Val6 KBE5L User manual

VAL6 Infrared Heater
Maintenance Manual
KBE5S & KBE5L
(2-step)

■
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

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

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

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)

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)

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

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

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

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