Service Manualmonitorproducts.com/wp-content/uploads/Service manuals...MONITOR GF500 Vented Heating System Service Manual • The information contained herein is proprietary to Monitor

MONITOR GF500Vented Heating System

Service Manual•

The information contained herein is proprietary to Monitor Products, Inc. shall not be disclosed, duplicated, nor

otherwise copied in whote or part for any other purpose without express written permission of the Legal Department

of Monitor Products, toe. This data is issued to authorized Monitor Servicing Personnel for guidance in the

installation and maintenance of the subject product and is intended for use by authorized Monitor service personnel

only. Further, Monitor Products, Inc. reserves the right to make improvements and corrections and to alter

specifications of products described herein, at any time without prior notice.

P. O. BOX3408

PRINCETON, NEW JERSEY 08543

MONITOR HEATING SYSTEMTable of Contents

Section 1: Description Page 1 -71-1 Specifications; 1-2 Special Features; 1-3 Safety Features; 1-4Munual Gas Valve; 1-5 Automatic Gas Valve; 1-6 Gas ControlValve; 1-7 Burner; 1-8 Orifice; 1-9 Ignition Plug Unit; 1-10 IgnitionTransformer; 1-11 Flame Detector; 1-12 Combustion Blower;1-13 Heat Exchanger; 1-14 Flue Pipe; 1-15 Air Circulation Fan;1-16 Air Pressure Switch; 1-17 Overheat Protector Switch; 1-18Thermal Fuse; 1-19 Overcurrent Fuse; 1-20 Electrical System;1-21 Microprocessor; 1-22 Temperature Sensor; 1-23 SafetyMechanisms; 1-24 Cloth Covered Exhaust Pipe; 1-25 AirCirculation Fan Guard; 1-26 Slide Selector For The Reset Temp.

Section 2: Installation Page 9 -152-1 Notice Before Installation; 2-2 Heater Installation; 2-3 FluePipe Clearances; 2-4 Installing An Extension Kit; 2-5 GasConnection; 2-6 Gas Conversion Procedure; 2-7 High AltitudeInstallation; 2-8 Manifold Pressure Readings

Section 3: Operation Page 17 - 253-1 Introduction; 3-2 Operating Specifications; 3-3 OperatingControls And Indicators; 3-4 Pre-operation Check List; 3-5Operation; 3-6 Manual Heater Operation; 3-7 Automatic HeaterOperation; 3-8 Reprogramming The Monitor Heater; 3-9 HeatSensor; 3-10 Monitor Shutdown; 3-11 Recovery From A PowerFailure; 3-12 Recovery From Overheat Condition; 3-13 RecoveryFrom Blown Fuse; 3-14 Operation Control System

Section 4: Maintenance/Servicing • Page 274-1 Cleaning The Cabinet; 4-2 Checking The Flue Pipe; 4-3Cleaning The Interior; 4-4 Cleaning The Blower Guard; 4-5Electric Motor Maintenance; 4-6 Checking The Burner Flame;4-7 Cleaning The Burner

Section 5: Troubleshooting Page 29-51Resistance ValuesComponent Voltage ReadingsTest Point VoltageTroubleshooting Diagrams (Mechanical / Electrical)Indication of Failure Mode

Section 6: Electrical System Page 53-55SchematicWiring Diagram

MONITOR HEATING SYSTEMSection 1: Description

1-7 BURNERThis burner is a Bunsen type with a speciallystructured flame port section, which shapes andpositions the flame, so it can be wrapped by thesecondary air flow, and burn completely. Secondary Air

Flame Port SectionPrimary Air and GasMixture

Burner Assy

Secondary Air

Mixing Plate Orifice 1-4

1-8 ORIFICE NOTE:The orifice is made of brass, inserted into the For altitude applications over 2,000 feet refer togas passage of the mixer, and fixed by the gas page 15.pipe.

/t\. WARN ING:Use of incorrect orifice will create a fire hazardand damage unit.

Gas Type

Shape, Stamp

Orifice size

Natural

nii

VDia 3.50mm

LP

h

I: uDia 2.64mm


1-9 IGNITION PLUG UNITThe Electrode is applied high voltage, anddischarges to the Grounding Rod to ignite theburner. The discharge gap between the Electrodeand the Grounding Rod is 3.5 ± 0.8 mm.

y\V=^

7Flame Detector Rod

Electrode

Grounding Rod

Figure 1 -6

1-10 IGNITION TRANSFORMERThe Ignition transformer generates high voltageusing 120 VAC power, dischaged by the Ignitionplug to ignite the burner.

PowerTerminal

W

High Tension Cord

Grounding Terminal

Rgure1-7

/!\ WARNING:Do not touch when functioning. High voltage of15 kV is generated.


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1-11 FLAME DETECTORAn Electrode which detects that the burner hasbeen ignited, using the flame as a conductor,instantaneously detects when the flameextinguishes and shuts down the AutomaticValve.

1-12 COMBUSTION BLOWERThe Combustion Blower has a two stage intakefan. The intake fan draws in outside air thru theflue pipe for internal combustion.Burner modes control fan speeds and theSolenoid Damper in the Blower Casing. Thosefunctions are as follows:

COMBUSTION AIR CONTROLBum Mode Fan Speed Solenoid Damper

High High Off (open)Low Low On (close)

Setting air flow for Solenoid Damper on Lowmode should read 9±0.5 mm for Nat. and8.4±0.5 mm for LP.

1-13 HEAT EXCHANGERAn inlet at the top of the Heat Exchanger permitsthe heated air to travel from the CombustionChamber into the Heat Exchanger.An outlet, at the bottom of the Heat Exchanger,permits combustion by-products to be vented tothe Flue Pipe.While moving through the Heat Exchanger, thehot air within the Heat Exchanger heats theoutside metal walls. The hot metal walls, in turn,heat air that is pushed past the Heat Exchangerand is circulated into the room. An air baffle,directly in front of the Heat Exchanger, deflectsthe heated air downwards, and out, through theLouver assembly.

