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Toyotomi Laser 300, Service Manual

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Toyotomi Laser 300 Service Manual Download Page 39

 

S E R V I C E

  M A N U A L    

37

L A S E R   H E A T I N G   S Y S T E M S

Trouble Shooting

Section 4

SOLUTION

CAUSE

RESULT

CHECK5

RESULT

CHECK4

RESULT

CHECK3

RESULT

CHECK2

RESULT

CHECK1

Clean out air and exhaust ducts

Intake or exhaust line clogged

Remove obstructions

Clogged air supply or exhaust piping

Correct as specified

Not as specified

Replace blower motor

Replace fuel pump

Fuel pump malfunction

Blower motor failed

Correct wiring

Wiring failure

Check or replace main circuit board

Main circuit board malfunction

Check or replace main circuit board

Main circuit board malfunction

Check or replace flame sensor

Flame sensor malfunction

Room temp. is too low.

Normal

Abnormal

Normal

Abnormal

Yes.

No.

Is a unit
placed hori-
zontally?

Room temp.

is below 14˚F

(-10˚C)

Yes.

No.

Check if the

power source

is 120V-60Hz.

Room temp

indicates

"LO"

Yellow high

flame

whistling

noise or

smoke

produced

when set

"HIGH"

Does blower

motor work

properly?

Check out

side end of

flue pipe for

flow of air

and exhaust

Normal

Abnormal

Yes.

No.

Burner ring

sit properly

in the

burner?

Check for

obstructions

(such as

wasps nests

in exhaust

or air supply

piping)

Stops

operation and

indicates error

code "E-23"

FAILURE

8

9

10

Check and correct or replace the

burner ring

Check or replace room temperature

sensor.

Room temperature sensor malfunction.

Heater operates normally after flame

disappears.

There is flame before ignition.

Check or replace main circuit board

Main circuit board malfunction

Check the power souce

Power source failure

Stops

operation and

indicates error

code "E-0"

Summary of Contents for Laser 300

Page 1: ...VENTED HEATER SERVICE MANUAL Laser 300 TypeA Laser 530 TypeA Laser 560 TypeA Laser 730 TypeA ...

Page 2: ...Normal Detecting Temperatures 1 35 Power Failure Recovery System 1 36 Backup Life 1 37 Deleting The Error Code History 1 38 Detection of Abnormal Electrical Frequency Condition 1 39 Power Button Malfunction 1 40 Low Voltage Detection 1 41 Forced Flame Detection 1 42 Manual Ignitor Cleaning System 1 43 Automatic Ignitor Cleaning System 1 44 Manual Combustion Operation Mode 1 45 High Altitude Settin...

Page 3: ...ntly the heater shuts down and goes through a post purge mode for approx 3 minutes The Laser Heater is equipped with a programmable 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 1 4 Description The Laser Heater is composed of the following A drip tray A cabinet A forced fl...

Page 4: ...the cylindrical space between the tubes Combustion by products are vented through the inner tube As cool air enters the flue pipe it is heated by the hot air that is exiting the system 1 12 Blower Motor Assembly The turbo fan is used for the combustion blower on the intake air side only The exhaust gas is expelled through the flue pipe The blower motor assembly on Laser 560 730 is a dual function ...

Page 5: ...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 Laser 300 Laser 530 Laser 560 Laser 730 20470234 IMPORTANT Withi...

Page 6: ... F 90 C Should a heater overheat internal temperature rises beyond 194 F 90 C the overheat protector switch also called a high limit switch will open to shut off the heater Error code E 12 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 158 F 70 C the system can be restarte...

Page 7: ...the external fuel storage or the removable fuel tank Laser 560 Fuel must be maintained at the level corresponding to the burn mode so that combustion can be conducted efficiently The fuel pump controls the flow of fuel from the fuel sump to the burner through a copper fuel pipe and a fuel nozzle 1 27 Electrical System All electronic diagrams such as the wiring diagram the circuit board and layout ...

