Val6 FIR-X5 User manual

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Troubleshooting ………………………………………….
Standard resistance & Voltage …………………………
Check & Repair …………………………………………
Names of Components …………………………………
Safety Devices ……………………………………………
Error Code ………………………………………………
Sequence Time Chart …………………………………….
Wiring Diagram ……………………………………………
Specifications …………………………………………….
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ED2 2021.08
Contents
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3．
Maintenance Manual
1

【Names of Components】
1 Combustion chamber 16 Solenoid valve 30 Off-timer display lamp
2 Radiation tube 17 Solenoid valve 31 Down button
3 Guard 18 Flame monitor 32 Up button
4 Operation panel 19 Draft tube 33 Conbustion level lamp
5 Exhaust port 20 igniter 34 Mode switching button
6 Wheel 21 Control board 35 Thermo control mode lamp
7 Fuel tank 22 Fuel preheater 36 Auto control mode lamp
8 Fuel gauge 23 Fuse 37 Off-timer setting button
9 Fuel tank cap 24 Preheating lamp 38 Continuous Conbustion lamp
10 Burner cover (Burner inside) 25 Run lamp 39 1hour lamp
11 Tip-over switch 26 Low fuel lamp 40 2hours lamp
12 Fuel sensor 27 Display 41 4hours lamp
13
Overheat protection
(The backside of the
burner)
28 Display switching button 42 8hours lamp
14 External thermostat cord 29 Temperature display lamp 43 Operation switch
15 Combustion fan
1
2

2【Safety Devices】
3【Error Code】
Display Safety device Explanation
A1 Flame detection
When misfire occurs or flame goes out during the operation, the heater shuts
down automatically.
A2 Low fuel
No fuel in the fuel tank.
A3 Overheat
When overheating is detected, the heater shuts down automatically.
A4 Tip-over
When the heater receives a large vibration or shock, it shuts down
automatically.
A5 Abnormal fan speed
When an abnormality of the combustion fan is detected during combustion,
the heater shuts down automatically.
A6 Low voltage stop
When the supply voltage is about 70V or less, the heater shuts down
automatically.
A7 3 consecutive misfire
When there are 3 consecutive misfire, the operation is prohibited
automatically.
A8 Circuitboard communication abnomality
When communication between the control board and the operation board
fails, the operation is prohibited automatically.
HV High voltage
When the heater is connected to an abnormal high voltage, the operation is
prohibited automatically.
LV Low voltage detection
When the power supply volatage drops below appoximately 90volts during
operation, 「LV 」is displayed and the operation is continued.
※Refer to「7.Troubleshooting (P.6)」for countermeasure.
Safety Devices Detecting condition Working condition after detecting
Flame detection（Misfire） When the heater cannot detect a ignition during operation.
The error code「A1」is displayed and the fan cools down the heater for
about 5 minutes ( hereafter refferd to as Post-purge).
When the heater detects a out of fuel at the beginning
of operation.
The error code「A2」is displayed .
When it pasted 60 minutes after the heater detects
a out of fuel.
The error code「A2」is displayed and Post-purge sequence runs for 5
minutes.
Overheat protection
When the heater overheats.
The error code「A3」is displayed and if the heater is operating , Post-
purge sequence will run for 5 minutes.
Tip-over When the heater detects a vibration or an impacts.
The error code「A4」is displayed and if the heater is operating, Post-purge
sequence will run for 5 minutes.
Abnormal fan speed
When the heater detects an abnormal fan speed.
The error code 「A5」is displayed and if the heater is operating, Post-
purge sequence will run for 5 minutes.
High voltage
When the heater detects a high voltage(about 145V) at
the beginning of the operation.
The error code「HV」is displayed and the operation is prohibited.
Low voltage stop
When the heater detects a low voltage(about 70V) at the
during of the operation.
The error code「A6」is displayed and if the heater is operating, Post-purge
sequence will run for 5 minutes.
3 consecutive misfire When there are three consecutive misfire.
There error code「A7」is displayed and the heater runs for 5 minutes.After
that the operation is pohibited.
Circuitboard communication
abnomality
When a communication between the control board and the
operation board fails.
The error code 「A8」is displayed and if the heater is operating, Post-
purge sequence will run for 5 minutes.
Low voltage detection
When the heater detects low voltage (about 90V) during
the operation.
The error code「LV」is displayed and the operation is continued.
Power outage safety device
When the power supply is restored after it shuts down
during operation because of blackout or other reason.
The error code「--」is displayed and the operation is prohibited.
Low fuel
3