1-14 FLUE PIPEFlue Pipes are available in three (3) sizes. Thisprovides the flexibility to meet the installationrequirements for dwelling of various wallthicknesses. One side of the Flue Pipe containsa "T"-shaped fitting consisting of four ports. Thisside is mounted on the interior wall of thedwelling. The pipe side of the Flue Pipe is ventedoutside the dwelling. The Flue Pipe assemblyconsists of two concentric tubes. Outside air isdrawn through the cylindrical space between thetubes.As the cool air enters, it is heated by the hot airthat is exiting the system.A large-bore, flexible hose connects the air inletport on the Flue Pipe with the Combustion

Blower; a cloth-covered metal pipe connects theHeat Exchanger with the exhaust outlet on theFlue Pipe.

1-15 AIR CIRCULATION FANThe Circulation Fan is driven by a two speedmotor and is designed to circulate the heatedroom air. If the heater is running in low burnmode, the fan also runs at low-speed; in highburn mode, the fan advances to high-speed.Operation of the fan is controlled by theMicroprocessor and Fan Thermostat Switch.Physically assembled with a protective wirecage, the entire fan assembly is secured to abracket on the rear of the Heater Cabinet. Asheet metal conduit, at the rear of the Heater,protects the fan wiring from damage.


1-16 AIR PRESSURE SWITCHThis switch consists of a rubber diaphragm whichsenses changes in air pressure (it is connected tothe Combustion Blower and the CombustionChamber) and a normally-open, micro switch.Should an abnormal pressure differential exist,the switch opens to disable the circuitry thatcontrols the supply of gas. Since the flow of gasto the Burner is cut off, the flame extinguishes,and the burner Status Indicators blink.This safety mechanism can be triggered byseveral conditions:

- Leak, loose, or broken tubing which connectsthe Air Pressure Switch with the CombustionBlower or the Combustion Chamber

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

blocked- Combustion Blower is inoperable

1-17 OVERHEAT PROTECTOR SWITCHThe normally-closed Overheat Protector Switchsafeguards the heaters against damage due tooverheating.The Switch is rated 115°C (239°F). Should aMonitor overheat (internal temperatures risebeyond 115°C/239°F) switch will open to shutdown the heater. After extinguishing the flame, theBurner Status indicators continue to blink. TheOverheat Protector Switch will automatically resetafter cooling down. Once the heater has cooled to90CC(194°F), the system can be restarted. Torestart 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 ON.E. Proceed with normal operation.

1-18 THERMAL FUSEShould Overheat Protector Switch malfunction,and the heater be further overheated, the thermalfuse(internal temperatures rise beyond 145CC/293CF) melts and prevent further overheating.

1-19 OVERCURRENT FUSE2-amp., 125VAC, fuse protects the heater fromdamage resulting from power overloads. In theevent of a power surge or internal wiring hazards,the fuse opens and power to the heater is cut off.

1-20 ELECTRICAL SYSTEMElectrical power is supplied to the Monitor to runthe Microprocessor and the other electrically-energized component.

Electrical operation of the Monitor can be thoughtof as having the following eight(8) distinctphases: plug in; turn on; pre-purge; ignition; pre-combustion; heating; shutdown and post-purge.

1-21 MICROPROCESSORPrincipally consisting of a 64-pin IntegratedCircuit, the Microprocessor provides safetytimings, controls relays and provides clock andthermostat functions for the Monitor heater.

1-22 TEMPERATURE SENSORThe sensor which is capable of sensing roomtemperature within a range of 42°F to 96°F, canbe left mounted on the back of the heater cabinetor be wall mounted.

Approximately 61/2' (about 200 cm) of No. 20AWG Wire is supplied with the sensor to facilitatewall mounting the sensor in a favorable location.

I-23 SAFETY MECHANISMSSeveral safety mechanisms have been built intothe Monitor Heating System. These devicesprotect the user against personal injury, protectthe heater against damage, and shutdown theheater if a malfunction occurs.

1-24 CLOTH COVERED EXHAUST PIPEInsulating cloth covers are to be placed over allmetal surfaces of the Exhaust Line duringinstallation. Since combustion by-products arevented at elevated temperatures, the ExhaustPipe will become hot during operation. Theinsulating cloth covers protect the user from bumhazards associated with accidental contact withthese heated metal surfaces. During installationmake sure that all Exhaust Lines are tight. Do notoperate the heater without the insulating covers.

1-25 AIR CIRCULATION FAN GUARDThis guard is an integral part of the fan assembly.The guard protects the user against physicalinjury which could occur from accidental contactwith revolving metal fan blade.

1 -26 SLIDE SELECTOR FOR THE RESET TEMP.Once power is restored after power interruptionby power failure or by disconnecting heater plugfrom wall outlet, heater will resume operation inthe MANUAL mode and maintain roomtemperature according to the setting temperatureselected by using the selector for the resettemperature at the lower right hand side of thecabinet.

6

1 cAIR CIRCULATION FAN

FLUE PIPE

INTAKE OUTDOOR AIR

<={> EXHAUSTEXCHANGER

COMBUSTION CHAMBER

AIR DAMPER

COMBUSTIONBLOWER

FLAME DETECTOR

GAS CONTROL VALVE

AUTOMATIC GAS VALVE /

MANUAL GAS VALVETRANSFORMER

BURNER ASSY

SOLENOID DAMPER

AIR PRESSURE SWITCH

Figure 1 -8 ELEMENTS OF COMBUSTION SYSTEM

OzH

(/> O

I?

MONITOR HEATING SYSTEMSection 2: Installation

2-1 NOTICE BEFORE INSTALLATIONThe heater must be installed by a qualified serviceperson according to this installation instruction .

The installation must conform with local codes or,in the absence of local codes, the National fuelGas Code, ANSI Z223.1 .

The installation must conform with local codes or,in the absence of local codes, the current CAN 1 -B149 INSTALLATION CODE.