Page 8: ...ures L300 L530 above 120 C or 248 F normal L560 L730 above 100 C or 212 F normal 1 35 Power Failure Recovery System The error codes weekly timer setting C F setting Power Saver operation and fuel pump flow setting are stored in the involatile memory and will not be erased due to power failure The time however is stored by the capacitor and will only last for so long This could be 30 minutes or lon...

Page 9: ... the countdown finishes the unit will shift back to normal operation 1 44 Manual Combustion Operation Mode To put the unit in Manual Fuel Pump Operation Mode first have the power button ON and then push and hold the DOWN and UP button at the same time for 3 seconds A buzzer sound will occur To return to normal operation push these buttons again at the same time for 3 seconds the unit will then shi...

Page 10: ...hes at 1 0Hz and counts down every minute The countdown is shown on the right side of the display in double figures as 04 03 02 01 1 47 Flow Volume Setting Mode for The Fuel Pump To adjust the Fuel Pump Flow Rate first get in the Flame Electric Current AD Value FECADV see Manual Fuel Pump Operation above then press both CLEAR and DAY SELECT buttons at the same time for 3 seconds There are 3 fuel p...

Page 11: ...haust pipes must be covered by an insulating cloth cover Check fuel for water and or other contamination If the removable fuel tank is used for Laser 560 the tank filter should be checked cleaned or replaced Also make sure that the fuel supply hose is tightly connected to both the removable fuel tank and the fuel sump Fuel filter or water block filter on the fuel line is recommended Fuel color sho...

Page 12: ...urner bottom Use a small stiff brush or a short piece of soft copper wire to clean any blocked air holes Replace the burner mat if necessary Clean the igniter Gently scrape any carbon deposits from igniter WARNING Be careful when you remove the igniter it may be difficult to loosen and may crack Check air intake pipe exhaust pipe and blower motor assembly every year Replace the air line if it is w...

Page 13: ... turn pull it up slightly to loosen the spring clips 8 Use a wire brush to clean inside the heat exchanger and burner air holes Clean all carbon on the burner bottom by using a flat bladed screw driver or wire brush Vacuum all burner deposits and wipe clean NOTE Make sure that all air inlet openings are clear 9 Remove the igniter and the fuel nozzle from the burner 10 The burner ring may deform an...

Page 14: ...nsor Lo Room temperature is lower than 14 F 10 C Room temperature sensor malfunction or disconnected Check room temperature sensor Should problems arise during operation or ignition use this chart to determine the cause and the proper steps to take Be sure to unplug heater and allow to cool completely before taking corrective measures In the event that heater should extinguish itself without any a...

Page 15: ...er half way B Turn heater to ON C Igniter should start to glow red within 30 40 seconds If the igniter does not glow red check for power at 120V AC or 220V AC and resistance 17 to 19Ω at room temperature of 73 F 23 C CAUTION If igniter malfunctions do not turn the heater to ON repeatedly Otherwise excess fuel may drain in the burner pot STEP 3 Reassembly of Heater Turn the heater to OFF and replac...

Page 16: ...be reprogrammed after the power is restored 3 10 Fuel Contamination Fuel contamination is often difficult to diagnose even though it will adversely affect the heater operation and performance The best course of action to take when fuel contamination is suspected is to examine all of the system sfuel filters beginning with the fuel storage tank If a Laser kerosene lifter is part of the fueling syst...

Page 17: ... the blower motor and other parts if necessary STEP 1 Cleaning the Exhaust Fan A Remove the blower motor case from the heater base Remove the top cover B Loosen the set screw that secures the exhaust fan to the motor shaft Remove the retaining nut NOTE 2 0 mm 5 64 in hex key and 7 mm 9 32 in socket are required C Remove the exhaust fan Clean the fan and the housing D Re assemble the exhaust fan an...

