MONITOR HEATING SYSTEMS Service Manual

MONITOR HEATING SYSTEMSService Manual

MONITOR 422 MONITOR 441

The information contained herein is proprietary to Monitor Products. Inc. shall not be disclosed, duplicated, norotherwise copied in whole or part for any other purpose without express written permission of the LegalDepartment of Monitor Products. Inc. This data is issued to authorized Monitor Servicing Personnel for guidancein the installation and maintenance of the subject product and is intended for use by authorized Monitor servicepersonnel only. Further, Monitor Products, Inc. reserves the right to make improvements and corrections and toalter specifications of products described herein, at any time without prior notice

P.O.BOX3408PRINCETON, NEW JERSEY 08543

MONITOR HEATING SYSTEMSTable of Contents

Section 1: Description Pa9e 1 71-1 Specifications: 1-2 Special Features: 1-3 Safety Features:t-4 Description; 1-5 Spill Tray: 1-6 Heater Cabinet: 1-7 Combus-tion System: 1-8 Combustion Chamber: 1-9 Burner Pot; 1-10 Combus-tion Ring Assembly: 1-11 Burner Cap: 1-12 Flame Sensor; 1-13 Igniter;1-14 Combustion Air System: 1-15 Flue Pipe: 1-16 Combustion Blower:1-17 Heat Exchanger: 1-18 Air Circulation Fan; 1-19 Air PressureSwitch; 1-20 Fuel Delivery System; 1-21 External Fuel Tank; 1-22Fusible,Link Valve: 1-23 Fuel Constant Level Valve; 1-24 SolenoidPump: 1-25 Electrical System; 1-26 Microprocessor; 1-27 Tempera-ture Sensor; 1-28 Safety Mechanism; 1-29 Cloth Covered ExhaustPipe; 1-30 Air Circulation Fan Guard; 1-31 Fuse; 1-32 OverheatProtector Switches : 1-33 Slide Selector For the Reset Temp.

Section 2: Installation Page 9-212-1 Introduction; 2-2 Physical Placement of Heater 2-3 DrillingRequirements: 2-4 Power Requirements; 2-5 Fuel Tank Require-ments: 2-6 Temperature Sensor Wiring Requirements; 2-7 BuildingCodes: 2-8 Un-packing; 2-9 Heater Installation; 2-10 Installing anExtension Kit; 2-11 Typical Monitor Lifter Pump Installations; 2-12Uses for the Elbow Adapter Kit; 2-13 Fuel Tank Installation; 2-14Heater Installation

Section 3: Operation Page 23-343-1 Introduction; 3-2 Operating Specifications; 3-3 Operating Con-trols and Indicators; 3-4 Pre-operation Check List 3-5 Operation; 3-6Manual Heater Operation: 3-7 Automatic Heater Operation; 3-8Reprogrammmg the Monitor Heater: 3-9 Heat Sensor; 3-10 MonitorShutdown: 3-11 Out of Fuel; 3-12 Recovery from a Power Failure; 3-13Recovery from Overheat Condition; 3-14 Recovery from Blown Fuse3-15 Operation Control system

Section 4: Maintenance Page 35-384-1 Introduction; 4-2 Periodic Maintenance: 4-3 Inspect Exhaust AirPiping; 4-4 Verify Igniter Operation, 4-5 Clean Fuel Constant LevelValve Filter; 4-6 Cleaning Fusible Link Valve Intake Fitting on M-422;4-7 Corrective Maintenance: 4-8 Replacement of Fuses; 4-9 FuelContamination

MONITOR HEATING SYSTEMSTable of Contents

)Section 5: Servicing Page 39 - 41

5-1 Introduction; 5-2 Measurerment of Fuel Flow rate; 5-3 Removal ofWater Deposits and Contaminants from Fuel Constant Level Valveand Fuel Lines: 5-4 Cleaning the Bum Chamber 4 Burner Pot: 5-5Cleaning the Fuel Inlet

Section 6: Troubleshooting Page 43-56Resistance Valuescomponent Voltage ReadingsTest Point VoltageTroubleshooting Diagrams (Mechanical)Troubleshooting Diagrams (Electrical)Indication of Failure mode

Section 7: Electrical System Page 58-66SchematicMonitor 441 Printed Circuit Board Wiring DiagramMonitor 422 Printed Circuit Board Wiring Diagram

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MONITOR HEATING SYSTEMSSection 1: Description

1-1 SPECIFICATIONS

ModelFuel TypeHeater Efficiency

Monitor 441Crystal Clear K-i Kerosene93% '

Monitor 422Crystal Clear K-1 Kerosene93%'

Heat Rating High:43.000 8TU/hourH.Medium:33,900 BTU/hourLMedium:21.000 BTU/hourLow:l6.200 BTU/hour

High:22.000 BTU/hourH.Medium:17,400 BTU/hourL.Medium:11,700 BTU/hourLow:9.600 BTU/hour

Heater Output High:40.000 BTU/hourH.Medium: 31,500 BTU/hourLMedium: 19,500 BTU/hourLow: 15.000 BTU/hour

High:20,400 BTU/hourH.Medium: 16.200 BTU/hourLMedium: 10,900 BTU/hourLow: 8,900 BTU/hour

Fuel Tank SeparateiNot supplied with heater) 1.32 Gallons; Separate tank optionalFuel Consumption High: 0.319 Gallon/hour

H.Medium: 0 25 Gallon/hourL.Medium: 0.16 Gallon/hourLow 0.12 Gallon/hour

High: 0.164 Gallon/hourH.Medium: 0.13 Gallon/hourL.Medium: 0.09 Gallon/hourLow: 0.07 Gallon/hour

Power Source 120 Volts AC; 60 Hz. 120 Volts AC; 60 Hz.Power Consumption Ignition: 340 Watts

Operation: 80 Watts (Average)Ignition: 250 WattsOperation: 55 Watts (Average)

Heated Air Delivery High: 388 Cubic feet/minuteH.Medium: 388 Cubic feet/minuteLMedium: 300 Cubic feet/minuteLow: 300 Cubic feet/minute

High: 176 Cubic feet/minuteH.Medium: 176 Cubic feet/minuteLMedium: 113 Cubic feet/minuteLow: 113 Cubic feet/minute

Vent Pipe HoleDimensions

Weight

2 'Hnches DiameterHeight: 26.6 inchesWidth: 28.7 inchesDepth: 13.8 inches82 Pounds, empty

2 Y* -inches DiameterHeight 25.6 inchesWidth: 20.9 inchesDepth: 12.4 inches55 Pounds, empty

* When considering heat of condensation is lost tnen net efficiency

1-2 SPECIAL FEATURESAUTOMATIC IGNITIONMemory Back Up: Set memory can be kept in case

of power failure for up to 5 minutes.Dual Blowers: Separate fans for combustion and

room air circulation.Thermostatically Controlled: Adjusts to the desired

room temperature.Built-in Timer: Heater will automatically operate as

programmed by the user.Automatic Reset After Power Failure: Heater will

automatically resume operation after power isrestored.

Indicator Lights: Easy-to-see signals show-whenheater is in operation, when timer is activated.and when the burner is operating in low, mediumor high modes.

Choice of Fuel Supply: Large tank gravity fedsystem, large tank system with pump.(M-44i)Built-in capsule tank or connect to separate tank.(M-422)

Multiple Heat Exchanger: Extracts 87% of heat fromburner.

S 87%.

Clean Operation: Products of combustion are ventedoutside.

Consumes No Room Air Air for combustion is drawnfrom outside.

Easy Installation: Complete instructions included inthis guide.

1-3 SAFETY FEATURESSAFE RE-LIGHTING: Heater will not restart until its

combustion chamber has cooled.ELECTRICAL PROTECTION: Heater automatically

shuts off in the unlikely event of a malfunction inthe electrical circuitry or disruption of the powersupply.

NO EXHAUST IN ROOM: Products of combustionare discharged outdoors.

FLUE PIPE: Outside air is drawn through a pipe-within-a-pipe venting system. This processpreheats combustion air and regains heat fromexhaust gases.

1-4 DESCRIPTIONThe Monitor heaters are composed of the following:


a SDMI tray, a cabinet, a combustion system, an aircirculation system, a fuel delivery system, electricaland electronics systems and a variety of safetymechanisms.1-5 SPILL TRAYThe Spill Tray:

— Protects the floor from damage resulting fromfuel spillage.

— Provides a secure, tip-resistant heater baseMetal retainers (2) secure the heater to the SpillTray.The legs are positioned with in the circular indenta-tions.

1-6 HEATER CABINETA steel Cabinet holds and protects all internalcomponents.A number of primary parts are assembled to formthis housing.

1-7 COMBUSTION SYSTEMThe Combustion System is responsible for theproduction of heat which is circulated into the room.In the Combustion Systems a mixture of fuel and airis burned to produce heat. Air is drawn from outsidethe dwelling into the Combustion Chamber. At thesame time, fuel is metered from a storage cavity intothis same Combustion Chamber.Within the cham-ber.the air fuel mixture is ignited to produce heat.The Monitor combustion systems are safeguardedby a pair of overheat protector switches; They willshut down the heater (to protect it from damage) inthe event of excessive heat build-up. The overheatprotector switches reset automatically after coolingdown.

1-8 COMBUSTION CHAMBERThis tall cylinder is positioned on the Heater Base.It is secured to the base by phillips head screws.Connected to the Combustion Chamber are theigniter, (located within the chamber) a fuel line, theHeat Exchanger, and a Flame Sensor.Within the Combustion Chamber are the Burner Pot.the Combustion Ring Assembly and the BurnerCap(M-422). Access to those internally-locatedparts is facilitated by a removable Service panel.A Window on the panel lets the technician visuallyexamine the combustion process(i.e. glowing igniteror proper flame color).An airway, in the Cabinet Base, extends from theintake fan of the Combustion Blower to the hollowbase of the Combustion Chamber. This airwaychannels air to the Combustion Chamber.The Flame Sensor is mounted with two (2) phillipshead screws onto the wall of the CombustionChamber.

1-9 BURNER POTDesigned specifically to support combustion, theBurner Pot (refer to Figure 1-2) contains a series ofair holes, an igniter tube (to accommodate theIgniter), and a fuel inlet fitting (interconnects the fuelline). It is secured to a mounting plate near thebottom c" 'he Combustion Chamber.The Combustion Ring Assembly is seated on three(3) screws or pins in the Burner Pot.

1-10 COMBUSTION RING ASSEMBLYThis assembly is a special structure, designed topromote efficient combustion.

1-11 BURNER CAPSecured by tabs and a screw on the Burner Pot, theBurner Cap "shapes" the flame into its configurationand height. (M-422 only)

1-12 FLAME SENSORMounted on the outside wall of Combustion Cham-ber, the Flame Sensor always supervises the flame.

1-13 IGNITERLocated within the igniter tube of the Burner Pot, theIgniter is designed to pre-heat the Burner Pot and tovaporize and ignite the air fuel mixture to start thecombustion process.The Igniter is secured by a bracket and screw to theigniter tube. The cover plate is secured to thecombustion chamber by three (3) phillips headscrews.

1-14 COMBUSTION AIR SYSTEMThe Combustion Air System channels air to andfrom the heater.Outside air is drawn into the heater by the Combus-tion Blower through an airway to the CombustionChamber.A Combustion Blower draws the intake air into thethrough a Flue Pipe. This air enters the CombustionChamber at the Burner Pot and mixes with the fuelto support combustion. Remaining air is heated andis drawn into the Heat Exchanger.As the heated air passes through the Heat Exchan-ger, an Air Circulation Fan blows room air past theHeat Exchanger and out again into the room, heat-ing passing air by convection. Exhaust vapors exit-ing from the Hear Exchanger are vented through theFlue Pipe.A deterioration of air pressure at the Air PressureSwitch is an abnormal condition; the heater is shutdown by the malfunction.


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1-15 FLUE PIPEFlue Pipes are available in three (3) sizes. Thisprovides the flexibility to meet the installationrequirements for dwelling of various wall thicknes-ses.One side of the Flue Pipe contains a "T"-shapedfitting consisting of four ports. This side is mountedon the interior wall of the dwelling. The pipe side ofthe Flue Pipe is vented outside the dwelling.The Flue Pipe Assembly consists of two concentrictubes. Outside air is drawn through the cylindricalspace between the tubes.Combustion by-products are vented through theinner tube.As the cool air enters, it is heated by the hot air thatis exiting the system.A large-bore, flexible hose connects the air inlet porton the Flue Pipe with the Combustion Blower; acloth-covered metal pipe connects the CombustionBlower with the exhaust outlet on the Flue Pipe.

IMPORTANT: If extension Kits are utilized, use thecorrect damper as follows:

Extension kit M-441 M-422Up to 3 elbows with E«r-i 'STANDARD" "STANDARD"Short Extension kit damper damperLength: 1V ;"-7! ,"

Table 1-1 COMBUSTION AIR CONTROL

Uo to 3 elbows withShort Extension KitLength: IV ;'\-20! ,"

Up to 3 elbows withMedium Extension KitLength: 20' , -38"

Up to 3 elbows withLong Extension KitLength: 38"-73"

•STANDARD" "STANDARD"damper damper

"EXTENSION"damper

"EXTENSION"damper

unused

unused

1-16 COMBUSTION BLOWERThe combustion blower on the Monitor 422 is a dualfunction fan.The intake fan draws in outside air thru the flue pipefor internal combustion. The cooling fan which runson a common shaft with the intake fan circulates airinside the heater cabinet to keep internal compo-nents cool.

