Shizuoka Seiki VAL6 KBE5S, Service Manual

Page 1: ...VAL6 Service manual ...

Page 2: ...ption 0 85gallon h Power Source 120V 60Hz single phase Power Consumption 80W in burning 100W in igniting Ignition System High Intensity Discharge EXTERNAL DIMENSION L W H 27 4 27 9 36 2 in 695 708 918 mm Safety Device Photocell Flame Monitor Overload Check Device 3A Fuse Dry Weight 83 8lbs Names of Components 1 2 ...

Page 3: ...elay F Line Fuse Z Surge Absorber ES Emergency Short RUN MISFIRE CN1 CN5 CN4 CN3 CN2 CN6 CN9 CN8 CN7 CN10 CN11 CN12 CN13 Connector No CN1 Power Source CN2 CN3 Fan Motor CN4 Igniter CN5 CN6 Solenoid Pump CN7 Tran CN8 Operating Switch CN9 Thermostat Short CN10 CN11 Flame Monitor CN12 Running Lamp Misfire Lamp CN13 Operation Switch Solenoid Pump Fan Igniter ON OFF 180 sec 5 sec within 10 sec 10 sec p...

Page 4: ...gniter does not spark Igniter does not operate Sequence of operation is normal but it doesn t ignite 3 Misfire within 25 seconds after ignition Misfire lamp is lit 5 4 Combustion stop during the operation Misfire lamp is lit 6 5 Odor comes out 7 6 Smoke comes out 8 7 Combustion is not stable 9 8 Fuel leaks 9 Fuse blows out When the plug is put into the socket 10 When the switch is turned on About ...

Page 5: ...nd then check each lead with circuit tester If either of the lead is broken power cord is broken Make sure the power cord 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 on contact Plug in connector CN 1 firmly Loose connection of transformer connector Plug in transfor...

Page 6: ...ting 0 Ω when turned on Failure of burner control Measure voltage at input side of transformer connector CN 7 If power source is normal and tester reads 0V at input side burner control fails Replace burner control Standard AC120V white red Run lamp is lit Loose terminals on control device Firmly connect terminals for control device If it works normally terminals for control device are loose Firmly...

Page 7: ...p connector on burner control If voltage is normal fuel pump fails Replace fuel pump Failure of burner control Standard AC60 96V red blue If tester reads 0V burner control fails Replace burner control 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 C...

Page 8: ...orks normally loose connection of igniter connector Plug in connector CN 4 surely Failure of igniter Measure voltage at igniter connector CN4 on burner control If voltage is normal igniter fails Replace igniter Failure of burner control Standard AC120V black black If tester reads 0V burner control fails Replace burner control Electrode is out of alignment Measure the alignment of electrode Refer t...

Page 9: ...of combustion air inlet opening If opening is too wide flame is short because combustion air is too much Decrease opening to reduce combustion air Normal scale 3 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 Unplug flame monitor connector ...

Page 10: ...t detects a little light Wipe lens of flame monitor with soft cloth Remove burner and then check clarity of draft tube and vane If draft tube or whirl vane is dirty flame monitor detects little Clean draft tube and whirl vane Picture 7 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 ...

Page 11: ...ctly Decrease gate opening of combustion air inlet Normal scale 3 Nozzle clogged Replace nozzle If it works normally nozzle is clogged Replace nozzle Filter clogged Check condition of filter If filter is dirty amount of fuel flow decreases because of clogged filter Replace filter Wrong nozzle Check makers imprint of the nozzle Mark 0 85USgal h 60 H If makers imprint is incorrect the nozzle is shou...

Page 12: ... 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 AC120V 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 higher than the altitude of 3300ft heater burn...

Page 13: ...Tighten joints 8 Fuel leaks Loose joints in fuel line Check looseness of each joint If any joint is loose fuel is leaking Tighten joints Failure of drain gasket Remove drain bolt after removing fuel from tank and then check that gasket isn t broken Fuel leaks because of broken gasket Replace drain gasket Amount of fuel in the tank is too much Check the fuel level Fuel overflows because quantity of...

Page 14: ...d about 350Ω white red Standard about 9Ω purple purple 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 Replace transformer When the switch is turned on Short circuit of fan coil Unplug fan connector CN 3 from burner controller then measure resistance between terminals If resistance value is...

Page 15: ...ut tester Unplug connector CN 4 from igniter and then start operation If fuse doesn t blow out igniter is short circuited Replace igniter About 5 seconds after turning on Short circuit of pump coil Unplug fuel pump connector CN 6 from burner controller then measure resistance between terminals If resistance value is 0Ω pump coil is short circuited Replace fuel pump Without tester Unplug fuel pump ...

Page 16: ...out 4 5KΩ Solenoid Pump ＣＮ6 Red Blue about 130Ω Fan motor ＣＮ3 Gray Gray about 10Ω gate Normal scale 3 60Ｈz When heater is used above 3 000ft sea level adjust air inlet on fan motor for better combustion Chart２ Input Output of Burner Control Parts Connector Ｎｏ Lead Condition Voltage Power code ＣＮ１ Black White AC 120V 10 Transformer ＣＮ7 Red White input AC 120V 10 Purple Purple output about AC 15V Ig...

Page 17: ...rn on the resistor and set resistor range Insert the lead head of resistor to connector lead wire side and measure resistance Insert the lead head of resistor to connector and measure resistance Picture 3 Removing a burner Unscrew two silver nuts with holding gold nuts and remove two fuel hoses Unscrew two screws and take a burner cover off Unscrew three nuts and take a burner off Nut screw ...

Page 18: ...out Standard pressure 99 psi 4 Picture 5 Standard position of electrode Picture 6 Inspection terminals for control device Check whether the terminals for control device are coupled firmly Manufacturer does not recommend to fix electrode as they are very sensitive to position ...

Page 19: ...nd fan are dusty please clean them up Open the fuse box and check whether the fuse blows out Picture 9 Inspection fuse Picture 10 Clean up fuel gauge Object Serial Number 01Q 040000 01P 01N If air intake of fuel gauge is clogged clean it up Open a screw cap and take out a fuse draft b whirl Check whether fuse is blown out air i k ...

Page 20: ... new one Plug the new filter in and tighten the metal ring If dirt or water is found in the cup clean the cup throughly Also clean the inside of fuel tank Drain the dirty fuel from the bottom of the tank Drain the old fuel from the bottom Loose the drain bolt again of fuel tank by loosing the drain bolt to drain the dirty fuel Place the drain bolt back Place the drain bolt and fuel cap firmly Pour...

Page 21: ...ull out the flame monitor and check if sensor is dirty If the sensor is dirty please wipe the surface of its lens with a soft cloth Place the sensor back into the position Observations When removing the flame monitor hold it by its main assembly do not pull out the cord 1 3 2 ...