Page 18: ...B 55 7 14 174 8 46 124 3 78 100 2 AA 79 9 DC 55 0 15 172 8 47 123 7 79 99 8 AB 79 5 DD 54 3 16 170 9 48 123 1 7A 99 3 AC 79 1 DE 53 7 17 169 1 49 122 5 7B 98 9 AD 78 7 DF 53 0 18 167 3 4A 121 9 7C 98 5 AE 78 3 E0 52 3 19 165 7 4B 121 4 7D 98 1 AF 77 8 E1 51 5 1A 164 1 4C 120 8 7E 97 7 B0 77 4 E2 50 8 1B 162 5 4D 120 3 7F 97 3 B1 77 0 E3 50 0 1C 161 1 4E 119 7 80 96 9 B2 76 5 E4 49 2 1D 159 7 4F 11...

Page 19: ... 8 77 0 6 A9 0 4 DB 0 1 14 than 46 0 8 78 0 6 AA 0 4 DC 0 1 15 1 47 0 8 79 0 6 AB 0 4 DD 0 1 16 48 0 8 7A 0 6 AC 0 4 DE 0 1 17 49 0 8 7B 0 6 AD 0 4 DF 0 1 18 4A 0 8 7C 0 6 AE 0 3 E0 0 1 19 4B 0 8 7D 0 6 AF 0 3 E1 0 1 1A 4C 0 8 7E 0 6 B0 0 3 E2 0 1 1B 4D 0 8 7F 0 6 B1 0 3 E3 0 1 1C 4E 0 8 80 0 6 B2 0 3 E4 0 1 1D 4F 0 8 81 0 5 B3 0 3 E5 0 1 1E 50 0 8 82 0 5 B4 0 3 E6 0 1 1F 51 0 8 83 0 5 B5 0 3 E7 0...

Page 20: ...18 SERVICE MANUAL ...

Page 21: ...SERVICE MANUAL 19 L A S E R H E A T I N G S Y S T E M S Trouble Shooting Section 4 4 1 Electrical System BL GY BK RD GN BK YL WT BL WT RD RD YL OR RD BN CL ...

Page 22: ...ONENT READING TAKEN AT Laser300 Laser530 Laser560 Laser 730 730AT Fuel Pump F P CN17 OR to YL DC 24V 15 Igniter I H CN2 AC 120V 15 Transformer TF1 TP 5V to F R GN CN6 DC 5V 15 TP 12V to F R GN CN6 DC 12V 15 TP 28V to F R GN CN6 DC 28V 15 Transformer TF2 Primary Side 1 to 4 AC 120V 15 Secondary Side 5 to 8 AC 140V 15 Circulation Fan Motor F M CN4 Motor connected High AC 118V 15 AC 118V 15 AC 118V 1...

Page 23: ...ng T3 5 2 sec Shift to M2 after flame detection 4 Blower motor BM delay timing T4 15 3 sec At start 5 Fan motor FM starting timing T5 120 10 sec 6 Fan motor H speed timing T6 5 3 sec At start 7 Pre combustion timing T7 300 15 sec 8 BM delay timing T8 5 2 sec 9 Fuel pump delay timing T9 1 0 5 sec 10 FM delay timing T10 30 5 sec 11 Post purge timing T11 180 10 sec No flame after detection 12 Miss ig...

Page 24: ...ng combustion shift to extinguishing process and stop operation Only when the detection current exceeds 0 6 A 1 Detection current More than 0 6 A recommended value is 0 3 A 2 Allowable leakage resistance More than 1 5 M 3 Room thermistor Thermistor used is B constant 4100 resistance at 25 deg C is 10 K 1 Maximum set temperature 32 7 2 3 Shall display 90 deg F 2 Minimum set temperature 10 4 2 0 Sha...

Page 25: ...l room thermistor combustion control after T7 ends For the set temperature Less than 1 0 deg 1 0 to 0 deg Over 0 deg High combustion Medium combustion Low combustion 2 0 7deg Flame extinguishing begins when the set temperature is exceeded by more than 2 degrees C Operation begins again when the temperature inside the room falls below the set temperature during the flame extinguishing process 9 Pow...