The Monitor 441 combustion blower has a two stageintake fan.Burner modes control fan speeds and the solenoiddamper in the blower casing. Those functions are asfollows:

Burn Mode

High

Medium-High

Medium-Low

Low

Fan Speed Solenoid Damper

High

Medium-High

Low

Low

Off (Open)

Off i Open i

On (Close)

On (Close)v ,

1-17 HEAT EXCHANGERAn inlet at the too of the Heat Exchanger permits theheated air to travel from the Combustion Chamberinto the exchanger.An outlet, at the bottom of the exchanger, permitscombustion by-products to be vented to the FluePipe.While moving through the Heat Exchanger, the hotair within the exchanger heats the outside metalwalls. The hot metal walls, in turn, heat air that ispushed past the exchanger and is circulated intothe room. An air baffle, directly in front of theexchanger, deflects the heated air upwards, and out,through the louver assembly.A pair of Over-Heat Protector Switches protect theheater from damage due to excessive heat built-up.

1-18 AIR CIRCULATION FANBoth Monitor circulation fans are driven by two-speed motors and are designed to circulate theheated room air.If the heater is running in low and medium-low burnmodes, the fan also runs at low-speed; in medium-high or high burn modes, the fan advances tohigh-speed.Operation of the fan is controlled by the micro-processor and fan thermostat switch.Physically assembled with a protective wire cage forthe Monitor 441 and 422, the entire fan assemblyis secured to a bracket on the rear of the HeaterCabinet.A metal conduit, at the rear of the heater, protectsthe fan wiring from damage.

1-19 AIR PRESSURE SWITCHThis switch consists of a rubber diaphragm whichsenses changes in air pressure(it is connected tothe Combustion Blower) and normally-open, microswitch.Should an abnormal pressure differential exist theswitch opens to disable the circuitry that controlsthe supply of fuel. Since the flow of fuel to the Burner


Pot <s cut off.the flame extinguishes (after all fuelcurrently in the line has been consumed), and theBurner Status Indicators blink.

This safety mechanism can be triggered by severalconditions:

— Leak or loose connection in air line- Leak, loose, or broken tubing which connects

the Air Pressure Switch with the CombustionBlower

- Clogged or blocked Air Line- Blocked or clogged Flue Pipe- Intake port of Combustion Blower is blocked.- Combustion Blower is inoperable

1-20 FUEL DEUVERY SYSTEMFuel Delivery is a very important aspect of theMonitor s operation.The fuel flow must be maintained at a level corre-sponding to the bum mode, so that combustion canbe conducted efficiently.Fuel moves by gravity-flow from the external fuelstorage tank or the capsule fuel tank to the FuelConstant Level Valve.The Solenoid Pump meters the flow of fuel from theFuel Constant Level Valve to the Burner Pot.The metered flow of fuel is carried to the Burner Potby a copper fuel line.

1-21 EXTERNAL FUEL TANKThe Monitor 422 gives the user the option of eitherusing the internal capsule tank or hooking up to anexternal fuel tank.Fuel for the Monitors can be stored in, and fed froman external storage tank. The tank, which generallyis dealer installed, should contain a shutoff valve, afuel filter and a vent. Installation of the tank shouldconform to local regulations and to the specifica-tions and guidelines documented in this ServiceManual.(Capsule tank cannot be used in Connecticut andMassachusetts.)1-22 FUSIBLE UNK VALVEBasically, the Fusible Link Valve is a safety mecha-nism that cuts-off fuel to the heater m the event ofan overheat condition at the valve.The fusible link valve is mounted as a standard itemon the Monitor 422. Located outside the rear of theHeater Cabinet, the Fusible Link Valve is a spring-loaded device that cuts off the supply of fuel to theheater when the temperature level (at the valve)exceeds a predefined maximum limit.An inlet on the bottom of the valve allows fuel to

pass into the heater The hardle-wnich can alsomanually be opened or closed-sits on a spring-loaded stem which contains a low-meiting pointalloy.The fusible link valve can be externally mounted onthe Monitor 441 if required.

1-23 FUEL CONSTANT LEVEL VALVEThis valve has an automatic shutoff safety mecha-nism and a Fuel Set Lever. The safety mechanismprevents fuel from flooding or overflowing from thefuel reservoir. The Fuel Set Lever resets the float sothe Fuel Constant Level Valve can resume opera-tion.The fuel reservoir is a tank which contains a floatassembly, a safety mechanism, and a priming lever.Both the Monitor 441 and 422 fuel control valves arebasically the same, however they are of differentsize and material and can not be interchanged.Fuel enters the Fuel Constant Level Valve throughan inlet at the bottom of the reservoir. As the levelof fuel rises, it passes through a filter (whichremoves most particles and foreign matter from thefuel), flows up through an open inlet valve andenters the tank.

IMPORTANT: The Fuel Constant Level Valve filtershould be cleaned or replaced peri-odically. Time intervals will dependon purity and quality of fuel.

Within the Valve, a float mechanism controls thelevel of fuel that will be permitted to the reservoir. Asthe fuel level drops, the float drops down to increasethe inlet valve opening to admit more fuel into thevalve. When the fuel level reaches its maximumvolume, the float rises to shut the inlet valve.in the event that fuel within the reservoir rises to anabnormally high level, a float within the reservoirrises to trip a safety lever. This safety lever drops toprevent fuel from entering into the reservoir.Should a foreign substance cause the inlet valve tostick (or prevent it from opening), the Fuel Set Leveris utilized to free the valve and to admit fuel to thereservoir.

CAUTION: Care must be taken to preventdust, dirt, or other debris fromclogging or blocking the inletvalve. If debris collects on theseat of the inlet valve it maycause tripping of the safety leverand will require cleaning.

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1-24 SOLENOID PUMPThe Solenoid Pump is mounted on the Fuel Con-stant Level Valve, controlled by a microcessor.andfour modes (High. Medium-High, Medium-Low. Low)fuel flow is delivered to the Burner Pot.

1-25 ELECTRICAL SYSTEMElectrical power is supplied to the Monitor to run theMicroprocessor and the other electrically-energizedcomponent.Electrical operation of the Monitor can be thought ofas having the following eight(8) distinct phases:plugm; turn-on; pre-purge pre-heat; ignition; pre-combustion; heating; Shutdown and post-purge.All electronic diagrams. Such as wiring diagram,circuit board layout, and electrical schematic can befound in Section 7 of this Service Manual.

1-26 MICROPROCESSORPrincipally consisting of a 54-pin Integrated Circuit,the Microprocessor provides safety timings, controlsrelays and provides clock and thermostat functionsfor the Monitor heater. A component layout of thePrinted Circuit Board is found in Section 7 of thisService Manual.

1-27 TEMPERATURE SENSORThe sensor which is capable of sensing room tem-perature within a range of 42T to 96'F, can be leftmounted on the back of the heater cabinet or bewall mounted.Approximately 6' .'. (about 200 cm) of No, 20 AWGWire is supplied with the sensor to facilitate wallmounting the sensor in a favorable location.

1-28 SAFETY MECHANISMSSeveral safety mechanisms have been built into theMonitor Heating System. These devices protect theuser against personal injury, protect the heateragainst damage, and shutdown the heater if amalfunction occurs.

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1-29 CLOTH COVERED EXHAUST PIPEInsulating cloth covers are to be placed over allmetal surfaces of the Exhaust Line during installa-tion.Since combustion by-products are vented at ele-vated temperatures, the Exhaust Pipe will becomehot during operation. The insulating cloth coversprotect the user from burn hazards associated withaccidental contact with these heated metaf sur-faces.

During installation make sure that all Exhaust L.resare tight. Do not operate the heater without theinsulating covers.

1-30 AIR CIRCULATION FAN GUARDThis guard is an integral part of the fan assemoiyThe guard protects the user against physical miurywhich could occur from accidental contact withrevolving metal fan blade.

1-31 FUSE2-amp. and 10-amp.. 125VAC, fuses protect theheater from damage resulting from power overloads.In the event of a power surge or internal wiringhazards, the fuse opens and power to the heater iscut off.The electrical outlet into which the heater is con-nected should be protected by at least a 15-amp.fuse or circuit breaker.

1-32 OVERHEAT PROTECTOR SWITCHESConnected in series, two (2) normally-closed Over-heat Protector Switches safeguard the heatersagainst damage due to overheating.The Monitor 422 switches are rated 110'C (230'F).The Monitor 441 switches are rated 115'C (239'R.Should a Monitor overheat (internal temperaturesrise beyond 110'C (230'F) on me Monitor 422. 115'C(239'R on the Monitor 441) either or both switcheswill open to shut down the heater. After extinguish-ing the flame, the Burner Status indicators continueto blink. The Overheat Protector Switches will auto-matically reset after cooling down.Once the heater has cooled to 90'C (194'F), thesystem can be restarted. To restart the Monitor,proceed as follows:

A. Press ON OFF Switch to OFF.B. Allow heater to cool.C. Troubleshoot the cause of the overheat.D. Press ON OFF switch to ONE. Proceed with normal operation.

V33 SLIDE SELECTOR FOR THE RESET TEMP.Once power is restored after power interruption bypower failure or by disconnecting heater plug fromwall outlet, heater will resume operation in theMANUAL mode and maintain room temperatureaccording to the setting temperature selected byusing the selector for the reset temperature at thelower right hand side of the cabinet.


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MONITOR HEATING SYSTEMSSection 2: Installation

2-1 INTRODUCTIONInstalling the Monitor System at the user s locationcan oe cerformed quickly and economically. TheMonitor 422 can oe used as either an internally fueled(capsule tank) or remotely fueled System. TheMonitor 441 model is strictly a remotely fueledsystem and both are externally vented. As such bothneed the installation of an externally vented intakeexhaust system and if remotely fueled, will need theinstallation of a remote fuel storage tank.By completing each step of the easy-to-followinstallation instructions (each step should be com-pleted in the exact order specified), the Technicianis directed through the installation process.This section contains all relevant installation infor-mation including:

— Installation specifications— List of installation tools— Alternative types of venting systems (and in-

stallation procedures for each)— Basic requirements for fuel tank installation— Instructions to install the Monitor System

IMPORTANT: Before beginning installation of theMonitor vented heating system (in-cluding any electrical wiring andfuel supply equipment), check localbuilding,electrical, mechanical andfire codes. The requirements ofthese codes must be followed toinsure lawful installation and use.

The heater can be located almost anywhere withinthe dwelling provided that electrical, fuel, and ex-haust specifications are met.

2-2 PHYSICAL PLACEMENT OF HEATERIn addition to the space taken up by the heater,interior space must also be reserved for free aircirculation. Remove all combustibles from the heat-ing area.Unless building or fire codes dictate otherwise, theMonitor system can be placed on any floor surface(including carpeting or other combustible material)and provide safe operation.

2-3 DRILLING REQUIREMENTSThrough-the-wall Flue Pipe installation requires thata 2 ;

;" (65mm) hole be drilled through the dwellingwall (interior to exterior). The hole must be pitcheddownward toward the outside at an approximateangle of 2 (about; . per foot). The appropriate wallarea (in which hole will be drilled) must contain nointernal obstacles such as piping, wiring, air ducts,or studs.

RECOMMENDED TOOL KIT FOR MONITORHEATER SERVICE TECHNICIANS

D -2 Phillips Head Screwdriver2) Steel Tape Measure3) Felt Tip Pen or Pencil4) Caulking Material (exterior grade)5) Electrical Drill

(reverse capability recommended)6) Hole Saw. Saber (Jig) Saw. or other appropriate -

tool for cutting a 2.5" diameter hole for flue pipe7) Rubber Clipping Tool8) Long Drill Bit—' ."9) =2 Standard Screwdriver

10) Adjustable Wrenches (various sizes)11) Copper Tubing Cutter12) Copper Tubing Flaring Tool13) V.OM(Volt, OnM. Meter with shielded probes)14) Level15) Plumber s Pipe Thread Tape16) Small assortment of Self-Tappeng Screws17) Assorted Pliers (Slip Joint, Needlenose, Cutting,

LocK Joint)18) Phenolic Probe or Insulated Screwdriver19) Supply of 125V, 2 and 10 Amp fuses20) Floor mat to cover carpeting21) Quart size pan for draining fuel

2-4 POWER REQUIREMENTS

WARNING

THE MONITOR POWER CORD MUST BE PLUGGEDINTO A DIRECTLY ACCESSIBLE WALL OUTLET.DO NOT USE AN EXTENSION CORO TO MAKETHIS ELECTRICAL CONNECTION.

Line current to the system should be 120 VAC at 60Hz. The electrical system should be protectedagainst current overload by means of at least a15-ampere fuse or circuit breaker.

NOTE The wall outlet should supply electricity forthe Monitor system only. Do not connectany other electrical appliance to it.

CAUTION: In some installations, it may bebest to hard-wire the heater to thenous* circuits. A competent,licensed electrician should dothis.


2-5 FUEL TANK REQUIREMENTS

WARNING:

INSTALLATION OF ANY REMOTELY LOCATEDFUEL TANKS MUST COMPLY WITH ALL LOCALSTANDARDS AND OR BUILDING CODES.

Heater fuel (crystal clear kerosene only) can bestored m remotely located storage tanks rangingfrom 55 gallon drums to 275 gallon tanks. Whenusing large tanks a pressure regulator with a max. of2.5 PSI should be installed near heater inlet.

CAUTION: In some installations, it may betotter to install permanent fueltank plumbing. A licensedPlumber should do this.

2-6 TEMPERATURE SENSOR WIRING REQUIRE-MENTSA wall-mounted temperature Sensor gauges roomtemperature and automatically regulates the heatingcycles of the Monitor System.The standard sensor wire is 6J f\ long and can beleft mounted on the back of the cabinet as shipped.If this is not practical the sensor can be mounted ona wall.

CAUTION: If sensor is to be mounted re-motely be careful not to place it indirect sunlight on uninsulatedexterior walls in drafty areas etc.,as this will create an inaccuratetemperature reading.

2-7 BUILDING COOESFire regulations, electrical and other local buildingcodes may govern the installation and use of avented heater and related fueling systems. Prior toinstallation, check and comply with all codes.

2-8 UNPACKINGSave all shipping materials until the Monitor hasbeen completely installed and is working properly.A. Cut the two plastic ribbons that hold the ship-

ping carton together.B. Remove the top.C. Remove from the shipping carton the Cardboard

(drilling) Template and the Owner s Guide.