For mobile housing and recreational installationthe current Standard CSA Z 240.4 GASEQUIPPED RECREATIONAL VEHICLES ANDMOBILE HOUSING.

A manufactured home (mobile home) installationmust conform with the Manufactured HomeConstruction and Safety Standard, Title 24 CFR,Part 3280, or, when such a standard is notapplicable, the Standard for Manufactured Homeinstallations, ANSI A 225.1/NFPA 501 A.

Due to high temperatures the appliance shouldbe located out of traffic and away from furnitureand draperies.

Children and adults should be alerted to thehazards of high surface temperatures and shouldstay away to avoid burns or clothing ignition.

Young children should be carefully supervisedwhen they are in the same room as the appliance.

Clothing or other flammable material should notbe placed on or near the appliance.

Make sure that the flow of combustion andventilation air not be obstructed.

Any safety or guard removed for servicing anappliance must be replaced prior to operating theappliance.

A\ WARNINGDo not operate appliance with the panel removed,cracked or broken. Replacement of the panelshould be done by a licensed or qualified serviceperson.

Installation and repair should be done by aqualified service person. The appliance should beinspected before use and at least annually by aqualified service person. More frequent cleaningmay be required due to excessive lint fromcarpeting, bedding material, etc. It is imperativethat control compartments, burners andcirculating air passageways of the appliance bekept clean.

Do not use this heater if any part has been underwater. Immediately call a qualified servicetechnician to inspect the heater and to replaceany part of the control system and any gas controlwhich has been under water.

The appliance, when installed, must be electricallygrounded in accordance with local codes or, inthe absence of local codes, with the NationalElectrical Code, ANSI/NFPA 70 .

The appliance, when installed, must be electricallyconnected and grounded in accordance with localcodes or, in the absence of local codes, with thecurrent CSA C22.1 CANADIAN ELECTRICALCODE.

/^WARNINGTHIS APPLIANCE IS EQUIPPED WITH A THREE-PRONG (GROUNDING) PLUG FOR YOURPROTECTION AGAINST SHOCK HAZARD ANDSHOULD BE PLUGGED DIRECTLY INTO APROPERLY GROUNDED THREE-PRONGRECEPTACLE. DO NOT CUT OR REMOVE THEGROUNDING PRONG FROM THIS PLUG.

/KwARNINGIN MANUFACTURED/MOBILE HOMES WIREDFOR 120/240V, ENSURE THAT THE GF500 ISONLY PLUGGED INTO A 120 VOLT CIRCUIT.


2-2 HEATER INSTALLATIONIn choosing a location for the Heater, the followingguidelines must be considered:• Install the Heater where there are no obstacles

in front of it and where it will most effectivelywarm the room.

• Do not install the Heater near a door or in draftylocation.

X

• Install the Heater to permit easy access to theroom's gas cock, and the power receptacle.

• Do not install near stairs or an emergency exit.• Exhaust pipe must be kept clear of flammable

materials. ,„

•Keep Heater clean and do not store anyflammable items on or near the Heater.

• This Heater is not designed to be built in

• Keep flammable materials, trees, shrubs etc.away from flue pipe.

• Do not vent unit into other rooms. Flue pipemust be outside.

• Do not install nor exhaust the flue pipe into acrawl space or underneath floor nor into a flueor chimney

XOfChimney

• The area around the heater should be free ofobstacles that might interfere with the free flowof air. Allow the clearances shown in theillustration. _60cm, 24in

13.5cm, 5>£in

15cm, 6in

100cm, 39in

• The heater may be installed on combustibleflooring on the metal tray provided.

NOTE: Use the cardboard template provided withthe Heater for flue pipe location.

Just in case the template was misplaced, theapproximate flue pipe hole location measurementsare follows: ne center 0, the joint Pjpc

/Fuel Inlet

10


2-3 FLUE PIPE CLEARANCES• Vent terminal must be located at least 3 feet above any forced air inlet located within 10 feet.• The vent terminal of a direct vent appliance with an input of 50,000 Btu per hour or less shall be

located at least 9 inches from any opening through which flue gases could enter a building, andsuch an appliance with an input over 50,000 Btu per hour shall require a 12-inch vent terminationclearance. The bottom of the vent terminal and the air intake shall be located at least 12 inchesabove grade.

• Flue pipe installations should provide for venting to a confined space through which there is a freeflow of outdoor air. Clearances to adjacent walls or obstacles must comply with the requirementsshown below.

Prrtntsil f^lour*riUlllal wlccu c info11 iL.tr

A 24- (60cm)

/l\ CAUTION :Do not attach anything onto the outletof the flue pipe.

Overhead Clearance

24" (6

or more1

W j| (I35cm|

Wall -Clamp

_

'^

u•

Lri

»

=

Heater

- WallAny constructionabove Flue Pipe

5H' must not come _(14 within 24'(6Ocm)cm) ot front obstacle

.or* 24' (60cm) .more or more

j^>_ Flue Pipe

12- (30cm)or more

Front Obstacle

Ground or slab surface

Side ClearanceNon -combustible

Ocm)or more

wail

(135cm)~~ I *m^-^r

Clamp |T-J>

Heater - 1 ;

—_^j=

- Wall Combustible

yWallClaT i Side obstacle

yy)r 24" (60cm)-j(r or more

45' /

\£

Ground

T12" (30cm)or more

Flue Pipe Heater-

— •'""•" r •t '= 18' (45cm)

Or mofc8 _ J^/ h— ,

HS| ^^ 1f Flue Pipe

nan

or slab surface

IMPORTANT:Rgure 2-1

(1) In areas of heavy snow falls, ground surfaceclearance must be increased according toaverage snow falls, to prevent flue pipe frombeing buried.

(2) In open area with strong wind, a wind break maybe necessary.

Long v

Extensionkit

1Must oe higher

Snow

Figure 2-2

NOTE: Unit should not be vented through a window.