Page 26: ...sed is B constant 5250 resistance at 25 deg C is 8 02 K 5 Fuel pump frequency control H combustion H1 combustion M combustion M1 combustion M2 combustion L combustion A 15 970 0 5Hz B 20 540 0 5Hz A 14 373 0 5Hz B 18 486 0 5Hz A 11 380 0 5Hz B 14 263 0 5Hz A 11 380 0 5Hz B 14 263 0 5Hz A 7 985 0 5Hz B 10 269 0 5Hz A 6 330 0 5Hz B 7 990 0 5Hz 6 1 Blower motor control Speed 1 minute average High H M...

Page 27: ...ull wave B Full wave A 5 1 ON OFF B 3 1 ON OFF A 2 1 ON OFF B 1 3 ON OFF 8 Overheat protector Abnormal overheat detection When normal ON When abnormal overheat is detected When abnormal overheat is detected during electromagnetic pump operation shift to extinguishing process and stop operation Display E 12 9 Power failure recovery system More than 30 minutes Keep in memory of current time set time...

Page 28: ...L M H T5 T6 T21 T10 T10 H M H M L M H M A B A B Flash3 Lit Lit Flash1 Flash2 Flash2 FlashB LitC LitC LitB LitA LitB LitC time set temperature room temperature time set temperature room temperature time room temperature and set temperature Flashing frequency Burning mode indicator RT ST Flash1 2 0Hz A RT ST 1 0 Flash2 0 5Hz B RT ST 2 0 Flash3 1 0Hz C RT ST RT ST 1 0 Buzzer RT ST 6 0 A on 100msec B ...

Page 29: ... H M L M L1 H M1 M1 M2 H1 H M L M1 M2 T5 T6 T21 T10 T10 H M H M L M A A Flash3 Lit Lit Flash3 Flash1 Lit Flash1 Flash2 FlashB LitC LitB LitA FlashB time set temperature room temperature room temperature and set temperature Flashing frequency Burning mode indicator RT ST Flash1 2 0Hz A RT ST 1 0 Flash2 0 5Hz B RT ST 2 0 Flash3 1 0Hz C RT ST RT ST 1 0 Buzzer RT ST 6 0 A on 100msec Title Class Remark...

Page 30: ... A A Flash3 Lit Lit Flash3 Flash1 Lit Flash1 Flash2 FlashB LitC LitB LitA FlashB Lit time set temperature room temperature room temperature and set temperature Flashing frequency Burning mode indicator RT ST Flash1 2 0Hz A RT ST 1 0 Flash2 0 5Hz B RT ST 2 0 Flash3 1 0Hz C RT ST RT ST 1 0 Buzzer RT ST 6 0 A on 100msec Title Class Remarks other indicator Burning mode indicator AUTO indicator TIMER i...

Page 31: ...H M M H M M1 M H M M H M A D D Flash3 Flash1 Lit Flash2 FlashB LitB LitC time E 2 time E 6 time room temperature and set temperature Flashing frequency Burning mode indicator RT ST Flash1 2 0Hz A RT ST 1 0 Flash2 0 5Hz B RT ST 2 0 Flash3 1 0Hz C RT ST RT ST 1 0 Buzzer RT ST 6 0 A on 100msec D on 100msec off 100msec 25times Title Class Remarks Burning mode indicator Fuel pump AUTO indicator TIMER i...

Page 32: ... M A D A D A D Flash3 Flash1 Flash3 Flash1 Flash3 Flash1 FlashB FlashB FlashB E 2 time E 2 time E 2 2 room temperature and set temperature Flashing frequency Burning mode indicator RT ST Flash1 2 0Hz A RT ST 1 0 Flash2 0 5Hz B RT ST 2 0 Flash3 1 0Hz C RT ST RT ST 1 0 Buzzer RT ST 6 0 A on 100msec D on 100msec off 100msec 25times Title Class Remarks AUTO indicator TIMER indicator other indicator ti...