NOTE: The Dealer should complete the Registra-tion Card at time of customer purcnase andreturn it to Monitor Products. Inc. as soonas possible.

D Remove the spill tray from shipping carton, andremove the plastic bag.

E. Remove the plastic bag covering the heater.F. Remove the plastic bag containing the heater

parts.and set it aside.G. Remove the Flue Pipe from the rear of the

heater. When ready to install, separate FluePipe from cardboard packing materials.

H. Firmly grasp cabiet handles (one on each sideof heater cabinet) and lift heater off the card-board shipping base.

I. Check for parts as listed in Monitor OwnersGuide.

.

IMPORTANT: Only the standard-size Rue Pipe isshipped with the heater. The Moni-tor dealer will also stock MediumRue Pipes, Window Kits, ExtensionKits, and other accessories thatmay be required for non-standardinstallations.

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2-9 HEATER INSTALLATIONIn choosing a location for your heater, the followingguiceiines Tiust ce ccnS'Cerec:«The Beater MAY ne .nstaiied on combustible

•loors.• The area around the heater should be free of

oostacles that might interfere with the free flow ofair.Allow the clearances shown in Figure 2-1.

• The heater must not be installed m a combustiblefireplace.

• An AC wall outlet must be within reach of theheater s power cord. Extension cords must not beused.

• The area outside where the flue Dice will emergeshould be free of foliage, fuel storage tanks andflammable objects. Air should circulate freely inthe area. Allow the clearances shown on follow-ing page.

• The wall where flue pipe hole will be cut shouldbe free of plumbing pipes, electrical wires, studs.air ducts and other obstacles.

13.5cm, 5'iin

15cm, 6m

NOTE: After using tne installation ;errciate 25 aguide for drilling tne flue pipe ncie. :reMonitor Flue Pipe can be normally .nstailecaccording to the illustration procedure ^the Monitor Manual.

Just m case the template was misplaced, tre ap-proximate flue pipe hole location measurements areas follows:

Tha center of The Joint Pipeopening, which connectsto the Flue Pipe. Back of Heater

The center of The Joint Pipe Back of Heater

Fuel Inlet

Figure 2-2

100cm, 39inFigure 2-1


FLUE PIPE CLEARANCESFlue oioe installations should orovide for venting to an unconfined space through which there s a vee 'lowoutdoor air Clearances to adiacent walls or obstacles must comply with the reauiremems shown

Frontal Clearance Combustible^CAUTION:Do not artacn anything onto tne outletof tne flue

24 (60cm)or more

_(I3.5cm>

BodyClamp

— wall

(14cm)

-or—more

Any constructionabove Flue Pipe |must not comewithin 24••t60cmi "of front oOstacie i

24' (60cm |or more Front Obstacle

r •Heater

ar(20cm>or more

Ground or slab surface

Overhead Clearance Combustible - Non-combustible

Combustible

Ground or slab surface

Side Clearance

.

Heater-

BodyClam

L

° i Side obstacle^ ',, ...MUiiuiUHllimnni , ...mmuniiili , T^

iff (45cm)or more

1 i> =T • 'Flue Pipe

wail

IMPORTANT:in ooen area with strong wind, a wind break may benecessary.

i— 24"min -»,

Rgure 2-3to


HOW TO PREVENT FREEZING IN COLD CLIMATE.

Front Obstacle

In areas of heavy snow falls,ground surface clearance mustbe increased according toaverage snow falls, to ore ventflue pipe from being buried.

— SNOW SURFACE or GROUND

LongExtension's Must be higher.

Snow

Figure 2-4 FLUE PIPE CLEARANCES

INSTALLATION OF FLUE PIPE WINDOW KITA window kit makes it possible to vent the heaterfrom dwellings in which through-the-wall venting isneither practical nor possible.The Window Kit is available in two sizes. The ShortWindow Kit accommodates windows from 20 to 32"wide; the Long Window Kit accommodates windowsfrom 31 to 50" wide.

NOTE: The procedure below describes how aWindow Kit is installed in a double-hungwindow. The Window Kit can also be in-stalled in a vertical, sliding type window.

Install the Window Kit in the manner outlined below:

STEP 1: Install Rue Pip* in Window KitA. Push the rubber seal into the Flue Pipe hole on

the window kit frame. The hole on the sealshould be positioned at the exterior side of theframe.

B. Using the four (4) Phillips head screws, fastenthe spacer to the frame.

C. With the arrow on the Flue Pipe pointing UP.align the screw holes on the Rue Pipe withthose on the Spacer. Secure with three (3)Phillips head screws.

13


STEP 2: Install Window Kit in the Window

IMPORTANT: Prior to installation, clean the win-dow frame of all dust dirt, anddebris.

A Raise the lower windowB Place the window kit frame into the innermost

track of the window.C Expand the frame until it fits loosely within the

width of the window; it may be necessary toloosen the large set screw on the frame m orderto do so.

D. Slightly lift window kit frame. Slide the L-Adapter under the frame and position it at the

point where the inner and outer frame meet.Expand the frame to fit tre window tigr.tlyAdiust the position of the L-Adapter. if neces-sary. Tignten the set screw to secure the frame.Secure the L-Adapter to the window sill withtwo 12) wood screws.Lower the window firmly down upon the top ofthe Window Kit frame.Measure the width of the upper (outer) window(which is located m the outer track). Cut alength of the Rubber Packing to this size.Remove the protective bac -ig and firmlymount it onto the underside ct the outer win-dow.

Figure 2-5


STEP 3: Install Window LockA special window lock replaces the usual clam-

shell lock.To install the window lock, proceed as follows:A. Turn locking lever to left and disengage lock

from lock bracket.B. Attach lock bracket to left-hand side of upper

window frame. Use the two wood screwsprovided.

NOTE: If the lock bracket prevents the lowerwindow from sliding upward, notch thebracket into the upper window frame.

C. Slip lock into lock bracket.

IMPORTANT: Window can be locked by turninglocking lever to right; to open, turnlocking lever to left and removelock from bracket.

D. Two adjustable-position stops are supplied toaccommodate various window sash thicknes-ses. If short stop is too small, remove tworetaining screws and brackets which hold theshort stop to the underside of the lock. Removethe short stop and substitute the long stop.Adjust to proper position, and secure withscrews and washers previously removed.(Before securing the stop to the window,remove the protective backing and firmly stickthe stop packing onto the underside of thestop.)

NOTE: Windows with deep sills may require theuse of an extra intake and exhaust elbowto provide clearance for flue pipe hook up.A piece of the air intake line can be cut tojoin the two intake elbows together.

Deep Window Sill

One Exhaust Elbow

Two Intake Elbows

Figure 2-6

15


2-10 INSTALLING AN EXTENSION KITInstalling an Extension Kit requires the constructionof an air line and the exhaust line. The air line isconnected between the Air Supply Elbow at the rearof the heater and the air inlet port on the Fiue Pipe.Similarly, the exhaust line is connected between thejoint pipe at the rear of the heater, and the exhaustport on the Flue Pipe.

IMPORTANT: The PVC air line is longer than theexhaust line and may need to be cutto size. Be sure, however, to thor-oughly deburr all rough edges.

Figure 2-7 COMPONENTS OF EXTENSION KIT

ITEM=

1

2

3

4

5

DESCRIPTION

PIPE, Air supply

JOINT, Air line

ELBOW 90 Air line

LEG, Wall-standoff

PIPE CLAMP, Top

ITEM::

6

7

8

9

DESCRIPTION

PIPE CLAMP, Bottom

SCREW, Legs, mounting

SCREW, Pipe Clamp

BOND, Adhesive

16


Max lengths and bends allowable using extensionkits.

Extension kits are available in four diffirent lengths.For exact dimensions refer to the accessoriescatalog.

3-90° Bends10 Ft.Max

Figure 2-8 MAX LENGTHS AND BENDS ALLOWABLE USING EXTENSION KITS

17


2-tl TYPICAL MONITOR UFTER PUMP INSTALLA- For more detailed information look under KeroseneTIONS Lifter manual.

NOTE; The same minimum and maximum pumpheights must be maintain as is with otherfuel tanks. Figure 2-12

MONITOR™ KEROSENE LIFTER MONITOR™ KEROSENE UFTER(CAN BE POSITIONED BEHIND UNIT)

MONITOR™ KEROSENE UFTER MONITOR™ KEROSENE UFTER GRAVITY

Figures 2-9

18


2-12 USES FOR THE ELBOW ADAPTER KITConvert from Monitor 20/30 to 422/441 using anelbow adapter Kit tpan = 32i3) and utilizing existingflue pipe installation.

Noin

Unit

11112

PARTS LIST EXPLODEDName

Ref. ofNo. Part1 Exhaust Pipe Clamp2 Exhaust Elbow3 Exhaust Joint4 Joint Supporter5 Heat Insulation Cover6 Self-Tapping Screws7 Hose Clamp (this part comes with your

Monitor:M Heater)8 Air Damper (this part comes with your

Monitor™ Heater)9 Flue Pipe (this part comes with your

Monitor:M Heater)

A. Remove Monitor 20 30 heater and flue pipe.B. Install Monitor 422/441 flue pipe into sleeve.C. Slide the exhaust elbow onto the exhaust port

opening on the rear of the heater. (To locateexhaust port opening, see your Monitor Owners Guide.)

D. Secure the exhaust elbow by attaching theexhaust pipe clamp to the heater cabinet withtwo self-tapping screws.

E. Cover the adjustable exhaust pipe with heatinsulation cover. •

Figure 2-10

Remove metal cap on side mounted exhaust ocrtof flue pipe and replace into the unused oort ;:heMonitor 422/441 is now ready to be positionedinto place.)

NOTE: Be sure the exhaust elbow is firmly fixed onthe flue pipe with a joint supporter.

G. Insert air supply elbow opening over flue pipeair intake flange and secure with hose clamp.

NOTE The Standard Air Damper is installed overthe flue pipe "air intake flange." (To locateflue pipe "air intake flange", see yourMonitor™ Owner s Guide.)

Elbow adapter Kits may also be used to raise a fluepipe high enough to clear certain base board heat-ing systems.

2-13 FUEL TANK INSTALLATIONPictorial views of alternative types of storage facil-ities and delivery systems are illustrated (Figure2-12).Since fuel storage tank installation techniquesvary from place-to-place (often dependent uponapplicable codes), a particular installationprocedure cannot be specified. However, certaincriteria govern the fuel hook-up of the Monitor.Use the following check list as a guide to the fuelstorage facilities:

WARNING:USE ONLY CRYSTAL CLEAR KEROSENE. NEVERUSE GASOLINE, WHITE GAS, CAMP FUEL OROTHER FLAMMABLE LIQUIDS. USE OF SUCHFUELS CAN RESULT IN AN EXPLOSIVE RRE ANDCAUSE SEVERE INJURY.

Fueling Options AvailableFueling of the Monitor Heating Systems can beaccomplished in one of 3 ways:1. Capsule Tank (on the Monitor 422)2. Gravity Fed Large Capacity External Tank:

Practical for large heating needs where bulkdelivery of kerosene is available. This systemshould be installed by a qualified plumber orfuel supply technician.

'3. Large Capacity External Tank with Pump: Forlarge heating needs where a gravity fedsystem is not practical. An electric pump, theMonitor™ Kerosene Lifter, especially designedfor use with Monitor heating systems.

'if a pumping system is used to supply fuel, theinlet pressure to the heater must not exceed 2.5psi.

10


To install a large capacity, gravity fed external tank,follow the instructions below. Use of a qualifiedinstaller is recommended.

• Installation height of the bottom of the fuel tankshould be 16 mcnes or more above the floorsurface on which the heater stands. Thisinsures that inlet fuel pressure will be sufficient.The top of the fuel tank should be no higherthan 8' : feet above the floor under the heater.This insures that inlet fuel pressure will not beexcessive.

• The horizontal length of piping should notexceed 100 feet and should be free of sharpbends or obstructions.

• Piping should include no inverse U-type bends(to avoid air locks, which could block the fuelsupply).

• Only ! . -inch OO copper tubing should be used.The tubing should be bent carefully to avoidcrimping.

• A fuel filter is recommended for use on the fuelline near tank, and a shut-off valve should beinstalled at the tank.

• Flare connections should be used at the fusiblelink valve connection on the heater and at thefuel filter to be installed at the tank.

• The fuel tank should be located no closer than3 feet to a source of heat.

• The fuel tank should have an opening for fillingon the top and a vent with a weather-proof capon the side. On some tanks the vent and fillspout use the same opening.

55, 100, and 250 gallon tanks must contain:Shut-off valve at tank outletDisposable fuel filter (protects heater againstcondensation and other impurities)Fueling mlet (protected by weather-proof cap)Ventilation outletClearance of at least 3 from any source of heat

Allowable Height Dimensions:• Bottom of tank-at least 16" above floor holding

heater (maintains sufficient pressure)• Top of tank-maximum of 8' .' above floor

holding heater (prevents excessive line pres-sure above 2.5 psi).

• Position of Lifter-more than 8' above fuel inletof heater requires pressure reduction valve.

RECOMMENDATIONPipe fittings in the fuel supply to the Monitor heatingsystems should be sealed with pipe thread tape.The supply line from the tank to the Monitor X1

Kerosene Lifter must be absolutely air tight. 275gallons and bigger tanks should have a 2.5 P.S.I.max pressure reducer to avoid excessive pressureat heater inlet.

2-14 HEATER INSTALLATIONThe Monitor heaters can be physically situated oncarpeting or other combustible flooring with com-plete safety. The selected heater site must beaccessible to an electrical outlet, must support freeair ciculation (both internal and external), and mustnot contain combustible materials in the heater'simmediate vicinity.

Interior orexterior gravity-fed 55, 100. or 275-gallon tank

PressureReducer

Lifter

Lifter circulatesfuel from remotestorage tank

Figure 2-11 ALTERNATIVE SOURCES OF FUEL STORAGE

20


Outdoor Fuel TankShut-off Valve

'- Threaded Connection

-v '- 00 Copper TuDing

_ _Fusible Link

Valve Connection

1

-„ . OD CcDDer Tubingtj

f

NOTE: Fuel tank must be a minimum 3 feet away from flue pipe.

