FT. (1000 m) above sea
level, follow the procedure on
paragraph 2-13.
2-2 PHYSICAL PLACEMENT OF HEATER
2-3 DRILLING REQUIREMENTS