11


2-4 INSTALLING AN EXTENSION KITInstalling an Extension Kit requires theconstruction of an air line and the exhaust line.The air line is connected between the Air SupplyElbow at the rear of the heater and the air inletport on the Flue Pipe. Similarly, the exhaust line isconnected between the joint pipe at the rear ofthe heater, and the exhaust port on the Flue Pipe.

IMPORTANT: The PP air line is longer than theexhaust line and may need to becut to size. Be sure, however, tothoroughly deburr all rough edges.

NOTE: 1 inch minimum clearance must be maintainto combustibles from exhaust piping.

REF.NO.

NAMEOF PART

1 Exhaust Pipe Clamp

2 Exhaust Elbow

3 Adjustable Exhaust Pipe

4 Exhaust Joint

5 Air Extension Pipe

6 Pipe Joint

7 90° Joint

8 Support ( Base)

9 Support (Cover)

10 Leg

11 Joint Supporter

12 Heat Insulation Cover

13 Band

14 Self-Tapping Screws

15 Self-Tapping Screws

16 Machine Screws

17 Bond

18 Hose Clamp(this part comes with yourMonitor Heater)

Connect air supply elbow here (air19 Air Damper supply elbow is a component of ^—^

(this part COmeS With your your Monitor Heater; it is not"1

Monitor Heater) included in this kit).

•Q

20 Flue Pipe(this part comes with yourMonitor Heater)

21 Long Wall Clamps

Use the long wall clamps in place ofthe wall clamps supplied with yourMonitor Heater.

12

14

Figure 2-3

12


Max lengths and bends allowable usingextension kits.

Extension kits are available in four differentlengths. For exact dimensions refer to theaccessories catalog.

Exhaust portion of extension kit needs 1"minimum clearance to combustibles.

1-901 BendFt.Max

2-90" Bends13 Ft.Max

W3-9CT Bends10 Ft.Max

Figure 2-4 MAX LENGTHS AND BENDS ALLOWABLE USING EXTENSION KITS

13


2-5 GAS CONNECTION1.The gas supply line shall be gas-tight, sized

and so installed as to provide a supply of gassufficient to meet the maximum demand of theheater without loss of pressure.

2. A shut off valve should be installed in theupstream of the gas line to permit servicing.

3. Flexible pipe and any appliance connectorvalve used for gas piping shall be typesapproved by nationally recognized agencies.

4. Any compound used on the threaded joint ofthe gas piping shall be a type which resists theaction of liquefied petroleum gas.

5. Supplied gas pressure must be within thelimits shown in the specifications.

6. After completion of gas pipe connections, alljoints including at the heater must be checkedfor gas-tightness by means of leak detectorsolution, soap and water, or an equivalentnonflammable solution, as applicable.CAUTION: Since some leak test solutions,including soap and water, may causecorrosion or stress cracking, the piping shallbe rinsed with water after testing, unless ithas been determined that the leak testsolution is noncorrosive.

7. The appliance and its individual shut off valvemust be disconnected from the gas supplypiping system during any pressure testing ofthat system at test pressure in excess of 1/2psig.The appliance must be isolated from the gassupply piping system by closing its individualmanual shutoff valve during any pressuretesting of the gas supply system at testpressure equal to or less than 1/2 psig.

8. A 1/8" test plug is provided for testing ofmanifold pressure see schematic for location(page 59)At time of installation installer must supply a1/8" N.P.T. plugged tapping, accessible fortest gauge connection, immediately upstreamof the gas supply connection of theappliance.

9. The minimum and maximum inlet gas supplypressure are for the purpose of inputadjustment.

Gas Inlet

V2" Threaded connection

Gas Piping

Manual Gas Valve

Figure 2-5

14


2-6 GAS CONVERSION PROCEDURE1. Replace the natural orifice with the LP orifice

which is included in the conversion kit.Check orifice fitting for gas leak as perinstruction page 14 #6.

2. Replace the air damper with that for LP whichis included in the conversion kit.

3. Slide the gas type selector on PCS to the LPposition.

4. Check that the manifold pressure matches thefollowing values. If not adjust them to thefollowing values using volume resister (VR 1:HiVR 2: Lo)on the PCB.

Hi: 3.4" .̂25 W.C.. _ . • « * A n +0-16 \ * / ^^LO. 1.14 .Q W.L..

After check, reinstall fitting and check for leaks.

2-7 HIGH ALTITUDE INSTALLATIONAll Units must be installed according to thefollowing chart to determine which orifice will beused for the appropriate altitude.

NATURAL GASUP TO 200X3 feet No changing orifice (3.50 mm)2000 - 6000 feet 3.35 mm drill size orifice

LPGASUP TO 2000 feet No changing orifice (2.64 mm)2000 - 6000 feet 2.53 mm drill size orifice

/iXWARNING:Do not use above 6000 feet

2-8 MANIFOLD PRESSURE READINGSManifold pressure readings are based on the unitin a standard installation.Use of extension kits will increase readings asfollows.

Gas Installation Manifold Pressure W.C.High bum Low bum

extension kits 3.50" 1.26"Nat. up to 20"

extension kits 3.70" 1.30"exceeding 20"

extension kits 3.62" 1.26"LP up to 20"

extension kits 3.82" 1.32"exceeding 20"

15

MONITOR HEATING SYSTEMSection 3: Operation

w

3-1 INTRODUCTIONMonitor is an easy-to-operate vented gas heater.Routine operation features high BTU output,automatic adjustment of room temperature, lowpower 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.