Figure 2-12 TYPICAL FUEL UNE CONNECTIONS

MONITOR HEATING SYSTEMSSection 3: Operation

3-1 INTRODUCTIONMonitor is an easy-to-operate vented keroseneheater. Routine operation features high BTU output,automatic adjustment of room temperature, low fueland power consumption, and choice of automatic ormanual heater operation.This section provides all information necessary tooperate the Monitor Heating System. All operationprocedures specified should -be performed in theorder in which they are described.

3-2 OPERATING SPECIFICATIONSThe following specifications apply to the operationof the Monitor 441 and the Monitor 422.

Monitor 441- Rated Efficiency (as applied to kerosene

heaters): 93?^*- Rated Efficiency (as applied to central heating

systems): 87%— Power Consumption : as follows

- Circulation Fan Output : 388 cubic feet mm.- Fuel source : Remote, separate tank- Potential heating area : 900-3200 sq. feet

'The energy from the combustion process isreleased in the form of heat and vaporized water.Normally, heating systems discharge water fromcombustion to the atmosphere without condensingit. This 93% efficiency rating-means that; assumingthe water cannot be condensed, 93% of the heatproduced by the combustion process is recovered.Assuming the water can be condensed, the effi-ciency is 87%.

NOTE: Actual effective heating area depends uponnumerous factors such as type and severityof climate, type of dwelling construction,condition of dwelling, and thickness andeffectiveness of dwelling insulation.

Table 3-1 lists Monitor 441 performance specifica-tions at various user-selected heat output settings.

HIGH MEDIUM-HIGH MEDIUM-LOW LOWIGNITION BURN BURN BURN BURN340watts 65watts 62watts 58watts SSwatts

Table 3-1 HEATER PERFORMANCE SPECIRCATIONS

Specification

Rating

Heater Output hr.

Fuel Consumption (gal/hr)

8-hrs day burntime (5-gal. tank)

Continuous-use burntime (5-gal.tank)

8-hrs day burntime (55-gal.tank)


8-hrs day burntime (275-gal.tank)


Setting

Low

16,200

15,000

0.12

5.2days

41.7hrs.

57.3days

19.1 days

286.5days

95.5days

MediumLow

21,000

19,500

0.16

3.9days

31.3hrs.

43days

14.3days

214.8days

71.6days

MediumHigh

33,900

31,500

0.25

2.5days

20hrs.

27.5days

9.2days

137.5days -

45.8days

High

43,000

40,000

0.319

2.0days

15.7hrs.

21.6days

7.2days

107.8days

35.9days

23


Monitor 422- Rated Efficiency (as applied to kerosene

heater): 93°b'- Rated Efficiency (as applied to central heating

systems): 87%- Power Consumption : as follows

HIGH MEDIUM-HIGH MEDIUM-LOW LOWIGNITION BURN BURN BURN BURN250watts 52watts Slwatts SOwatts SOwatts

- Circulation Fan Output : 176 cubic feet min— Fuel source : 1.32 U.S. gal., separate tank

optional— Potentional heating area : 600-2000 sq. feet

Table 3-2 lists Monitor 422 performance specifica-tions at various user-selected heat output setting.

• •

Table 3-2 HEATER PERFORMANCE SPECIFICATIONS

Specification

Rating

Heater Output hr.

Fuel Consumption (gal 'hr)

8-hrs day burntime (1.32-gal. tank)

Continuous-use burntime (1.32-gal.tank)

8-hrs day brntime (55-gal.tank)


Setting

Low

9,600

8,900

0.07

2.4days

18.9hrs.

98.2days

32.7days

MediumLow

11,700

10,900

0.09

1.8days

14.7hrs.

76.4days

25.5days

MediumHigh

17,400

16,200

0.13

1.3days

10.2hrs.

52.9days

17.6days

High

22,000

20,400

0.164

I.Odays

B.Ohrs.

41.9days

14.0days

NOTE: Capsule tank cannot be used in Connecticut and Massachusetts.

•

24


3-3 OPERATING CONTROLS AND INDICATORSSeveral controls and indicators are used to operatethe heater and to monitor its performance as follows:

RUN AUTO ECÛ°SMY EMPTY BURNER STATUS

i

3 4 5

Figure 3-1, INDICATORS

6

TEMP. AM

'PM

7 8

SET =OOM

l~~l l~l • 539

11 12 13 14 15

OPERATION :TIMffR SELECTOR

ON/OFF AUTO ECONOMY CsETKJ^ 2nd 3rd 4th

16

TIME/TEMP SET

21 22 23I

10

Figure 3-2, CONTROLS

TIME(~ ~~l HOUR MINUTE SET CLEARCD oTEMP(~~~| UP opvVN

17 18 19 20

FIGURE AND ITEM NO CONTROL OR INDICATOR. FUNCTION

Figure 3-1. Iteml

Figure 3-1, Item2

Figure 3-1. Item3

Figure 3-1. Item4

Figure 3-1. ItemS

RLJN Indicator Light Light to indicate that power has been aplliedto heater.Illuminates when operation ON/OFF push-button switch is pressed to position ON

AUTO Indicator Light Lights when heater runs in automatic mode.AUTO. RUN, and appropriate BURNER STA-TUS Indicators are illuminated simultaneouslyif heater is burning.

ECONOMY PLUSIndicator Light

Lights when heater runs in Economy Plusmode.

Empty Indicator Light In case of using the cartridge tank, when thefuel is empty, EMPTY Indicator Light blinks.This Light is not provided with Monitor 441.

BURNER STATUSIndicator Lights

Light in accordance with heat output as fol-lows:Heat Output Light PatternHigh 8indicators-ONMedium High 6indicators-ONMedium Low 4indicators-ONLow 2indicators-ON

25



Figure 3-1. Item6 TEMP Indicator Lignt Lights when heater is running and DigitalWindow is snowing the temperature.

Figure 3-1. Item? AM Indicator Light

Figure 3-1. ItemS PM Indicator Light

Figure 3-1. Item9 Digital Display Indicates" SET and ROOM • temperature whenheater is running, and indicates time whenheater is Off.indicates time and temperature for automaticoperation setting.

Figure 3-2. ItemlO TIMER SELECTORpush-button switch

The automatic function allows the program-ming of different temperatures for differenttimes of the day. Two, three or four settingscan be used.

Figure 3-2, Itemll CLOCK SETIndicator Light

Allows programming of current time whenilluminated.

NOTE: Prior to programming current time,Digital Display shows 88:88.

IMPORTANT: One*progrvpushtMseconplay »progr

\ma has b»«n pro-• tha SET pu»h-Ithln 00 »«cond»

K dl«pl*V will r«-uily programmed

Figure 3-2, Iteml2 1st Indicator Light Allows programming of first automatic timeand temperature selection when illuminated.When programmed, heater automatically oper-ates at specified time and temperature (i.e. 6:00 a.m., 70'F), if set for AUTO, providing thatheater has been set for automatic mode ofoperation.TIME, TEMP, HOURUP), MINUTE(DOWN) andSET push-button switches are used to pro-gram first operated time and temperature.IMPORTANT: Once time and temperature have

been programmed, the SET but-ton switch must be pressedwithin IS seconds. Otherwise,time and temperature will revertto prevloualy programmed time,If any.programmed time, if i -

When this Light illuminates. "' .».itly pro-grammed time and *• _.ure displayed.

Figure 3-2. Iteml3 2nd Indicator Light Allows programming of second automatictime and temperature selection when illumi-nated.


FIGURE AND ITEM NO CONTROL OR INDICATOR. FUNCTIONFigure 3-2. ItemU 3rd Indicator Light Programs 3rd automatic neater operation as

same as 1st Indicator Light.

Figure 3-2, ItemlS 4th Indicator Light Programs 4th automatic heater operation assame as 1st Indicator Light.

Figure 3-2. Item16 TIME push-buttonswitch

This switch is used to set time and changedisplay over.

Figure 3-2, Item17 TEMP push-buttonswitch

This switch is used to set temperature andchange display over, in 2 degree increments.

Figure 3-2, Iteml8 HOUR UP.MINUTE DOWNrepetitive-actionpush-button switch

Programs time or temperature.NOTE Each time push-button switch is

pressed, the digit advances in incre-ments of one digit. If push-button ispressed and held, the digits areadvanced repetitively.

Figure 3-2. Item19 SET push-button switch'

.

'Sets' time and or temperature.If this control is not pressed after time and ortemperature have been programmed, the timeand or temperature programmed (as indicatedby display window) will not be accepted, andwill revert to previously programmed time and/or temperature.

Figure 3-2. Item20 CLEAR push-button switch

.

•

Erases any programmed time and temperature.When cleared, time and /or temperature previ-ously programmed and displayed disappears)from window.IMPORTANT: Both current time and auto-

matically programmedtime<s), temperatures) willhave to be reprogrammed ifelectrical operation is inter-rupted by power failure or bydisconnecting heater plugfrom wall outlet beyond 5minutes. If this occurs, theneater will go into MANUALmode of operation and main-tain room temperature accord-ing to the setting temperatureyou've selected by using theslide selector for the resettemperature at the tower righthand side of the cabinet

Figure 3-2, Item2l ON OFF push-buttonswitch ON position (push-button is "in")applies power

to the unit. When this occurs, the RUN indica-tor lights to indicate that heater operation hasbegun.OFF position (push-button is "out") removepower from the heater. All circuits-except forClock and Air Flow — are shut down.

27



Figure 3-2. Item22 AUTO push-buttonswitch

Places heater in automatic mode of operation.AUTO indicator lights to confirm automaticoperation.Assuming that the heater has been properlyprogrammed and heater is in ON position.heater will operate automatically.When pressed again, AUTO indicator goes outand then heater will operate in MANUALmode. During manual operation, the user turnsheater ON and OFF. at will.When AUTO is disengaged, the unit willoperate on a manual temperature determinedby the AUTO setting for that time of day.

Figure 3-2, Item23 ECONOMY PLUSpush-button switch

Places heater in Economy Plus mode ofoperation. ECONOMY PLUS indicator lightsto confirm Economy Plus operation.When pressed again, ECONOMY PLUSindicator goes out and then Economy Plusmode will be cancelled.NOTE: Economy Plus mode is accepted only

in the MANUAL mode.

3-4 PRE-OPERATION CHECK LISTAfter heater installation, but prior to Monitor heaterstart-up, inspect the system for operational readi-ness. The following check list specifies those itemsthat should be inspected on a routine basis:

Check that the Monitor heater is plugged intowall outlet(120 Vac, 60 Hz)Verify that adequate supply of kerosene isavailable in fuel tankConfirm that fuel is free of water or othercontaminantsCheck fuel tank for good operating condition; itmust be free of rust, corrosion, and or leaksInspect Fuel Line for signs of leaks, looseconnections, cracks, air pockets or blockagesConfirm that Fuel Valves on Fuel Tank andFusible Link Valve are open so fuel can flowfreelyOutside dwelling, check area immediatelyaround Flue Pipe for combustibles or obstruc-tions to free air circulationInspect Air Line for cracks, loose connectionsor blockageCheck Exhaust Line for cracks, loose connec-tions or blockageAt rear of heater, verify that air flow to the AirCirculation Fan is not blocked

Inspect dwelling interior and confirm that imme-diate area near heater is free of combustibleand obiects that might interfere with free airflow.Make certain that Heat Sensor is not exposedto drafts, direct sunlight, nor direct heat fromthe Monitor.Confirm that heater is level

if this msoection reveals any system deficiencies,correct the problems before operating the heater.

3-5 OPERATIONOperation of Monitor heater can be controlledmanually by the user, or run automatically by themicroprocessor.Paragraphs 3-6 through 3-10 provide the details ofheater start-up, operation, and shutdown. Thecontrols and indicators illustrated by Figure 3-1 and3-2 are used to operate the system and to monitorthe heater s performance.


3-6 MANUAL HEATER OPERATIONOperation of the heater js under the direct control ofthe user Beater will net operate automatically) Theheater »vni. ôwever. automatically respond tochanges m room temoerature signaled by the HeatSensor to maintain the temperature of the room at acomfortable level.

NOTE: Resetting the Fuel Constant Level Valve isnecessary only if the heater is being start-ed for the first time, hasn t been used for anextended period of time, or if tank has runempty If priming is unnecessary skip tostep 2.

STEP1: Prime the HeaterGently press and release the Fuel Constant LevelValve Reset Lever four or five times

STEP2: Select Manual OperationIf heater operation is in AUTO mode, press theAUTO push-button switch and change Auto toManual mode.

STEP3: Select Temperature SettingPress the TEMP push-button switch and presseither the UP or DOWN push-button switch to setthe digital set room temperature indicator to thedesired temperature, and then press the SET push-button switch.

IMPORTANT: In case no temperature is set tem-perature will automatically be set atthe setting temperature selected byusing the slide selector (or the resettemperature.

STEP4: Turn Monitor OnPress the ON OFF push button switch to positionON The RUN indicator light illuminates to indicatethat power has been applied to the instrument andthe heater is cycled for manual mode of operation

INSTRUCTIONS FOR ECONOMY PLUS MODETo engage the economy plus mode, simply pressdown the button labeled 'Economy Plus', todisengage press again.NOTE: Operation switch must be 'ON" and in

MANUAL mode.This feature minimizes the ON " and "OFF" cyclingof the unit by allowing it to overshoot the settemperature by 12 degrees instead of the normal4 degrees.

The advantages of this feature are to increase theoverall efficiency of the unit by:

1. Decreasing electrical consumption by decreasingthe frequency of ignition cycles.

2. Reducing heat loss during the prepurge andpostpurge cycles.

3. Reducing .nefficient combustion associated withstart up and shut down.

4. Prolonging component life by decreasing expan-sion and contraction of internal parts.

NOTE: This feature could be compared to drivingan automobile in stop and go traffic (regularmode) versus highway driving with cruisecontrol engaged (Economy Plus mode).