4【Sequence Time Chart】
5【Wiring Diagram】
CN12
CN9
CN11
CN10
CN13
CN5
CN6
CN8
CN7
CN4
CN1
CN3
CN2
CN17
Ignition
a: Ignition delay timer d: Post ignition
ｂ： Pump delay timer e: Stable time
ｃ： Solenoid valve delay timer
※Fuel pre-heater ： When the power cord is connected, the heater preheats for 3 minutes if the outside temperature is
less than 41℉.
50sec
e
300sec
Post purge
Fuel pre-heater
15sec
a
2sec
b
5sec
c
10sec
d
Operation Switch
Fan Motor
Igniter
Fuel Pump
Solenoid Valve
Flame Monitor
PLUG
SWITCH
SWITCH
IN
ON
OFF
4

6【Specifications】
Specifications
Model Type VAL6 FIR-X5
Type Radiated / Direct-fired
Ignition System High intensity discharge
Fuel Kerosene or Fuel-Oil no heavier than No.2(Diesel)
Fuel Consumption
(Heat Output)
Level 5 : 0.53 GAL/h, 1.72 kg/h (75,100 BTU, 22.0 kW)
Level 4 : 0.50 GAL/h, 1.63 kg/h (71,300 BTU, 20.9 kW)
Level 3 : 0.48 GAL/h, 1.55 kg/h (67,600 BTU, 19.8 kW)
Level 2 : 0.45 GAL/h, 1.46 kg/h (63,800 BTU, 18.7 kW)
Level 1 : 0.42 GAL/h, 1.38 kg/h (60,100 BTU, 17.6 kW)
Tank Capacity 7.9 gallons（29.9Ｌ）
Continuous Operating Time Level 5 : 14 hours（Stopped by fuel sensor）
Dimensions (inch) 46.0 H x 59.6 W x 13.6 D
Weight (w/empty tank) 172 Lbs, 78kg
Power Supply AC 120V (60Hz)
Power Consumption
Igniting : 65W,
Burning : 45W(Lv.5), 41W(Lv.4), 37W(Lv.3), 34W(Lv.2), 31W(Lv.1)
+44W When Preheater is operating
Electric Fuse 3A 250Ｖ
Operating Noise Level 56 dBA(Lv.5), 55dBA(Lv.4), 54dBA(Lv.3), 53dBA(Lv.2), 52dBA(Lv.1)
Safety Systems
Tip-over Switch
Flame Monitor
Electrical System Protection
(High Voltage, Low Voltage,
Prevention of automatic ignition after black-out)
Overheat Protection
Anomaly detection system for fan motor
Other Systems
Preheater for fuel supply
Solenoid valve for remaining fuel
Valve for draining air
Functions
Combustion mode
Thermo control mode
( The combustion level is manually maintained. )
Auto control mode
( The combustion level is automatically adapted
to programed temperature setting )
OFF-timer ( 1, 2, 4, 8 hours )
Display(7seg) switching
( Temperature[F], OFF-timer remaining time )
5

【Troubleshooting】
Contents
Page
7
8
9
11
11
12
12
13
13
13
13
1
Fuel leaks
4
3
10
The heater does not start
The heater does not ignition
Smoke comes out
Fuse blows out
Smell of fuel comes out
8
7
Combustion is not stable
Misfire within 40 seconds after ignition
7
Display「LV」
Combustion stop during the operation
9
№
2
Phenomenon
5
11
6
Noise occurs
6