3-3 OPERATING CONTROLS AND INDICATORSSeveral controls and indicators are used tooperate the heater and to monitor its performanceas follows:

3-2 OPERATING SPECIFICATIONSThe following specifications apply to the operationof the Monitor GF 500.- Rated Efficiency: 81%- Power Consumption: as follows

High Bum 80 watts, Low Bum 70 watts- Circulation Fan Output: 388 cubic feet/min- Potential Heating Area: 900 - 3200 sq. feet

RUN AUTO EC£LN°S

MY BURNER STATUS

Figure 3-1, INDICATORS

11 12 13 14 15

OPERATION

ON/OFF

TIMER SELECTOR

16I TIME/TEMP SET

21

HQUR MlNUTE SET CLEAR

TEMP| 1 \j>

17 18 19 20

Figure 3-2, CONTROLS

FIGURE AND ITEM NO CONTROL OR INDICATOR. FUNCTION

Figure 3-1, Item 1 RUN Indicator Light Light to indicate that power has beenapllied to heater.Illuminates when operation ON/OFF push-button switch is pressed to position ON

Figure 3-1, Item 2 AUTO Indicator Light Lights when heater runs in automaticmode.AUTO, RUN, and appropriate BURNERSTATUS Indicators are illuminatedsimultaneously if heater is burning.

Figure 3-1, Item 3 ECONOMY PLUSIndicator Light

Lights when heater runs in Economy Plusmode.

Figure 3-1, Item 5 BURNER STATUSIndicator Lights

Light In accordance with heat output asfollows:Heat Output Light PatternHigh 8 indicators-ONLow 4 indicators-ON

17



Figure 3-1, Item 6 RUN Indicator Light Lights when heater is running and DigitalWindow is showing the temperature.

Figure 3-1, Item 7 AM Indicator Light

Figure 3-1, Item 8 PM Indicator Light

Figure 3-1, Item 9 Digital Display Indicates SET and ROOM temperaturewhen heater is running, and indicates timewhen heater is Off.Indicates time and temperature for auto-matic operation setting.

Figure 3-2, Item 10 TIMER SELECTORpush-button switch

The automatic function allows the pro-gramming of different temperatures fordifferent times of the day. Two, three orfour settings can be used.

Figure 3-2, Item 11 CLOCK SETIndicator Light

Allows programming of current time whenilluminated.

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

IMPORTANT: Once current time hasbeen programmed, pressthe SET push-button switchwithin 60 seconds. Other-wise clock display willrevert to previously pro-grammed time, if any.

Figure 3-2, Item 12 1st Indicator Light Allows programming of first automatictime and temperature selection whenilluminated.

When programmed, heater automaticallyoperates at specified time and temper-ature (i.e. 6: 00 a.m., 70°F), if set forAUTO, providing that heater has been setfor automatic mode of operation.TIME, TEMP, HOUR(UP), MINUTE(DOWN)and SET push-button switches are usedto program first operated time andtemperature.IMPORTANT: Once time and temperature

have been programmed, theSET push-button switchmust be pressed with in 15seconds. Otherwise, timeand temperature will revertto previously programmedtime, if any.

When this Light illuminates, 1st presentlyprogrammed time and temperaturedisplayed.

Figure 3-2, Item 13 2nd Indicator Light Allows programming of second automatictime and temperature selection whenilluminated.

18



Figure 3-2, Item 14 3rd Indicator Light Programs 3rd automatic heater operationas same as 1 st Indicator Light.

Figure 3-2, Item 15 4th Indicator Light Programs 4th automatic heater operationas same as 1st Indicator Light.

Figure 3-2, Item 16 TIME push-buttonswitch

This switch is used to set time and changedisplay over.

Figure 3-2, Item 17 TEMP push-buttonswitch

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

Figure 3-2, Item 18 HOUR/UP,MINUTE/DOWNrepetitive-actionpush-button switch

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

pressed, the digit advances inincrements of one digit, If push-button is pressed and held, thedigits are advanced repetitively.

Figure 3-2, Item 19 SET push-button switch "Sets" time and/or temperature.If this control is not pressed after timeand/or temperature have been pro-grammed, the time and/or temperatureprogrammed (as indicated by displaywindow) will not be accepted, and willrevert to previously programmed time and/or temperature.

Figure 3-2. Item 20 CLEAR push-button switch

•

Erases any programmed time andtemperature. When cleared, time and/ortemperature previously programmed anddisplayed disappears) from window.IMPORTANT: Both current time and

automatically programmedtime(s), temperature(s) willhave to be reprogrammed ifelectrical operation isinterrupted by power failureor by disconnecting heaterplug from wall outlet beyond5 minutes. If this occurs, theheater will go into MANUALmode of operation andmaintain room temperatureaccording to the settingtemperature you've selectedby using the slide selectorfor the reset temperature atthe lower right hand side ofthe cabinet

Figure 3-2, Item 21 ON/OFF push-buttonswitch

ON position (push-button is "in") appliespower to the unit. When this occurs, theRUN indicator lights to indicate that heateroperation has begun.OFF position (push-button is "out")remove power from the heater. All circuits-except for Clock and Air Flow—are shutdown.

19



Figure 3-2, Item 22 AUTO push-buttonswitch

Places heater in automatic mode ofoperation. AUTO indicator lights to confirmautomatic operation. Assuming that theheater has been properly programmedand heater is in ON position, heater willoperate automatically.When pressed again, AUTO indicator goesout and then heater will operate inMANUAL mode. During manual operation,the user turns heater ON and OFF, at will.When AUTO is disengaged, the unit willoperate on a manual temperaturedetermined by the AUTO setting for thattime of day.

Figure 3-2, Item 23 ECONOMY PLUSpush-button switch

Places heater in Economy Plus mode ofoperation. ECONOMY PLUS indicatorlights to 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 Monitorheater start-up, inspect the system for operationalreadiness. The following check list specifiesthose items that should be inspected on a routinebasis:

Check that the Monitor heater is pluggedinto wall outlet (120 VAC, 60 HZ).Ensure the gas type is correct for theMonitor heater.Inspect Gas Line for signs of leaks, looseconnection or cracks.Confirm that Gas Valves in the room andManual Gas Valve are open so gas can flowfreely.Outside dwelling, check area immediatelyaround Flue Pipe for combustibles orobstructions to free air circulation.Inspect Air Line for cracks, looseconnections or blockage.Check Exhaust Line for cracks, looseconnections or blockage.At rear of heater, verify that air flow to theAir Circulation Fan is not blocked.

V Inspect dwelling interior and confirm thatimmediate area near heater is free ofcombustible and objects that might interferewith free air flow.