3-7 AUTOMATIC HEATER OPERATIONAutomatic operation is established by programmingthe time temperature settings for specific times. Ona daily basis, a maximum of four time temperaturesettings can be programmed.If. subsequently, it should be desired to switch tomanual mode of operation, the changeover can bemade at any time.Proceed with automatic mode of operation in thefollowing manner

STEPi: Program Clock for Current TimeA. Press the TIMER SELECTOR push-button

switch, at which time the CLOCK SET indicatorlight will illuminate.

B. Press HOUR push-button switch to programcurrent hour on the ClocK.

IMPORTANT: Be sure to set clock for AM or PM,as appropriate.

NOTE: Both hour and minute digits on DisplayWindow are advanced in increments of oneby pressing the appropriate push-buttonswitch one time for each digit; digits canalso be advanced repetitively by pressingand holding the appropriate push-buttonswitch.

C. Press MINUTE push-button switch to programthe current minute(s) on ClocK.

D. Immediately after programming current time interms of hours and minutes, press the SETpush-button switch.

STEP2: Program the 1st Time TemperatureA. Pressing the TIMER SELECTOR push-button

switch will illuminate the 1st indicator light.B. Press TIME push-button switch.


C. Press HOUR and MINUTE push-buttonswitches to program 1st desired time.

IMPORTANT: Be sure to set the clock AM or PM.as appropriate.

D immediately after programming the 1st desiredtime, press the SET push-button switcn. Thisstep must be completed within fifteen secondsafter programming the time

E. Press TEMP push-button switch.F Press UP and or DOWN pusn-outton switchies)

to program 1st desired temperatureG. Immediately after programming the 1st desired

temperature. Press the SET push-button switchThis step must be completed within fifteenseconds after programming the temperature

STEP3: Program the Remaining TimesBy pressing the TIMER SELECTOR push-buttonswitch again, the 2nd Indicator Light will illuminate.at which time the 2nd setting can be programmed.Press again to set 3rd and again to set 4th.IMPORTANT: The SET push-button switch must be

pressed after each setting to lockinto memory.Should heater power be interruptedby a power failure or by disconnectionof the power cord beyond 5 minutes,heater reverts to MANUAL operation,and all AUTO programming is erased.

STEP4: Select Automatic OperationPress AUTO push-button switch. The AUTO in-dicator light will illuminate.

STEPS: Turn Monitor ONPress ON OFF push-button switch to position ON.The RUN indicator light will illuminate to indicatethat power has been applied to the heater

From this point, heater operation is as follow exam-ple:

76 F

6:OOAM 9.00AM 5:OOPM 1000PM

1 80 F| '68 F

64 FExample

3-8 REPROGRAMMING THE MONITOR HEATEROn occasion, it may be necessary to reprogram theMonitor.Reprogramming is performed as specified below.

STEP1: Reprogramming Current Timedf necessary)

A. Press the TIMER SELECTOR push-buttonswitch to illuminate the CLOCK SET indicatorlight.

8. Press HOUR and MINUTE push-buttonswitches to program new current time. Setapplicable time by watching Clock display

C. Press SET push-button switch.

IMPORTANT: If SET push-button switch is notpressed, current time will revert topreviously programmed time.

STEP2: Reprogramming Automatic OperationA. Press the TIMER SELECTOR push-button switch

to illuminate the appropriate indicator light. (1st,2nd. 3rd, or 4th)

8. Press TIME push-button switch.C. Press CLEAR push-button switch. Time dis-

played on window will disappear.D. Using HOUR and MINUTE push-button

switches program new desired time by watch-ing the Display Window.

E. Press SET push-button switch.F. Press TEMP push-button switch.G. Press CLEAR push-button switch. Set Temper-

ature displayed on Window will disappear.H. Using UP and DOWN push-button switches

program new desired temperature by watchingthe Display Window.

I. Press SET push-button switch.

3-9 HEAT SENSORHeat Sensor is located on the rear of the cabinet. Itis recommended to leave the sensor in its originalmounted position. However should relocation benecessary, choose a location for the sensor that isnot m the path of direct sunlight, drafts or the flow ofwarm air from the heater. Loosen the screw andrelease the sensor from the rear of the cabinet.Fasten the sensor to the wall with the screw.

3-10 MONITOR SHUTDOWNA simple one-step procedure is utilized-to shutdownthe MonitorPress ON OFF push-button switch to position OFF;the RUN indicator will extinguish.

IMPORTANT: Once heater has shut down, it can-not be restarted until post-purge cy-cle has been completed. H ON/OFFswitch is left in position ON, Monitoroperation will automatically restartupon completion of post-purge.


3-11 OUT OF FUELDuring either manual or automatic operation ofheater. fuel in the tank may oe deoleted.The Monitor un case of using external fuel tank) isknown to be out of fuel when all of the followingsymptoms are present:

- Burner Status indicator lights blink.- Absence of flame (visually verified through view

plate on wall of Combustion Chamber).

STEP1: Turn Heater OFFPress ON OFF switch to OFF

STEP2: Rll Fuel TankA. Close shut-off valve at outlet of Fuel Tank.B. Dram Fuel Tank (from bottom, if possible) to

remove all condensation, debris, and old fuel.C. Fill Fuel Tank with fresh, crystal clear keroseneD. Upon completion of stepC. open shut-off valve

which was closed m steoA above.

STEP3: Turn Heater ONPress ON OFF switch to ON. Proceed with normalheater operation.The Monitor 422 (in case of using capsule fuel tank)is known to be out of fuel as follows:

When the EMPTY indicator light illuminatesand flashes, a buzzer will sound for twentyseconds. The burner mode is changed to 'Low'automatically, and then, the heater will shut offafter 30 minutes.The remaining burning time is indicated at theDisplay Window.

Refueling:STEP1: Turn Heater OFFPress ON OFF switch and wait 15 minutes for theheater to cool.

STEP2: Lin Out the Capsule Fuel TankOpen the tank cover and lift out the capsule fueltank.Turn the tank upside down, and remove the fuelcap.

STEP3: Fill the Capsule Fuel TankFill the capsule fuel tank with fresh, crystal clearkerosene by using a siphon

STEP4: Reinstall the Capsule Fuel TankReplace and tighten the fuel cap. To insure properfuel flow, be sure the cap is secured correctly.

install the tank jvit^ tne arrow sclose tf*e tanK tover

or.va,-c. arc

STEPS: Turn Heater ONP'ess ON OFF switch to ON. Proceed -.vth normalheater operation

3-12 RECOVERY FROM A POWER FAILUREFor the power interruption of up to 5 minutes, theset memory is kept and will resume operationautomatically with the set memory.For power interruptions beyond 5 minutes, heaterwill resume operation (after a 3 minutes cool downperiod) in the MANUAL mode and maintain roomtemperature according to the setting temperatureselected by using the SLIDE SELECTOR for thereset temperature at the lower right hand side ofthe Cabinet.When the TIME push-button switch is pressed orthe TIMER SELECTOR push-button switch is pressedto 'illuminate the CLOCK SET indicator light, theDisplay Window will show 88:88 indicating theneed to reset the clock and re-program the heaterfor automatic operation.REMARK: In order to display reset temperature,

it should be set before the heater isplugged in and energized.New reset temperature selected afterplugged in will take effect only after apower loss.

3-13 RECOVERY FROM OVERHEAT CONDITIONThe Monitor is protected against damage resultingfrom an overheat condition by two 11G"C (Monitor422). 115'C (Monitor 441) automatic reset thermostats.In the event of an overheat the thermostats aretriggered to cut off the flow, of kerosene to theBurner Pot. the flame is extinguished automatically,and user is alerted to the overheat condition byblinking of the Burner Status indicators.To recover from an overheat condition, proceed asoutlined below:

STEP1: Turn OFF Heater

STEP2: Allow Monitor Heater to cool

NOTE: Be sure that heater is cool to touch.

A period of 30 to 45-mmutes should be sufficient topermit heater to cool completely.

STEP3: Unplug HeaterDisconnect heater power cord from wall outlet.


STEP4. Check for Cause of Overheating

NOTE: Overheating is usually caused by objects

that impede free air circulation.

Look for debns and other obstructions at front ofheater, at Circulation Fan at rear of the heater, andat Flue Pipe tip outside dwelling.

STEPS: Remove Louver Assembly

STEP6: Clean Heater Interior

WARNING:

BEFORE PROCEEDING TO CLEAN HEATER, BESURE THAT HEATER INTERIOR IS COOL ENOUGHTO TOUCH.

With a clean, lint-free, damp rag or other appropriatecleaning material, wipe up all dust, dirt and debrisfrom exterior of cabinet, including exterior of Com-bustion Chamber and Heat Exchanger

STEP7: Replace Louver Assembly

STEPS: Reconnect Monitor Heater Power Plug tothe Wall Outlet.

STEP9: Turn Heater ON

STEP10: Reprogram Heater Microprocessor

STEP11: Select Mode of Operation

CAUTION: If after the completion of recoveryprocedure, the heater overheatsagain, something is wrong 'Do not operate heater until prob-lem has been diagnosed and corrected.

3-14 RECOVERY FROM BLOWN FUSEAll electrical components of the Monitor heater areprotected against power overloads and electricalmalfunctions by two 2-amp fuses and a 10-ampfuse. Should fuse blow, the recovery procedure isoutlined below:

STEP1: Turn Monitor OFF

STEP2 Unplug heater

STEP3 Remove louver assembly

STEP4: Remove front cover

NOTE: As the Front Cover of the Monitor 441 isconnected to the Printed Circuit Board byLead Wires, pull the Front Cover to the frontside slightly and remove the Connector ofthe Lead Wires from the Printed CircuitBoard, and then, remove the Front Cover.

STEPS: Locate and replace fus*(s)

STEP6: Reattach front cover(In case of the Monitor 441, be sure thatthe connector is connected to the printedcircuit board.)

STEP7. Reattach louver assembly

STEPS: Plug heater power cord into wall outlet

STEP9: Turn Monitor ON

STEP10: Reprogram heater

STEP11: Program Automatic operation cycles (ifapplicable)

STEP12: Select Automatic operation (if appli-cable)


33

-15 OPERATION CONTROL SYSTEMM-441 OPERATION TIMING CHART

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M-422 OPERATION TIMING CHART

MONITOR HEATING SYSTEMSSection 4: Maintenance

4-1 INTRODUCTIONHeater maintenance is divided into two classifica-tions: periodic maintenance is required to maintainthe heater in good operating condition: correctivemaintenance is necessary to repair a malfunction.

4-2 PERIODIC MAINTENANCEThe Maintenance Schedule provided in Table 4-1describes the tasks that must be performed periodi-

cally in order to sustain the efficiency of the MonitorHeating Systems.At the time of the demonstration or installation,heater maintenance should be discussed with theuser: emphasize that a clean heater and proper fuelare the keys to optimum heater operation andperformance.

Table 4-1 SUGGESTED MAINTENANCE ACTIVITIES

Activity Material RemarksCheck all fuel pipes for leaks andloose connections

3 8" OD copper tubing Fuel piping must be secure andfree of leaks. Replace tubingwhen necessary.

Inspect exhaust piping for leaks orloose connections

All exhaust pipes must be coveredby a cloth insulation cover.If cloth cover shows signs ofdiscoloration at joints, checko-rings.

Check fuel for water and/or othercontamination.If the capsule tank is used on theMonitor 422 the capsule tank filtershould be checked, cleaned orreplaced, as well as the constantlevel valve strainer.

Fuel color should be crystal clear,if fuel is contaminated, see Cor-rective Maintenance procedure,paragraph 4-9,

Inspect Fuel Pipe for obstruction

Inspect electrical wiring forcracks, signs of deterioration, barewires and or loose connectors

WARNING:UNPLUG HEATER BEFORE PRO-CEEDING. HEATER MUST ALSOBE COOL BEFORE STARTING.

Clean heater Clean, lint-free cloth and a mildnon-abrasive household cleaningagent. USE ONLY NON-PETROLEUM DISTILLATECLEANERS.

Wipe down exterior of heater cabi-net. Vacuum heater interior (ifnecessary).

Clean Air Circulation Fan (Monthly) Vacuum fan cage. Wipe fanblades.

Inspect air piping for leaks or looseconnections.Inspect rubber Air Hose at rear ofheater.

Look for cracks, .wear, or signs ofdeterioration; replace if necessary.

Clean fuel constant level Valvefilter. Inspect fusible link Valveinput fitting.Clean only if necessary, Verify thatheater is level.

Clean Kerosene Refer to paragraph 4-5. Procedureis described in paragraph 4-6.Check Leveling Guide.

Inspect flue pipe for obstructionor corrosion.

35

If blocked, clean and vacuum.If corroded badly, replace.


)Activity Material Remarks

Inspect Combustion Ring. FlameSensor Rod. Baffle, and BurnerCloth.iSuggested frequency every3 years).

. .

Clean all carbon deposits. Replaceif excessively worn, warped, orcracked.NOTE: If any gaskets are torn

when Components areremoved, the gasket mustbe replaced.

Clean Combustion Chamber (every3 years)

Vacuum all carbon deposits frominterior of chamber.

Inspect air holes in Burner Pot Use a small, stiff brush or a shortlength of soft copper wire to cleanany blocked holes.The M422 may need air holesreamed with a torchtip cleaner ifpartially block on a 5 to 7 yearbasis.

Clean Igniter Scrape any carbon deposits fromigniter.

Check air piping that interconnectCombustion Blower and Air Pres-sure Switch.

Replace air piping that is worn,broken or brittle.

Check for carbon build up in fuelinlet going into burn chamber (everyyear)

•

-.