Result Cause Remedy
1
A. When the plug is put into an outlet.
0Ω Failure of transformer Replace transformer
0Ω
0Ω Failure of pre-heater Replace pre-heater
B. When the switch is turned on.
Failure of fan motor Replace fan motor
0Ω
C.
Failure of igniter Replace of igniter
D.
Failure of fuel pump Replace of fuel pump
0Ω
E. Failure of solenoid valve Replace of solenoid valve
0Ω
When fuse blows out about 17
seconds after turning on.
※When igniter is operated.
※When fuel pump is operated.
※When solenoid valve is operated.
Replace burner controller
Standard: white-white：about 110Ω ⇒ Figure 3
(P.17)
yellow-yellow：about 20Ω
Failure of burner controller
Replace burner controller
Unplug pre-heater connector, then measure coil
resistance values
Surge absorber is short-
curcuited.
Standard: black-black(Thick)：
about 4kΩ ⇒ Figure 3
(P.17)
Unplug fan motor connector (CN 3) from burner
controller, then measure resistance values
Fuse does not blow out
Unplug solenoid valve connector (CN 6) from burner
controller, then measure resistance values
Unplug igniter connector(CN 4) from electrode、then
measure coil resistance values of the high voltage side
Fuse does not blow out
standard red-red：about 1.8kΩ ⇒ Figure 3(P.17)
Unplug fuel pump connector(CN 5) from burner
controller, then turn on
How to check
Unplug igniter connector(CN 4) from burner controller,
then turn on
0Ω
Fuse blows out.
Unplug fan motor connector (CN 3) from burner
controller, then turn on
※When fan moter is operated.
Standard: other than 0Ω ⇒ Figure 5 (P.18)
Standard: red-blue：about 520kΩ ⇒ Figure 3 (P.17)
Disconnect all connectors from the burner controller,
then plug the power cable into an outlet
red-red：about 3Ω
Fuse does not blow out
Fuse does not blow out
Unplug transformer connector (CN 2) from burner controller,
then measure coil resistance values
Phenomenon
When fuse blows out about 15
seconds after turning on.
Fuse blows out
Measure resistance at surge absorber (SA1)
When fuse blows out about 22
seconds after turning on.
Unplug solenoid valve connector(CN 6) from burner
controller, then turn on
Unplug fuel pump connector (CN 5) from burner
controller, then measure resistance values
standard: blue-blue：about 88Ω ⇒ Figure 3 (P.17)
Standard: white-blue：about 400Ω ⇒ Figure 3 (P.17)
7

Result Cause Remedy
How to check
Phenomenon
2
A. The lamp does not light on.
AC 0Ｖ No power source is supplied Operate with appropriate power source
Fuse blows out Replace fuse
Disconnection of power cable Replace power cord
AC 0V
AC 0V Failure of transformer Failure of transformer.
∞Ω Disconnection of transformer Replace transformer
Failure of operating switch Replace operation switch
Failure of burner controller Replace burner controller
B.
Power source is restored
after blackout when operating
Power cord is connected with
switching on
Failure of burner controller
Replace burner controller.
C. Refuel the fuel tank and operate the heater It works normally. No fuel in the fuel tank. Refuel
Failure of fuel sensor
Replace fuel sensor
Replace fuel sensor cord
Standard: black-black : Conducting (0Ω) with fuel
Failure of burner controller Replace burner controller
Display「A2」
Pour the fuel in the fuel tank about a one-third and,
unplug fuel sensor connector (CN10), and then check
conduction with multimeter
※When it does not correspond to the above content
If the multimeter reads ∞ Ω,
Disconnection of fuel sensor
cord
Disconnection of power cable
The heater does not start.
Disconnection of transformer
Failure of burner controller
Disconnection of operation
switch connector
Disconnection of operation
switch cord
※When power outage safety device
is operated
It works normally
(Lamps is lit)
standard: yellow-yellow：AC 16V
yellow-yellow：about 20Ω
Measure voltage at output side of transformer connector
Unplug transformer connector (CN 2) from burner
controller, then measure coil resistance values
Replace burner controller
It does not conduct when operation
switch is turned on(∞Ω)
It works normally.
( A ambient temperature is
displayed)
※When it does not correspond to the above content
Plug connector (CN17) firmly
Replace operation switch cord
standard: white-white：AC 120V ⇒ Figure4 (P.17)
Plug connector (CN1) firmly
-
Standard: red-red : Conducting (0Ω) when turned on
Plug connector (CN2) firmly
※When it does not correspond to the above content
It works normally
(Lamps is lit)
Replug power cable(CN1), and then turn on
Unplug operation switch connector (CN17), and then
check conduction with multimeter
red-red：about 3Ω
Replug operation switch connector (CN17) , and then
turn on
red-red：AC 12.5V ⇒ Figure4 (P.17)
Display「--」
Turn off the operating switch, and then turn on
Standard: white-white：about 110Ω ⇒ Figure3 (P.17)
Measure voltage at (CN1) terminal burner controller
standard: AC 120V ⇒ Figure 4 (P.17)
Replug in transformer connector (CN 2), and then turn
on
Measure voltage at input side of transformer connector
It works normally
(Lamps is lit)
8