V Make certain that Heat Sensor is notexposed to drafts, direct sunlight, nor directheat from the Monitor

If this inspection 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 detailsof heater start-up, operation, and shutdown. Thecontrols and indicators illustrated by Figure 3-1and 3-2 are used to operate the system and tomonitor the heater's performance.

20


3-6 MANUAL HEATER OPERATIONOperation of the heater is under the direct controlof the user (heater will not operate automatically).The heater will, however, automatically respondto changes in room temperature signaled by theHeat Sensor to maintain the temperature of theroom at a comfortable level.

STEP1: Prime the HeaterTurn manual gas valve at rear of the heater to thefull ON position.

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

STEPS: 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 SETpush-button switch.

IMPORTANT: In case no temperature is set,temperature will automatically beset at the setting temperatureselected by using the slideselector for the reset temperature.

STEP4: Turn Monitor OnPress the ON/OFF push-button switch to positionON. The RUN indicator light illuminates toindicate that power has been applied to theinstrument and the heater is cycled for manualmode 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 inMANUAL mode.

This feature minimizes the "ON" and "OFF"cycling of the unit by allowing it to overshoot theset temperature by 12 degrees instead of thenormal 4 degrees.The advantages of this feature are to increase theoverall efficiency of the unit by:

1. Decreasing electrical consumption bydecreasing the frequency of ignition cycles.

2. Reducing heat loss during the prepurge andpostpurge cycles.

3. Reducing inefficient combustion associatedwith start up and shut down.

4. Prolonging component life by decreasingexpansion and contraction of internal parts.

NOTE: This feature could be compared todriving an automobile in stop and gotraffic (regular mode) versus highwaydriving with cruise control engaged(Economy Plus mode).

3-7 AUTOMATIC HEATER OPERATIONAutomatic operation is established by program-ming the time/temperature settings for specifictimes. On a daily basis, a maximum of fourtime/temperature settings can be programmed.If, subsequently, it should be desired to switch tomanual mode of operation, the changeover canbe made at any time.Proceed with automatic mode of operation in thefollowing manner.

STEP 1: Program Clock for Current TimeA. Press the TIMER SELECTOR push-button

switch, at which time the CLOCK SETIndicator light 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 ofone by pressing the appropriate push-button switch one time for each digit;digits can also be advanced repetitivelyby pressing and holding the appropriatepush-button switch.

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 1 st Time/TemperatureA. Pressing the TIMER SELECTOR push-button

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

21


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

IMPORTANT: Be sure to set the clock AM orPM, as appropriate.

D. Immediately after programming the 1stdesired time, press the SET push-buttonswitch. This step must be completed withinfifteen seconds after programming the time.

E. Press TEMP push-button switch.F. Press UP and/or DOWN push-button swrtch(es)

to program 1 st desired temperature.G. Immediately after programming the 1st

desired temperature, Press the SET push-button switch. This step must be completedwithin fifteen seconds after programming thetemperature.

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 tolock into memory.Should heater power be interrupt-ed by a power failure or bydisconnection of the power cordbeyond 5 minutes, heater reverts toMANUAL operation, and all AUTOprogramming is erased.

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

STEPS: Turn Monitor ONPress ON/OFF push-button switch to positionON. The RUN indicator light will illuminate toindicate that power has been applied to theheater.

From this point, heater operation is as followexample:

6:OOAM

76°F|

9:OOAM 5:OOPM 10:OOPM80°F|

68°F

Example64°F

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

STEP1: Reprogramming Current Time(if necessary)

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

B. 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 revertto previously programmed time.

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

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

B. Press TIME push-button switch.C. Press CLEAR push-button switch. Time

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

switches program new desired time bywatching 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 bywatching the 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 in the path of direct sunlight, drafts or the flowof warm 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 toshutdown the Monitor:Press ON/OFF push-button switch to positionOFF; the RUN indicator will extinguish.

IMPORTANT: Once heater has shut down, itcannot be restarted until post-purgecycle has been completed. IfON/OFF switch is left in positionON, Monitor operation will auto-matically restart upon completion ofpost-purge.

22


w-3-11 RECOVERY FROM A POWER FAILUREFor the power interruption of up to 5 minutes, theset memory is kept and will resume operationauto-matically with the set memory.For power interruptions beyond 5 minutes,heater will resume operation (after a 3 minutescool down period) in the MANUAL mode andmaintain room temperature according to thesetting temperature selected by using the SLIDESELECTOR for the reset temperature at thelower right hand side of the Cabinet.When the TIME push-button switch is pressedor the TIMER SELECTOR push-button switch ispressed to illuminate the CLOCK SET indicatorlight, the Display Window will show 88:88indicating the need to reset the clock andre-program the heater for 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.

3-12 RECOVERY FROM OVERHEAT CONDITIONThe Monitor is protected against damageresulting from an overheat condition by115 °C(239 °F) automatic reset thermostat.In the event of an overheat the thermostat istriggered to cut off the flow of gas to the Burner,the flame is extinguished automatically, and useris alerted to the overheat condition by blinking ofthe Burner Status indicators.

To recover from an overheat condition, proceedas outlined below:

STEP1: Turn OFF HeaterSTEP2: Allow Monitor Heater to cool

NOTE: Be sure that heater is cool to touch.

A period of 30 to 45-minutes should be sufficientto permit 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 objectsthat impede free air circulation.

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

STEPS: Remove Louver AssemblySTEP6: Clean Heater interior

WARNING:

BEFORE PROCEEDING TO CLEAN HEATER,BE SURE THAT HEATER INTERIOR IS COOLENOUGH TO TOUCH.

With a clean, lint-free, damp rag or other appro-priate cleaning material, wipe up all dust, dirt anddebris from exterior of cabinet, including exteriorof Combustion Chamber and Heat Exchanger.There is also a secondary thermal fuse set at145°C (293 °F). If this opens it must be replaced.