Disconnect copper fuel piping fromburn chamber and clear fuel inletline by reaming with a solid piece ofwire<such as copper.bailing wire,excoat hanger) which should be ableto go in approximately 3" withoutobstruction.NOTE: Removing and retightening

burner fuel connectionmust be done when theburner cools down com-pletely. If it is done whenthe burner is hot, the weld-ing on the fuel joint maybreak. Fixing torgue fornut ;30~40kg-cm(26~35lb-in)

4-3 INSPECT EXHAUST/AIR PIPINGVerify that all exhaust and air pipes are free of leaksand loose connections, as specified below:STEP1: Remove Protective ClothRemove cloth insulation cover(s) from all exhaustpipes.STEP2: Inspection of Exhaust/Air PipingA. Visually inspect both air and exhaust piping for

obvious cracks, leaks, or loose connections.Black carbon deposits may be evidence ofthese leaks, and o-rings may need to bereplaced.

8. Be sure that all pipes are installed tightly and 35

securely, especially at joints.C. Turn heater ON.D. Carefully apply a small amount of soapy water

(with a paint brush) to the surface areas of theair/exhaust piping.Any leaks that may exist will be readilyidentified by the appearance of bubbles.

STEP3: Return to Operating ConditionA. Turn heater OFF.B. Dry all pipes with paper towels.C. Repair any leaks that have been found (if

necessary, replace the tubing).Replace cloth insulation covers.

)


4-4 VERIFY IGNITER OPERATIONVisually inspect Igniter Operation

WARNING:

HEATER IS OPERATIONAL DURING THIS INSPEC-TION. AVOID DIRECT CONTACT WITH ANYHEATED OR ELECTRICAL COMPONENT.STEP1: Prepare for InspectionRemove Louver Assembly.STEP2: Visual InspectionA. Turn heater ON.B. Look (downward) through window on the Com-

bustion Chamber. Verity that igniter is glowing.If igniter does not glow, something is wrong.Refer to the Troubleshooting Chart in Section 6of this Service Manual to diagnose the problem.

C. An alternate inspection is to feel the ignitercover after the unit has been in the ignitionstage for about 5 minutes. It should be warm.

CAUTION: If igniter is broken.do not operate the"ON OFF switch button repeatedly.

STEP3: Reassembly of HeaterTurn the heater OFF and replace the Louver Assem-bly.

4-5 CLEAN FUEL CONSTANT LEVEL VALVE FIL-TER

Contaminants are trapped by the filter to preventthem from clogging the Fuel Constant Level Valve.The filter, itself has a great number of small pores.Whenever a filter is torn or disfigured (enlargedpores), it should immediately be replaced.Inspect and clean the filter as indicated by theprocedure below:

WARNING

CLOSE FUSIBLE LINK VALVE ON M-422 OR CLOSESHUT-OFF VALVE OF THE EXTERNAL FUEL TANKON M-441 TO AVOID DRAINING ALL FUEL FROMTANKS.NOTE: Power should be OFF during the perfor-

mance of this procedure.STEP1: DisassemblyA. Using a phillips head screwdriver, unscrew the

screws holding the rounded diamond-shapedcover plate at the bottom of the Fuel ConstantLevel Valve. Remove the cover plate.

NOTE: Position a six inch U shaped piece of metalor cardboard under strainer cover to drainfuel into a pan.

B. Carefully remove the rubber gasket which islocated behind the cover plate.

STEP2: Inspection and CleaningA. Pull the filter straight out of the fuel reservoir.B. If the filter is dirty (but undamaged), rinse the

filter in fresh, clean kerosene to remove allparticles. Replace damaged filters.

C. To drain off upper portion of fuel constant levelvalve, back out phillips head screw which islocated slightly above and to the left of filtercover plate. (See Fig4-1)

D. If upper portion drain is dirty or containingwater, then remove pump and inspect andclean its screen.

STEP3: ReassemblyA. Push the (new or cleaned) filter back into the

bottom of the fuel reservoir.B. Replace both the rubber gasket and the cover

plate. (Take care to properly align the screwholes in the gasket and cover plate).

C. Wipe up any spilled fuel.

StrainerCover

StrainerCover

Drain Guide Container Drain Guide Container

M-441 M-422

Rgure 4-1 CLEAN FUEL CONSTANT LEVEL VALVE

37


4-6 CLEANING FUSIBLE UNK VALVE INTAKE FIT-TING ON M-422

At periodic intervals, the fitting on the Fusible LinkValve should be cleaned to prevent any accumula-tion of foreign materials from clogging the inlet. Thisis accomplished as follows:

WARNING

STEP2: Installation of New puseA. Install a new fuse into the fuseholder. The fuse

must be a 250-V, 2 amp or a 250-V, 10 amp typeas marked on the printed' circuit board.Do not use oversized fuses.

B. Replace the Front Cover and the LouverAssembly and plug the heater into the walloutlet.

UNPLUG THE HEATER. POWER TO THE HEATERSHOULD BE OFF DURING THE PERFORMANCE OFTHIS PROCEDURE-

STEP1: Close off Fuel SupplyA. Shut off fuel at the Storage Tank or remove fuel

from the fuel sump tank with siphon and syringeif using the capsule fuel tank.

B. Manually turn handle to close Fusible LinkValve.

NOTE: Place paper towels underneath the FusibleLink Valve to catch any spilled fuel.

STEP2: Clean ValveA. Loosen hex nut on Fusible Link Valve inlet

fitting at rear of the heater. Disconnect thecopper tubing which delivers the fuel from thestorage or the fuel sump tank.Using a small, straight piece of wire carefullyand slowly ream-out the inlet fitting on theFusible Link Valve.

B

Avoid scratching the inside wall of the fitting.With a cotton swab, wipe the interior area of theinlet fitting.

STEP3: Reconnect Fuel LineA. Reconnect the copper tubing to the intake

fitting and tighten the hex nut.B. Turn ON fuel at Fusible Link Valve and at

storage tank or fuel sump tank.C. Check for leaks.4-7 CORRECTIVE MAINTENANCEThe two procedures below are remedies for verygeneralized types of operating difficulties.4-8 REPLACEMENT OF FUSESA short circuit or similar electrical malfunction couldcause the fuse to blow. Troubleshoot the cause ofthe blown fuse.Replace the fuse as follows:

WARNING

DO NOT REPLACE FUSE WHILE POWER IS ON.STEP1: Removal of FuseA. Unplug heater. Remove Louver Assembly and

Front Cover.B. Remove the fuse from fuseholder on the Printed

Circuit Board.

IMPORTRNT: Whenever the heater is unplugged,the Microprocessor must be repro-grammed when power is restored.

4-9 FUEL CONTAMINATIONFuel contamination is often difficult to diagnose,even though it will adversely affect heater operationand performance. The best course of action to takewhen fuel contamination is suspected is to examineall of the system s fuel filters, beginning with the fuelstorage tank. If a Monitor Kerosene Lifter is part ofthe fueling system, examine and clean that unit'sfilter, as well as the filter located in the Fuel Con-stant Level Valve. When it has been determined thatwater or some other contaminants have infiltratedthe fuel, the following action must be taken:

WARNING

BEFORE PROCEEDING FURTHER, UNPLUG THEHEATER.STEP1: Remove ContaminationA. Shut OFF the fuel supply at the storage tank or

at the Fusible Link Valve.B. Drain off the contaminants from the fuel storage

tank or the fuel sump tank(M-422). Fill withfresh, clean fuel.

STEP2: Clean me HeaterA. Clean fuel constant level valve filter and filter

compartment.B. Remove the Louver Assembly and Solenoid

Pump on the constant level valve. Clean theSolenoid Pump filter.

STEPS: Reinstall Cleaned ComponentsA. Replace the components correctly and install

new gasket.B. Turn on the fuel at the storage tank and at the

fusible link valve, and apply power to the heater.If problem still exists and contaminated fuel issuspected it can be checked byA. Shutting off the fuel supply at the storage tank

and at the fusible link valve.B. Drain off fuel at constant level valve.C. Disconnect fuel line at back of heater and hook

up a 5 gallon quick tank with proven good fuel.D. Test run heater to see if problem clears up with

use of new fuel.38

MONITOR HEATING SYSTEMSSection 5: Servicing

5-1 INTRODUCTIONServicing is required when the Monitor Heater is notrunning at proper efficiency. This section coverspossible causes and corrective procedures for effi-ciency loses.

Signs of improper heater efficiency and performancewould be:

- Yellowish lazy flame— Smoke from flue pipe exhaust— Heavy soot and carbon build up in combustion

chamber— Lowered heat output.

5-2 MEASUREMENT OF FUEL FLOW RATEFuel flow rates are preset and sealed. These ratesshould not and we recommend they do not bereadjusted.

5-3 REMOVAL OF WATER DEPOSITS ANDCONTAMINANTS FROM FUEL CONSTANTLEVEL VALVE AND FUEL LINES

NOTE: Disconnect the Monitor from power supply(unplug) before proceeding.

1. Use a syphon pump and a syringe to drain offany fuel in the fuel sump (in case of capsuletank use on the Monitor 422).

2. If using separate tank on the Monitor 422 shutoff fusible link valve. On the Monitor 441 shutoff valve of separate tank.

3. Bend a piece of sheet metal or cardboard into aU shape and place it under the fuel constantlevel valve strainer cover to drain bad fuel intoa 1-2 liter pan. (Figure 4-1)A. Remove strainer cover and drain.B. With strainer cover removed, inspect, clean

and, or replace strainer if damaged.C. Remove drain port screw and drain.D. Replace strainer, cover and screw.E. Open fusible link valve or shut-off valve to

refill system with fresh crystal clear ker-osene.

F. Repeat steps 1-3 until all contaminated fuelis drained off.

4. Remove fuel feed pipe from burner pot andsolenoid pump, and drain fuel into pan.

5. Once lines are clear, reconnect fuel feed pipe,turn operation switch ON and start a test run.

NOTE: Removing and retightening burner fuelconnection must be done when a burnercools down completely. If it is done when a

burner is hot. the welding on the fuel jointmay break. Fixing Torque for nut:30-40kg • cm(26-35lb.m).

5-4 CLEANING THE BURN CHAMBER & BURNERPOT

Under normal running conditions, soot will notdeposit in great quantities inside the burner, and alight covering of soot will not affect the performanceof the unit thus it need not be cleaned. However, ifheavy soot built up does occur the unit should beopened and cleaned.The burner is assembled using gaskets to maintainits air tightness. If these gaskets leak, the extra aircan cause a serious soot problem and or exhaustgases to escape into the area being heated.NOTE: If any gaskets are torn when components

are removed, replace. Disconnect powersupply to unit.

If cleaning is necessary, use the following method:1. On the Monitor 422

A. Remove louver assembly.B. Remove front cover.C. Remove top cover and lead wire con-

nectors.D. Remove front and top heat shields that

cover the bum chamber and their leadconnectors.

E. Remove fuel piping from burn chamber.F. Remove igniter.G. Remove flame detective rod lead from PCB

(DO NOT REMOVE FROM BURN CHAMBER).H. Remove screw at top of burner cap which

attached it to cabinet. Remove screw atback of cabinet from exhaust duct andremove the 4 screws holding the burnchamber to base.

I. Rock chamber back and forth lightly, raiseabout 1/2" and remove burn chamber andheat exchanger, as one assembly from unit.

J. Set chamber upside down and remove the4 screws which secure the burner pot tothe burn chamber. Pull the burner pot up andout.

2. On the Monitor 441A. Remove louver assembly.B. Remove front cover and wire connectors.C. Remove top cover.D. Remove heat shield that covers combustion

chamber.E. Remove service panel.F. Remove Flame detector rod.For a more thorough cleaning, use the sameprocedure as for the M422 above.

39


3 Turn counter-clockwise to remove combustionring. If ring does not turn, pull up slightly toloosen retaining clips.

4. Use wire brush to clean inside of combustionchamber.Vacuum and wipe clean with a waste cloth.

5. If tar is present on the burner bottom, removethe tar by using a flat-bladed screw driver orwire brush.then clean the area by using avacuum cleaner etc.

NOTE: Make sure all air inlet openings are clear.6. When cleaning the inside of the burner pot,

remove the igniter and change the burner cloth bythe following procedure.

7 On the Monitor 422A. Apply glue<P No8217) on the burner bottom

as shown in Figure5-1.

B.Figure 5-1

Put the burner cloth on the burner bottom,afterwards press and straighten out theburner cloth so that it is glued flat and evenon the burner bottom.

On the Monitor 441A. Apply glue arround the burner cloth as

shown in Figure 5-2.

Aooron 1/8

Clue

AQD'GX 1,1*5•I

Figure 5-2B. As shown in Figure 5-3 and 5-4, insert the

Burner Cloth narrow between the NozzleCollar and the Igniter Shield, then push theBurner Cloth, using your fingers or a screwdriver, so that it slips in under the NozzleCollar. Afrerwards press and straighten outthe Burner cloth so that it is glued flat andeven on the Burner bottom.

NOTE: In some cases, pulling out the Fuel Nozzleand Collar may make this procedure easier.An easy out can be inserted into nozzle tohelp break loose and remove it.

Nozzie Ccnar

Burner Cloth

Figure 5-3 Figure 5-4C. Apply glue at all 4 corners of Burner Cloth

as Shown in Figure 5-5.Aooro» 3/8

Glu.

3/16'

Burner CK>mFigure 5-5

NOTE: The Burner Cloth is not symmetrical inshape, therefore make sure to place it inthe correct position so that the wider sideof the cloth is at left side of the IgniterShield as shown in Figure 5-5.

9. Combustion ring may deform and deteriorateafter several years use and should be cleanedand inspected before reinstallation. If combus-tion ring is warped, has cracked or is deteriorat-ing excessively it should be replaced.

10. When reassembling the unit check that com-bustion ring is positioned with the correct sideup and is sitting squarely on all three supportscrews(M~422) or pins(M-441) inside the burnerpot.

11. Reassemble by reversing the procedure foll-owed during disassembly.

NOTE: Use of the economy plus feature canminimize service calls and extend com-ponent life.