Result Cause Remedy
How to check
Phenomenon
2
D. Display「A3」
Failure of overheat protection Replace overheat protection
Disconnection of overheat
protection cord.
Replace overheat protection cord
Lack of burner packing Add burner packing
Deterioration of burner packing
Replace burner packing
Failure of burner controller. Replace burner controller
E. Display「A4」
※Tip-over detector operation.
Failure of tip-over switch
cord
Replace tip-over switch cord
Failure of burner controller Replace burner controller
F. Display「A5」
Does not rotate or it move slowly Combustion fan is locked Cancel the lock or replace combustion fan
DC 170V Failure of combustion fan Replace combution fan
DC 0V Failure of burner controller Replace burner controlller
G. Display「A6」
Lower than AC70V Supplied voltage is too low Operate with appropriate power source
Failure of burner controller Replace burner controller
H. Display「HV」 Measure the voltage of AC outlet
More than AC 145V Supplied voltage is too high Operate with appropriate power source
Failure of burner controller. Replace burner controller
I. Display「A7」
Failure of burner controller. Replace burner controller
3
Display「A1」
A. Fuel pump does not operate at all. ∞Ω Failure of fuel pump.
※High voltage detection.
「A7」is not displayed
(A ambient temperature is displayed)
Disconnection of fuel pump
connector
「A3」is not displayed
(A ambient temperature is displayed)
Plug connector (CN11) firmly
Disconnection of overheat
protection connector.
Plug connector (CN3) firmly
Normal indication after 3
consecutive misfire
Plug connector (CN11) firmly
Replace tip-over switch
※When overheat protection is operated
Plug connector (CN5) firmly
Disconnection of fuel pump
connector
-
※Low voltage stop.
Standard: black-black : Conduction in horizontal(0Ω) ⇒
Figure3 (P.17)
※3 consecutive misfire.
※Combustion fan abnomality detection .
Plug connector (CN1) firmly
「A5」is not displayed
(A ambient temperature is displayed)
standard: AC 120V ⇒ Figure4 (P.17)
「A6」is not displayed
(A ambient temperature is displayed)
「A3」is not displayed
(A ambient temperature is displayed)
Replug in combustion fan connector (CN 3) and then
turn on
Replug in tip-over detector connector (CN 11), and
then turn on
standard: AC 120V ⇒ Figure 4 (P.17)
Unplug the fuel pump (CN 5) from burner controller,
then measure resistance values
Replug in power cable(CN1), and then turn on
Replug in the fuel pump connector (CN 5), and then
turn on
Measure the voltage of AC outlet
Turn off the operation switch, and then plug the power
cable again
※When it does not correspond to the above content
※When it does not correspond to the above content.
※When it does not correspond to the above content
Measure the voltage at CN3 terminal on burner controller
Unplug tip-over detector connector (CN 11),
and then check lead with multimeter
Confirmation of burner packing ⇒ Figure15 (P.23)
※When it does not correspond to the above content
「A1」is not displayed
(A ambient temperature is
displayed)
※When it does not correspond to the above content
Replug overheat protection connector (CN 11) , and
then turn on
The heater does not ignite.
Unplug overheat protection connector (CN 11), and
then check conduction with multimeter
The heater does not start.
Standard: red-red : Conduction(0Ω) ⇒ Figure3
(P.17)
Turn the combustion fan by hand
standard: DC 170V ⇒ Figure4 (P.17)
It does not conduct when operation
switch is turned on(∞Ω)
(Overheat protection is not
detected)
It does not conduct when operation
switch is turned on(∞Ω)
(Overheat protection is detected)
Disconnection of tip-over
connector
Failure of tip-over switch
Disconnection of combustion fan
connector.
Disconnection of power
source connector
It does not conduct in horizontal
Replace pump
standard: blue-blue：about 88Ω ⇒ Figure3 (P.17)
9