STEP7: Replace Louver AssemblySTEPS: Reconnect Monitor Heater Power Plug

to the Wall Outlet.STEP9: Turn Heater ONSTEP10: Reprogram Heater MicroprocessorSTEP11: Select Mode of Operation

CAUTION: If after the completion of recoveryprocedure, the heater overheatsagain, something is wrong!Do not operate heater until problemhas been diagnosed and corrected.

3-13 RECOVERY FROM BLOWN FUSEAll electrical components of the Monitor heaterare protected against power overloads andelectrical malfunctions by a 2-amp fuse. Shouldfuse blow, the recovery procedure is outlinedbelow:STEP1: Turn Monitor OFFSTEP2: Unplug heaterSTEPS: Remove louver assemblySTEP4: Remove front coverNOTE: As the Front Cover of the heater is

connected to the Printed Circuit Boardby Lead Wires, pull the Front Cover tothe front side slightly and remove theConnector of the Lead Wires from thePrinted Circuit Board, and then, removethe Front Cover.

STEPS: Locate and replace fuseSTEP6: Reattach front cover

(Be sure that the connector is con-nected to the printed circuit board.)

STEP7: Reattach louver assemblySTEPS: Plug heater power cord into wall outletSTEP9: Turn Monitor ONSTEP10: Reprogram heaterSTEP11: Program Automatic operation cycles (If

applicable)STEP12: Select Automatic operation (If appli-

cable)

23

3-14 OPERATION CONTROL SYSTEMGF500 OPERATION TIMING CHART

RELAY,TWAC,PHOTO TRIAC,OPERATIONALAMPLIFIER

MONITOR HEATING SYSTEMSection 4: Maintenance / Servicing

4-1 CLEANING THE CABINETWhen the cabinet is soiled, wipe it with a dampcloth. Restore the shine with a dry cloth. The useof abrasive household cleaners may dull the finish.

4-2 CHECKING THE FLUE PIPEAt the beginning of each heating season, checkthe inside of the flue pipe. Foreign matter, spiderwebs, etc. must be removed.Be sure all fittings and joints are tight.

NOTE: Make sure that all exhaust pipe and intakepipe connections are firmly mated.Make sure that the connections betweenthe flue pipe and exhaust/air intake pipeand hose are secured by the pipe holder(P/N 4006) and the hose band (P/N 4008).

4-3 CLEANING THE INTERIORRemove the louver, and vacuum and wipe awaydust or other accumulation.

4-4 CLEANING THE BLOWER GUARDHeating efficiency will be reduced if the blowerguard at rear of the cabinet is blocked with dirtor dust.Blockage also produces a rise in heat that couldcause the heater to shut off.Wipe the guard clean at least once a week.

4-5 ELECTRIC MOTOR MAINTENANCEMotors are permanently lubricated and need nolubrication. Keep fan and motor free of dust anddirt clean annually.

4-6 CHECKING THE BURNER FLAMEThe burner of this appliance does not needcleaning, but check the burner flame once a year.Flame pattern should be as shown in the followingfigures. The burner must flame evenly over theentire surface when operating correctly. The flamemust burn with a clear blue stable flame.

Blue Flame

Yellow Flame

4-7 CLEANING THE BURNERUnder normal running conditions, soot will notdeposit in great quantities at the burner, and alight covering of soot will not affect theperformance of the unit thus it need not becleaned. However, if heavy soot built up doesoccur the unit should be opened and cleaned.If heavy soot builds up in a short period of timealso check the air flows are normal, refer topage 5.

The burner is assembled using gaskets tomaintain its air tightness. If these gaskets leak,the extra air can cause a serious soot problemand or exhaust gases to escape into the areabeing heated.

NOTE: If any gaskets are torn when compo-nents are removed, replace.

Cleaning the burner requires disassemble of thecombustion chamber with the heat exchanger.

If cleaning is necessary, use the followingmethod:A. Remove louver assembly.B. Remove front cover and wire connectors.C. Remove top cover.D. Remove heat shield that covers combustion

chamber and its lead connectors. Removepressure detective pipe.

E. Remove screw at top of burner cap whichattached it to cabinet. Remove screw atback of cabinet and joint pipe from exhaustduct and remove the 6 screws holdingcombustion chamber to burner chamber.Leave burner chamber assy attached tobase.

F. Remove combustion chamber and heatexchanger, as one assembly from unit.

G. If soot is present at the burner, remove thesoot by using wire brush, then clean the areaby using a vacuum cleaner etc.It may also be necessary to clean the flameholder and burner port assy.

NOTE: Make sure all air holes are clear.

H. Use wire brush to clean inside of combustionchamber. Vacuum and wipe clean with awaste cloth.Before reassembly inspect flame holder, ifwarped or distorted replace it.

UNSATISFACTORY

27

MONITOR HEATING SYSTEMSection 4: Maintenance / Servicing

I. Reassembly by reversing the procedurefollowed during disassembly.

/^WARNING:Do not attempt to disassemble the heatexchanger and combustion chamber. Thiswork is criticaJ and must be done only by anauthorized technician.The disassembly of heat exchanger andcombustion chamber is critical work and mustbe done only an authorized technician.If any screws are torn or striped, they must bereplaced.

28

MONITOR HEATING SYSTEMSection 5: Troubleshooting

GF500 Resistance Values

COMPONENT

Ignition Transformer (connector E/E)

Power Transformer (1)-Primary (AC 120V)

Power Transformer (l)-Secondary ( AC 1 1V)

Power Transformer (l)-Secondary (AC 120V)

Power Transformer (2)-Primary (AC 120V)

Power Transformer (2)-Secondary (AC 22V)

Damper Solenoid (connector I/I)

Resistor (connector G/G)

Circulation Fan (WH & BK)

Circulation Fan (BK & BL)

Combustion Blower (WH & GR)

Combustion BloWer (GR & OR)

Thermistor (connector Q/Q at 77°F)

Fuse 2A (read with fuse out)

Gas Control Valve (connector P/P)

Gas Solenoid Valve (connector UL)

Gas Solenoid Valve (connector M/M)

APPROX. OHMS

108,000

66

1.6

647

66

6.4

4,600

91

115

258,5

78

92

10,000

0.1

87

2,400

2,400

WARNING:

DISCONNECT HEATER FROM POWER SOURCEBEFORE MAKING ANY RESISTANCE TESTS.