40


NOTE: Make sure the position of flame detector rod is centered between combustion ring and burner potbefore reassembling.(See Figure 5-6)

Flame Detector Rod

Combustion Ring Assy

BurnerPot

\ N - "N\ v .}\ I

V3

L CombustionChamber

.GapM-441: 4mm (0.16") or moreM-422: 3mm (0.12') or more

Figure 5-6

For minor adjustments of flame detector rod withoutdisassembling any components:1. Loosen the two retaining screws about half to

one full turn.2. Tightening down on the top screw first will

cock the rod outward away from the combustionring. Tightening the bottom screw first willcock the rod inward towards the combustionring.

5-5 CLEANING THE FUEL INLETWhen cleaning the combustion chamber and theburner pot. the fuel inlet nozzle should also becleaned. This can be done as follows:

1. Disconnect copper fuel line at burn chamber.

2. Push a piece of wire (about the same size asthe I.D. of fuel inlet pipe) into the fuel inletnozzle.

3. If obstruction is felt twist wire back and forth (tobrake up soot and carbon) so that wire ulti-mately penetrates igniter shield.On M-422, also check air holes surroundingfuel inlet for blockage and clear if necessary.

41

MONITOR HEATING SYSTEMSSection 6: Troubleshooting

Monitor 422 441 Resistance values

/*/*|4JDOMCWT

Igniter (connector B B)

Power Transformer - Primary (AC 120V)

Power Transformer - Secondary (AC 12V)

Power Transformer - Secondary (AC 120V)

Damper Solenoid (connector 1 1)

Resistor (connector G G)

Circulation Fan (M-422:RD & BK, M-441:WH & BK)

Circulation Fan (M-422:BK & YL. M-44VBK & BL)

Combustion Blower (M-422:BK & BK. M-441:WH & GR)

Combustion Blower (M-441:GR & OR)

Thermistor (connector Q Q, at IT F)

Fuse 2A (read with fuse out)

Fuse 10A (read with fuse out)

Solenoid Pump (coil)

APPROX.M-422

16.8

125

1.6

647

4,600

68

235

247.5

22

-

10,000

0.1

0.01

565

OHMSM-441

12.7

125

1.6

647

4,600

91

115

258.5

78

92

10.000

0.1

0.01

565

WARNING:

DISCONNECT HEATER FROM POWER SOURCEBEFORE MAKING ANY RESISTANCE TESTS.

43


Monitor 422 441 Component Voltage Readings

* Pulse can only be measured with a high impedance digital volt meter.

COMPONENT

Thermistor

ThermistorAir Pressure SwitchOverheat Protector ClosedAir Pressure SwitchOverheat Protector OpenDamper Solenoid

Solenoid PumpCirculation Fan High Speed

Circulation Fan Low Speed

IgniterPower Transformer(primary side)Power Transformer(secondary side)Combustion BlowerHigh SpeedCombustion BlowerLow SpeedResistor

READING TAKEN AT

Q on PCS Sensor disconnected

Q on PCB S---SOT connectedConnector J

Connector J

I on PCS

K on PCBRD to BK(M-422)WH to BK(M-441)~0 to BK(M-422)WH to BK(M-441)B on PCBAC 120V

AC 120VAC 12VF on PCB

F on PCB(Q1 is OFF)G on PCB

AC

110

0

1101109391

110110

12012

110

92(M-422)88(M-441)l8(M-422)22(M-441)

DC

5

1.5-3.2

105

pulse*

44


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46

GENERAL CHECKSIs power available in wall outlet?Is power Plug inserted in wall outlet?Has there been a power interruption? ( Displaywindow shows 88:88)Has Circulation Fan stopped?Is fuel in tank? Tank valve open?Has Fuel Constant Level Valve Set Lever raised and towered?

1 Is Operation Switch on?Is operation mode on Manual?Is set temperature in High position?Is Fusible Link Valve "open'?

SYMPTOM j CHECK1 1 RESULT 1 CHECK2 | RESULT | CHECK3 | RESULT | CHECK4 RESULT | | CHECKS RESULT J REASON

No ignition U- Operation

1

•J Yes t— is Igniter red?

through theCombustionChamberviewing window,ot leel ignitercoveriafterG 5minutes prepu-rge preheat itshould be warmto the touch

J NO P— Is Display Win- 1-1 1 H™, lit? I

h [ 1J

Incorrect winno of Flamesensor 01 Ground

Flame sensor rod louchesto burner parts ^ ™

CORRECTIVE MEASURE

Replace or check Circuit Board

Correct wiring

Correct 01 Change

Failure ol Air Pressure Switch 1 • i Replace Air Pressure Switch

— 1 ha.luie of Solenoid Pump 1 Replace Solenoid Pump

H Has constant level I I 1L« J Reset the fuel constant level valve 1valve safely tupped | | |

4 No 1— J Is winng __l Yes L—1 1 cofiecl' | ..II

1 1

LH N0 r-

i r * *>"•"" i_ LJ _j i'"'

Failure ol Combustion JBlower motor 1

Kulu-e of Circuit Board 1 1

Incorrect wiring I —4

Soot adhering to combustion i i»Jchamber interior. 1 1

1 ^t Failure ol solenoid Pump iT"~H

Failure of Igniter [ |

lor RnlPnn.H * P'"S on Cir- | 1 .. |Pumn cu,t board' L , . . 1 Failure of Circuit Board r^î

1 r . -4 Incorrect wiring i 1

4 Operation Switch ON '

1J fi i i i ~~|1 — r n ||1__|

1 1 , . __ . .

Is there 110V at ptug 1 I

Failure ol Circuit Board 1 j

Fuse open. | |

4 v- I HT___l

Short circuit of lead wire j 1

Failure of Circuit Board 1 1

is in Auto operation mode 1 1

Replace Combustion BlowerMotor.

Replace or checkCircuit Board

Correct winng

Clean gently with brush, etc

Replace Solenoid Pump

Replace Igniter

Replace or check Circuit Board

Correct wiring

Failure of Igniter relay on 1PCS replac..- boarj 1

Replace or checkCircuit Board

Change fuse

Correct or change

Replace or check CircuitBoard

Put in Manual-Burn Mode

P SYMPTOM j [ CHECK1 | j RESULT | [ CHECK2 | | RESULT j | CHECK3 j | RESULT | j CHECK4 ) | RESULT j REASON ] [ CORRECTIVE MEASURE

in fuelline?

Check forwater in fuel > Fusible link valve cl . ,-*i \ \ Replace handle of li;losed on M-422 I I Q( va|ve

lusible link valve

Tripped safety on Fuel constantlevel valve

Burner joint clogged Fuel Linepassageway into the CombustionChamber near base of Burne< Pot

I Fuel not fed because of suriasetension ol water

I Failure of Solenoid Pump.

Wiring failure.

Resel Fuel constant levelvalve

1 Clean burner joint

Waler gaihermg in fuel lank- frDischarge water

Replace Solenoid Pump

Con eel o/ replace wires

Straighten fuel line to remove airpocket, or. correct fuel lineinstallation

Fuel not enlenng into valve

«Overheat condition

Push Fuel Constant Level VatveSet Lever 4 or 5 times

t Push Operation Button (o "Off"2 Refuel tank3 Turn healer on

1 Unplug heater2 Remove air flow obstructions and

or determine cause of overheating.3 Replace cover and restart healer

Flame does 1 Make General Checks above, _^not increase I • ts fuel head too low?

~Hiflh' 1 • Is fuel line length correct?

• Is unit placed horizontally?

Poof flame, sounds of com-bustion, soot at the rear of theheater

H I

pump H^ghmode7

|_| Failure of solenoid pump [ j Replace solenoid pump |

L-J Failure ol circuit board 1 1 Replace or check Circuit board 1

SYMPTOM

duced whenset "High.-

CombuStion

ChamberWindow gets

running

CHECK1

placed hori-zon (all/?

la flue pipeloo long orhave too many

Section?,INSTALL:

Is ignitingtime too

(Usually 0.5-1

kerosene?

Is Healer

horizontally?

f la externalfuel tank tootow? (SeeSections.INSTALL.)

InstallAk Damper,if needed.

Is there anobstruction inthe CombustionAir intake

1 RESULT 1

1 11 """"" 1

1 11 UIIIIJ |

CHECK2

Fan

Check (ofobstructions

nests i in

supply piping

extend towhole area

| RESULT J | CHECKS [ RESULT [ CHECK4 [ RESULT | CHECKS j RESULT ]

r> r*

property?

^ Normal 1— cneck .s^ -j-J Normal I— ,s A,, -1-1 Yes I—

Pipe installedlor flo« ,it acCQ'ding to J —an ana etriausl "specifications?"

1 | __^_>^^^M| Al,,..,i,u.l J

-1 1 1~ f~~ 1

. L

i — i i

1 ixooeHy? 1 " |1 1

L

1

1 „_ 1

1

.

\_ _ _ J '« H»,h anH 1 n^ 1JS |imcs 1 '""' 1

— 1 Flame does not extend, 1

REASON

Fuel solenoid pump malfunctioning |

Clogged an supply or exhaust piping I—

improperly.

Air leaks from Igniter Cover. I—rdue to dust or bubbles in Fuel

Failure of solenoid pump. —

CORRECTIVE MEASURE

^S 1 oid A

— j Replace solenoid pump

to spectlicaiions

•" Remove obstructions.

He pe

1

H'

Install ComDusliO.. H.ng properly.

— . Replace gasket; correctly installcover.

• reset lever.

^J Replace solenoid pump.

SYMPTOM

Tho 0thpfrnnstat 'Snrttvnlod

CHECK1

Is windowcurtain looclose to thetern ot unit'

r.in Gua'ddusty1'

-

RESULT |

J Y« U1 Yes h

4 NO Un No r

CHECK2

tion fan operateproperly?

| RESULT | CHECKS 1 RESULT ]

1 n 11 r

I " \1 1

•

1

L

REASON

CirtBin m nthnr ohdtnirlinn |__—covers circulation air inlet.

air outlet.

Circulation Ian (ailed. •— • H

Incorrect wiring 1

CORRECTIVE MEASURE

Keep curtain from unit.

Replace Fan Motor.

Repair or replace wiring.

I SYMPTOM | | CHECK1 | [ RESULT | | CHECK2 ] | RESULT ) | CHECK3 | [ RESULT | | CHECK4 | | RESULT | JCHECK5 | | RESULT REASON ] [ CORRECTIVE MEASURE

I II 1 I in the disp

do not anempt to repair, replaceand send PCB thru your distrib-utor to MPI for repair.

')1

.

-

1 1 |TP3? | l_^_ J1

J j ~~11 J roo-7 ~| '" |

-

_| "| n • 1I f Hr,aS rvip,.i nf 7 P 7 1 L 1

luin into Hiqh 1-orn 1

H - 1 1

(On M-422)

1

button switch to (on M-422) Remove the connector of operation cn-

, ^^____ Tl nin ma Tfi pin .m PCB

-1 No ' U— Is lempeiatuie -J No I-M Does heater 1— pi Yes. t—L^HH_H BJ r)isplay«l '1 L. J 1 start to ooerate? 1 1 [ ^^ ^ |

LJ No I—

r |i Yes I

n

--L

L

M iFailure of Trans- 1 1 Replace transformer

(D6-O91

[ Failure of Capacitor

1

Failure of Capacitor(C9) |

processor Cl?

Failure of comparalar(ICl3)

[ Failure of resistor(R29 - R32) |

I Faikjre of Capacitor<C18> 1

[ Failure ol switch(SW1I

H IHelill luel |

Failure of resistor(R38. R39)

Failure of capacitor(C20)

Failure of operation [ 1 Replace operation circuit board. 1circuit board [^____ 1

Failure of resonator(XLt>.

(R59I.

I Failore of microprocessor

K*

[ SYMPTOM | [ CHECK1

| *,!,*„. | I jy^l

| RESULT |

rl NO 1—1 "• r

J Y« I—1 r

CHECK2

u there !2Vdcat coil of relay

onpre

Does combustion

during prepurgeand igniting?

|RESULT|

l-l No I—-| NO f-

-1 Y.S I—n (-

1-1 NO |_-J NO |_

_j Ye, l_1 YM h

CHECK3

Is theie 12VOCbetween TP3and IC(X it pin)?

switch work rxx-

1 RESULT

J No1

j iT 1

J Ki

1 N°

[ CHECK4 | | RESULT | | CHECKS | RESULT |

.

REASON

Iprocessor (1C1).

'— j Failure of TR artay(IC6)

Failure of relaiMJl.

~1 Fuse (F2i open.

-J Igniter open.

processor (rCIK

-j oiiLrc or m anoi iCQ.

(IC8I

^Failure of triacM

— J Failure of resistor.1 W. R51)

^Failure of capacitor»

^Failure of combustionblower.

Încorrect wiring ofcombustion blower.

pressure switch.

Rubber hose isbloked ondiscorrected.

—4 Incorrect wiring.

| CORRECTIVE MEASURE

1 I Replace fuse.

1 Replace igniter

M Replace combustionblower.

M Correct wiring.

M Replace air press-ure switch.

H Clear and orcorrect rubber ho*e.

"' 1 Correct wiring.©

SYMPTOM j | CHECK1 | | RESULT | | CHECK2 | | RESULT | | CHECK3 | | RESULT | J CHECK4 j | RESULT j | CHECKS \ \ RESULT | | REASON | | CORRECTIVE MEASURE |

Does solenoidpump wo**?

Failure of fuel supplyparts.

Failure of resistor(R2-R9)

Failure of capacitor(C4-C6).

Failure ol zener diode(ZD1).

Failure of diode(D3-D5).

I Failure ol trigger diode1 fTDJ.

Failure of thyristor(02.03).

hi Failure of *ode<D2)

Failure of reststor(R53).

Failure of photo triac(ICI!)

Failure of transistor(06. Oil).

Failure of micToprocessorOC1)

Failure of TR array(IC6)

Failure of diodefDtT).