Result Cause Remedy
How to check
Phenomenon
Display「A1」 There is a hole
Stop of operation due to light
leakage detection
Replace combustion chamber
A. Fuel pump does not operate at all. Failure of flame monitor Replace flame monitor
Check if the pipe is clogged
Fuel line is clogged Flow rate is lower by clogged Clean fuel line
B.
Fuel pump works but no fuel supply or
Check if filter element is dirty ⇒ Figure7(P.19)
Filter element is dirty Filter element is clogged Replace filter element
low supply. Check looseness of each joints
The connection has become loose Air is coming Fasten joints more tightly
Check if the fuel pump is clogged
Pipe is clogged Flow rate is lower by clogged Replace pump
Nozzle is clogged Flow rate is lower by clogged Replace nozzle
About DC 110V(For reference) Failure of solenoid valve Replace solenoid valve
0V Failure of burner controller Replace burner controller
∞Ω Failure of solenoid valve Replace solenoid valve
C. Igniter does not spark.
Igniter does spark. Plug connector (CN4) firmly
AC 120Ｖ Failure of igniter Replace igniter
Disconnection of Igniter
connector
AC 0Ｖ Failure of burner controller Replace burner controller
∞Ω Failure of igniter. Replace igniter
D. Igniter does spark. Check the fuel ⇒ Figure 8(P.19) Use fuel other than diesel and kerosene Low quality fuel Operate with appropriate fuel
Be mixed with water
Diesel and kerosenel goes bad
Measure the alignment of electrode. Part is out of standard position. Replace electrode
Check air inlet opening of fan moter. Air inlet opening is unusual. Operate with appropriate air inlet opening
Measure voltage at the CN4 terminal burner controller
Alignment of electrode is out
of standard
Check if there is a hole in the combustion section part
Standard: ⇒ Figure10（P.20)
Check if the nozzle is clogged
Unplug the solenoid valve connector (CN 6) from the
burner controller, then measure the resistance values
standard: 3.0 ⇒ Figure 13 (P.22)
standard: red-red：1.8kΩ ⇒ Figure3 (P.17)
Unplug the igniter connector(CN 4) from the
electrode、then measure the coil resistance values
Replug in igniter connector (CN 4), and then turn on
Voltage of flame monitor
The valves does not change or it is
much different from the standard
standard: dark：DC 5V or higher ⇒ Figure4 (P.17)
Measure voltage at CN6 terminal on burner controller
standard: black-black：about DC110V ⇒ Figure4 (P.17)
light：DC 5V or lower
Standard: black-black(Thick)：about 4kΩ ⇒ Figure3(P.17)
standard: AC 120V ⇒ Figure4(P.17)
Replug in solenoid valve connector(CN 6) , and then
turn on
Improper quantity of
combustion air
「A1」is not displayed
(A ambient temperature is displayed)
Disconnection of solenoid
valve connector
Plug connector (CN6) firmly
Disconnection of Igniter
connector.
10