Page 33: ... H H A D D Flash3 Flash2 time E 8 time time E 2 3 time room temperature and set temperature Flashing frequency Burning mode indicator RT ST Flash1 2 0Hz A RT ST 1 0 Flash2 0 5Hz B RT ST 2 0 Flash3 1 0Hz C RT ST RT ST 1 0 Buzzer RT ST 6 0 A on 100msec D on 100msec off 100msec 25times Title Class Remarks AUTO indicator Fuel pump Fan motor Buzzer Blower motor TIMER indicator other indicator POWER SAV...

Page 34: ...H M H M H M2 H1 H H M H M D D Lit Flash2 Lit Flash2 LitC LitC FlashB E 12 time E 13 time room temperature and set temperature Flashing frequency Burning mode indicator RT ST Flash1 2 0Hz A RT ST 1 0 Flash2 0 5Hz B RT ST 2 0 Flash3 1 0Hz C RT ST RT ST 1 0 Buzzer D on 100msec off 100msec 25times RT ST 6 0 Burner thermistor Ⓐ Laser300 530 200 40kΩ Laser560 730 450 90kΩ Title Class Remarks Blower moto...

Page 35: ... at room temp over 95F 35C Room temp is too high Yes No Yes No Check if the direction insertion and contact terminal of ribbon cable is correct Nomal Change fuse and plug in power cord Melted Check fuse Room temp exceeds set temp No Yes No Room temp is over 95F Yes Yes Room temp indicates HI Yes Yes Digital indicator lamp lit Does not operate 1 2 No No Yes Check blower motor if blower fan rotates ...

Page 36: ...l Check and correct wiring Disconnected or incorrect wiring Check and clean fuel nozzle Clogged fuel nozzle Clean fuel nozle Fuel nozzle is clogged Check or replace fuel pump Fuel pump malfunction Correct or replace wires Wiring failure Check or replace main circuit board Main circuit board malfunction Check or replace main circuit board Main circuit board malfunction Water gathering in fuel tank ...

Page 37: ...Fuel not fed because of surface tension of water Check and correct wiring Disconnected or incorrect wiring Check and clean fuel nozzle Clogged fuel nozzle Clean fuel nozle Fuel nozzle is clogged Check or replace fuel pump Fuel pump malfunction Correct or replace wires Wiring failure Check or replace main circuit board Main circuit board malfunction Water gathering in fuel tank Check or replace fue...

Page 38: ...nction Check and clean fuel pipe Check blower motor Check fuel pump Fuel drain in bumer Remove fuel in the burner Heater won t re start by the power switch Unplug the heater Ignition failure occured three times consecutively with E 2 error code Fuel may accumulate in the bumer Correct or replace wires Wiring failure Yes No Yes No Yes No Is window curtain too close to the rear of unit The overheat ...

Page 39: ... Normal Abnormal Yes No Is a unit placed hori zontally Room temp is below 14 F 10 C Yes No Check if the power source is 120V 60Hz Room temp indicates LO Yellow high flame whistling noise or smoke produced when set HIGH Does blower motor work properly Check out side end of flue pipe for flow of air and exhaust Normal Abnormal Yes No Burner ring sit properly in the burner Check for obstructions such...

Page 40: ... Shooting Section 4 2 7 45 45 45 45 60 19 33 28 45 11 27 12 37 26 25 46 14 15 41 16 13 50 58 18 23 40 22 24 50 50 9 50 17 3 66 8 30 59 32 38 45 6 48 4 5 31 45 45 29 67 68 20 21 50 52 39 42 57 54 55 55 53 56 57 1 48 36 61 63 65 64 45 10 34 47 35 43 45 51 48 46 49 62 47 44 Laser 300 4 3 Parts Description ...