Check fuel supply parts

I SYMPTOM 1 | CHECK1 "| | RESULT | | CHECK 2 ] [ RESULT | | CHECK3 "| | RESULT [ I CHECK4 I | RESULT | J CHECKS ] [RESULT | [ REASON CORRECTIVE MEASURE

I

Is there morethan 1.3Vdc atTP6?

FLAME ROO BYPASS CIRCUITFor testing purposes - A flame detector rod bypass circuit can be madeup. consisting of 2 insulated alligator clips. 2-6" pieces of insulatedcopper wire, 1-1 4" watt 400 volt diode, and 1-l/4~ watt 100k OHM resistor.These components are to be soldered together in sequence as shown indiagram below (note component sequence and polarity).

Once the bypass circuit is made the unit isturned on. immediately after the prepurge preheat cycle; when mode lightcomes on. the O and N pins are disconnected off the PCS and replacedwith the bypass circuit. The unit should then continue functioning asthough it had a good flame inside the burn chamber and servicetesta such as fuel flow can be checked.

(Note-WARNING, after all tests are completed,replace original flame rod wires as rt is a vital safety feature.)

Failure of resistor(RI8-R21. R25)

Failure of trans-former.

Replace tianslofmer.

Failure of capacitor(CU-ICt6|.

Failure of resistor(RIO. R22-R24)

Failure of compara-tor (IC3)

Failure of resistor<R27).

Failure of diodem*

-( F

1_J.C

ailure of capacitor(C29),

Failure of transistoitQT)

Failure of microprocessor(Cl),

Failure of resistor(R33.R34).

Failure of wiring forflame sensor and ground. hi Correct wiring

Incorrect installationof flame sensor rod

Correct installation

SYMPTOM | CHECK1 j | RESULT | [ CHECK2 | [ RESULT | j CHECK3 | | RESULT | REASON | CORRECTIVE MEASURE |

Change of bummode(High--Lowlis inpropef.

[ Is temperaturedisplay normal?

Connect tOKfl reststor at rat pins, andthen, set temperaturefrom Low to High.

rl Yes 1-i r

1 1N° r

able to changefuel flow rate?

approx. 2.8V

H NO1 "° \

J Yes 1i i

j ,.I ""

4 Yes1 YM

Is circulation Ian

change speed?

r ii Yes r

.

,

--L---~---LL

(ICll

Failure of photocouple«.ICIJ,

Failure erf TH array(IC6I,

1 Failure of solenoidPump

(ICO

Failure of photo triacIIC7)

1 Failure of TR arrayRtt

Failure ot circulationfan motor-

Failure of microprocessor(IC1).

Failure of TR array«C6).

Failure ot photo triac(IC8.9).

Failure of tnac(Q1).

Failure of resistor(Rl. RSt. R52).

1 Failure of capacitor(C2)

Failure ot combustionblower.

Failure of resistor forcombustion blower

1 Failure of dampersotenoKt

<R12, R13).

Failure of capacitor(C,,,

Failure of micro-processor (1CU

1 Replace solenoid pump

H Replace circulationfan motor.

H Replace combustionblower.

H Replace dampersolenoid


INDICATION OF FAILURE MODE

Digital Display The Reason of Indication Trouble Point

/_ n iL U I

At pre-purge, Flame rod is sensing flame , Flame sensing circuit, grounded

when there should be none. flame rod or pinched wire.

C U Jon, power supply to the micro- Timer clock circuit bad or

processor timing circuit is incorrect. j source to unit above or below

acceptable levels.

c nuAt starting of operation, the circuit to drive

photo triac of Solenoid Pump is mal-

functioning.

Solenoid Pump control circuit

has a malfunction.

56

MONITOR HEATING SYSTEMSection 7: Electrical SystemSchematics

58

i . P£fc •!"*••» P"-'!' i «*tf-^-, r i pZ4,«,. B3, / c":\ Llc?P3X^ ..U_£^sT ,-.?j5

\ ICh3 — *ZI ?

MONITOR HEATING SYSTEMSection 7: Electrical SystemPrinted Circuit Wiring Diagram

CONNECTION OF LEAD WIRESIfP

1

OPERATION TIMER SELECTOR Uf _ TIME. 1 | 1 r— 1 1— i r— i i—i i— i 1 IMt C_ ITEMPa C

Panel Printed Wiring Board

/TEMP SET=3 CD C_)

RUN AUTOES™ BURNER STATUS TEMPk=i cn c= / / / / / £*)|

SET ROOM

Lamp Printed Wiring Board

r^=\

=?—

TlT2T3

1-5ref7

I T8 1T910C

a«fg

AirPressureSwitch

Over HeatThermostat

Solenoid Valve

Blower forCombustion

Blo ol

jo o]C

|o o o|0

[ojN

[o oF

|o o|G

Resistor

[oj0

Mam PrintedWiring Board

PIqJK

|o o|0

L

Sensor (Thermistor)T10T11T12T13T14 Slide Switch

i~lol-Cfb-| Flame Detector

-=• Ground

Blower forCirculation

FanThermostat

BA

1 L

| Heater

8B

4r

•.

Junction Box

PowerCord

figure 7-1 Monitor441

59

MONITOR HEATING SYSTEMSSection 7: Electrical SystemPrinted Circuit Wiring Diagram

CONNECTION OF LEAD WIRES1

1

OPERATION TIMER SELECTOR T..., TIME(— I f— I a ==> = a a TIME a | — | ,

TEMP a C— 'Panel Printed Wiring Board

/TEMP SETZD CD C=J

01 IN «,UTQ PLUS PMPTY BURNER STATUS TEMPi — i i — i i — i i—i / I I I ! AMI I I ' ' P M

Lamp Printed Wiring Board

SET ROOM 1=3

^=-

Tl12T3T431

rr

~ri~

«Bc

•t__9

p>—'Pump

AirPressureSwitch

Over HeatThermostat

Solenoid Valve

A|o ol

B|o o|

Main PrintedWiring Board

[o olC

|o o o|0

|00|0

[•••II

[o oF

[o o|6 lol

[ojJ

pLO)K

_l [ Short

-cQ Terminal

Empty Lamp Switch(Float Switch)

Sensor (Thermistor)T10T11Tl?T13T14

kui n n1 Slide Switch

Flame Detector

i- Ground

Blower forCombustion O

Resistor Blower forCirculation

1cLiID

iBL

1A

I L

~1

.1

Heater

B,1 B:IT"

e,«9

E

PowerCord

Thermostat Junction Box

figure 7-2 Monitor422

60

MONITOR 441SERVICE PARTS LIST

MONITOR 441 SERVICE PARTS LISTITEMNO.

t23456789101112131415161718192021222324252627282930313233343536373839404142434445464748495051525354

PARTNO.

640050196301630263036304634464676450635764016363635863116115640263546403635561196196631363146122612361766315616463526353640461246125640563506317634963566321632263236406632461446348645164616462625362036172617364526187

DESCRIPTIONSPILL TRAYLEGAIR SUPPLY HOSE (A)AIR SUPPLY HOSE (B)CONSTANT LEVEL VALVEC.LV. STRAINERSTRAINNER GASKETFUEL PIPESOLENOID PUMPGASKET (1)BURNERBURNER CLOTHROPE GASKETHEATERGASKET (3)IGNITER BRACKETHEATER COVER PACKINGIGNITER COVERFLAME DETECTIVE PLUGPLUG PACKINGFL PLUG BRACKETGASKET (4)HEAT EXCHANGER ASSYGASKET (6)EXHAUST DUCTO-RING (P39)OIL SUMP PIPEJOINT SEAL PACKINGFUEL NOZZLEFUEL NOZZLE COVERBASE TRAY RETAINERWINDOW GASKETWINDOW FRAME GASKETWINDOW GLASSWINDOW BASE GASKET -CHAMBER GASKETCOMBUSTION CHAMBERCOMBUSTION RING ASSYCHAMBER CAPCONDENSER (2.5 ^FD)BLOWER ASSYDAMPER SOLENOID ASSYSUCTION CASE A ASSYSEAL PACKINGMOTER FOR COMBUSTIONPWB ASSYPWB SPACER CLIP (A)PWB SPACER CLIP (B)MICROPROCESSORBUZZERFUSE (250V 10A)FUSE (250V 2A)CAPACITOR (1.5. u FD)TR ARRAY (M54563P) IC4

ITEMNO.555657585960616263646566676869707172737475767778798081828384858687888990919293949596979899100101102103104

PARTNO.62046251632663436136646364646137646661394833603761386186627862066207620840046407640861454014401640064008480561476148607564536454645563326409645664576458626663376338646561946197645963421153821682178219

DESCRIPTIONPHOTO COUPLER IC12POWER TRANSFORMERAIR LINEAIR PRESSURE SWITCHRUBBER BUSHOVER HEAT THERMOSTATFAN THERMOSTATCORD CONNECTORJUNCTION BOX COVERPOWER SUPPLY CORDCORD BUSHINGLEVEL GUIDECARRYING HANDLESENSOR ASSYSLIDE SWITCH ASSYSLIDE SWITCH COVERSLIDE SWITCH PANELSLIDE SWITCH KNOBJOINT PIPEAIR DAMPER (E)AIR DAMPER (S)AIR SUPPLY HOSE ASSYEXHAUST OUTLET CAPAIR PORT O RINGPIPE HOLDERHOSE BANDAIR OUTLET CAPFLUE PIPE ASSYSLEEVE FLANGE SETFANCIRCULATION MOTORBLOWER GUARDWIRING GUARDUNDER COVERLOUVERCONTF1OL COVERFRONT COVERLAMP PANELSWITCH & LAMP ASSYTOP COVERRESISTORCABINET ASSYWALL CLAMPSSCREW SET FOR FLUE PIPECARTON BOXCUSHION SETOWNERS GUIDETOUCH-UP PAINT (WHITE)GLUETOUCH-UP PAINT (GREY)

61

MONITOR HEATING SYSTEMEXPLODED VIEWS AND PARTS LIST

63

Touch-up Paint (White)

Glue

Touch-up Paint (Grey)

Screw Set for Flue Pipe

gg) Carton Box

Cushion Set

Owners Guide

MONITOR 441 EXPLODED VIEW

MONITOR 422SERVICE PARTS LIST

MONITOR 422 SERVICE PARTS LISTITEMNO.

123456789101112131415161718192021222324252627282930313233343536373839404142434445464748495051525354555657

PARTNO.620050196101610261036104610561066189610862506110616461116112618261136114611562776195611761916118611961966120612161226123617661246125606860696126612761816128612961306131625162526134613562536203617261736256618762046137610761846136

DESCRIPTIONSPILL TRAYLEGAIR SUPPLY HOSE (A)AIR SUPPLY HOSE (B)FUEL PIPEFUSIBLE VALVECONSTANT LEVEL VALVEC.LV. STRAINERSTRAINER GASKETSOLENOID PUMP PACKINGSOLENOID PUMPOIL SUMP PIPEJOINT SEAL PACKINGFUEL SUMPGASKET (1)BURNERBURNER CLOTHGASKET (2)GASKET (3)HEATERIGNITER BRACKETHEATER COVER PACKINGIGNITER COVERFLAME DETECTIVE PLUGPLUG PACKINGFL PLUG BRACKETGASKET (4)HEAT EXCHANGER ASSYGASKET (6)EXHAUST DUCT0-RING (P39)WINDOW GASKETWINDOW FRAME GASKETWINDOW PLATEWINDOW GLASSWINDOW BASE GASKETCOMBUSTION CHAMBER ASSYCOMBUSTION RING ASSYBURNER CAPBAFFLE ASSYCHAMBER GASKETCHAMBER CAPPOWER TRANSFORMERPWB ASSYPWB SPACER CLIP (A)PWB SPACER CLIP (B)MICROPROCESSORBUZZERFUSE (250V 10A)FUSE (250V 2A)CAPACITOR (1.8 uFD)TR ARRAY (M54563P) IC4PHOTO COUPLER IC12CORD CONNECTORAIR LINEAIR PRESSURE SWITCHRUBBER BUSH

ITEMNO.585960616263646566676869707172737475767778798081828384858687888990919293949596979899100101102103104105106107108109110111112113114

PARTNO.

627362606163613948336037613861866278620662076208614061416142614361446261626261806263626440046209614540144016400640084805614761486149621062656266626762686158615961796269617861776162627063456194621461976271617511548216821782196216

DESCRIPTIONOVER HEAT THERMOSTATFAN THERMOSTATAIR PACKING SETPOWER SUPPLY CORDCORD BUSHINGLEVEL GUIDECARRYING HANDLESENSOR ASSYSLIDE SWITCH ASSYSLIDE SWITCH COVERSLIDE SWITCH PANELSLIDE SWITCH KNOBBLOWER ASSYBLOWER MOUTH PACKINGDAMPER SOLENOID ASSYSUCTION CASESEAL PACKINGBLOWER GUARDCIRCULATION MOTORFAN BLADEWIRING GUARDWIRING HARNESS FOR FAN MOTERJOINT PIPEAIR DAMPER (S)AIR SUPPLY HOSE ASSYEXHAUST OUTLET CAPAIR PORT O RINGPIPE HOLDERHOSE BANDAIR OUTLET CAPFLUE PIPE ASSYSLEEVE FLANGE SETUNDER COVERLOUVERFRONT COVERSWITCH & LAMP ASSYTOP COVERLAMP PANELFUEL TANK COVERFUEL TANK ASSYFUEL TANK CAPFLOAT SWITCHFLOAT SWITCH PACKINGOIL FILTERRESISTORCABINET ASSYUNION NUTWALL CLAMPSBASE TRAY RETAINERSCREW SET FOR FLUE PIPECARTON BOXCUSHION SETOWNERS GUIDETOUCH-UP PAINT (WHITE)GLUETOUCH-UP PAINT (GREY)FUEL NOZZLE

64

MONITOR HEATING SYSTEMEXPLODED VIEWS AND PARTS LIST

!

66

Touch-up Paint(White)

fl2) GlueTouch-up Paint(Grey)

MONITOR 422 EXPLODED VIEW

Documents

MONITOR HEATING SYSTEMS Service Manual