Page 41: ...9 Drip tray BK 48 20470756 Screw 4D BK 10 20470252 Leveler fuel pipe 49 20477084 Screw F5 11 20479530 Pressure relief plate 50 20474050 Screw C 12 20470244 Heat exchanger 51 20474048 Screw B 13 20479593 Heat chamber gasket 52 20479585 Outside nozzle gasket 14 20479543 Burner ring 53 20474925 Oil catch 15 20470242 Burner assembly 54 20479584 Bent joint 16 20479594 Burner gasket 55 20474975 L shaped...

Page 42: ... Shooting Section 4 2 57 44 58 57 6 4 41 44 62 57 42 43 57 45 57 35 34 67 36 52 40 11 38 39 37 56 5 50 48 47 46 47 49 49 51 20 24 31 23 25 57 10 29 55 30 17 18 19 54 22 28 27 57 26 57 57 21 61 55 33 32 59 53 57 13 14 15 16 3 66 1 12 57 57 57 8 53 53 60 7 9 63 65 64 68 69 Laser 530 4 3 Parts Description ...

Page 43: ...ket 51 20474925 Oil catch 16 20479844 Heat exchanger 52 20470220 Screw 4I 17 20478343 Burner ring 53 20455862 Screw S2 18 20479893 Heat exchanger gasket 54 20474048 Screw B 19 20479842 Burner assembly 55 20476452 Screw B2 20 20479894 Burner gasket 56 20470353 Screw 4P 21 20479811 Primary flame rod 57 20470254 Screw 4J 22 20470273 Burner thermistor 58 20470355 Screw 4Q 23 20470218 Igniter 59 204783...

Page 44: ...63 44 58 58 13 58 56 74 59 66 12 62 58 48 43 42 49 41 46 80 79 46 79 78 2 9 3 45 27 65 64 69 25 26 75 24 15 22 60 77 14 17 76 72 16 58 23 73 5 58 71 20 19 18 21 58 58 32 28 31 58 70 29 68 30 60 34 58 33 4 50 36 37 62 47 35 61 58 38 39 40 58 78 10 57 8 7 1 34 57 58 58 6 51 84 67 85 82 81 83 81 82 55 52 Laser 560 4 3 Parts Description ...

Page 45: ...niter gasket 63 20450220 Screw 4l 20 20479521 Igniter guide gasket 64 20478091 Screw 1U 21 20474920 Igniter cover 65 20478090 Screw 1T 22 20470411 Primary flame rod 66 20470666 Screw 4C 23 20475094 Burner gasket 67 20474272 Screw M 24 20475093 Heat chamber gasket 68 20475874 Washer for blower motor 25 20475831 Mica window 69 20478509 Heat chamber assembly 26 20475881 Peep window gasket 70 20474983...

Page 46: ...0 AT 4 3 Parts Description 3 4 13 14 66 66 9 10 a 64 65 58 67 15 83 75 66 66 70 57 61 64 65 3 4 11 12 5 71 60 49 50 81 55 53 a 74 59 7 8 64 65 1 2 66 85 56 69 41 40 42 36 34 73 35 86 37 84 76 66 19 16 39 72 32 62 66 31 17 29 30 80 66 66 38 33 18 68 28 27 77 79 26 24 23 66 6 78 22 25 66 66 21 20 63 66 82 66 45 44 43 48 46 47 52 51 54 51 52 ...

Page 47: ...478643 Burner ring 63 20479885 Outside nozzle gasket 20 20478026 Fuel nozzle 64 20455862 Screw S2 21 20478383 Fuel nozzle gasket 65 20470756 Screw 4D Laser 730AT 22 20470218 Igniter 66 20470254 Screw 4J 23 17187582 Igniter gasket 67 20474039 Insulator A 24 20479521 Igniter guide gasket 68 20474057 Flange nut 25 20474920 Igniter cover 69 20470353 Screw 4P 26 20470611 Primary flame rod 70 20470355 S...

Page 48: ...TOYOTOMI U S A INC 604 Federal Road Brookfield CT 06804 www toyotomiusa com Printed in Japan New 11 15 Part B1500021 ...

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