29


GF 500 Component Voltage Readings

COMPONENT

Thermistor

All readings taken withThermistor

Air Pressure Switch/Overheat Protector Closed

Air Pressure Switch/Overheat Protector Open

Damper Solenoid

Gas Control Valve High mode

Gas Control Valve Low mode

Circulation Fan High Speed

Circulation Fan Low Speed

Ignition Transformer

Power Transformer (1)(primary side)

Power Transformer (1)(secondary side)

Power Transformer (2)(primary side)

Power Transformer (2)(secondary side)

Combustion Blower High Speed

Combustion Blower Low Speed

Resistor

Gas Solenoid Valve

Gas Solenoid Valve

READING TAKEN AT

Q on PCB Sensor Disconnected

components connected to PCB.Q on PCB Sensor connected

J on PCB

J on PCB

I on PCB

P on PCB

P on PCB

WH to BK

WH to BK

E on PCB

AC 120V

AC 11VAC 120V

AC 120V

AC 22V

F on PCB

F on PCB (Q1 is off)

G on PCB

L on PCB

M on PCB

AC DC

5

1.5-3.2

0

110

105

8.7

6.2

110

^91

110

110

11120

110

22

110

88

22

105

105

30


TEST POINT VOLTAGE

All readings take from EPOV.

'̂ v. Operation^^-^^ Mode

Test Point̂ ^^

TP1

TP2

TP3

TP4

TP5

TP6

TP7

TP8

Preparation

27V ± 50 %

12V ± 30 %

5V ± 10%

0.1V max.

pulse

pulse atplug in

0.1V max.

1.5 -3.2V

Pre-purge

27V ± 50%

12V ± 30%

5V ± 10%

0.1V max.

pulse

5V ± 10%

0.1V max.

1.5 -3.2V

Igniting

27V ± 50 %

12V ± 30%

5V ± 10 %

infinitlyvariable

pulse

5V ± 10%

0.4 - 1.1V

1.5 ~ 3.2V

Pre-combustion

27V ± 50%

12V ± 30%

5V ± 1 0%

1.2Vmin.

pulse

5V ± 10%

0.4 - 1.1V

1.5- 3.2V

Abnormal readings of TP1 and TP2 can be causedby either failure of a transformer or PCB.Abnormal readings of TP3-TP8 caused by failure of PCB.

^ -̂-̂ ^ Operation\̂. Mode

Test Point ̂ \^^

TP1

TP2

TP3

TP4

TP5

TP6

TP7

TP8

High

27V ± 50 %

12V ± 30%

5V ± 10%

1 .2V min.

pulse

5V ± 10%

0.7- 1.3V

1.5 -3.2V

Low

27V :r 50%

12V ± 30%

5V ± 10%

1.2V min.

pulse

5V ± 10%

0.3 - 1 .0V

1.5 -3.2V

Off

27V ± 50 %

12V ~ 30%

5V ± 10%

0.1V max.

pulse

5V ± 10%

0.1V max.

1.5 -3.2V

Post-purge

27V ± 50%

12V ± 30%

5V ± 10%

0.1V max.

pulse

5V ±10%

0.1V max.

1.5 -3.2V

31

1.

GENERAL CHECKSIs power available in wall outlet ?Is power Plug inserted in wall outlet ?Has there been a power interruption ? (Display window shews 88:88)Has Circulation Fan stopped ?Is Manual Gas Valve "open" ?te Operation Switch on?Is operation mode on Manual ?Is set temperature higher than room temperature?

SYMPTOM | CHECK1 | RESULT | CHECK2

No ignition k^ Does Run lamp •

Burner StatusindicatorsWink ?

H Yes. U— Does ignition

Check visuallythrough theCombustionchamberviewing window.

H No. I— Is Display

RESULT | CHECK3

H Yes. 1— Is there

4 No. V— is there 110V

on DrcuitBoard?

-j No. |— | Check Fuse

| RESULT CHECK4 | RESULT | CHECKS | RESULT |

f cI

1 1 I ., |

operate °

4 No. ^~ Is wiring -T^ Yes p™

-

rLH No h

i-

il__i1 u

REASON CORRECTIVE MEASURE

Incorrect wiring of Flamesensor or Ground.

Flame sensor rod touchesto burner parts.

Failure of Air Pressure Switch

- Replace or check Circuit Board.

Correct wiring.

Correct of Change

Check for Air blockage.Replace Ajr Piessure Switch.

Failure of Gas Control Valve, 1 1 Replace Gas Control Vatve

Failure of AutomaticGas Valve

Failure of CombustionBlower motor.

Failure of Circuit Board

Incorrect or disconnected wiring. —Replace AutomaticGas Valve.

Replace Combustion BlowerMotor.

Replace or check Circuit Board.

Correct wiring.

Failure of Ignition Transformer 1 1 Replace Ignition Transformer.

Failure of Circuit Board. [ [ Replace or check Ocuit Board.

— | Incorrect wiring. 1 1 Correct wiring

i

cord 1 1 1| |H Melted | ,_

i 1 IH

There is not 1 1 0V at plug.

Failure of Circuit Board.

Failure of Ignition Transformerrelay on PCB. Replace PCB.

Replace or checkCircuit Board.

Fuse open. | [ Change fuse.

Short circuit of tead wire. 1 1 Correct or change.

Failure of Circuit Board. Replace or check Circuit Board.

Is in Auto operation mode. 1 1 Put in Manual-Bum Mode.

\ I SYMPTOM I [ CHECK1 | | RESULT | | CHECK2 | | RESULT | [ CHECK3 ] | RESULT | | CHECK4 ] | RESULT | | CHECKS | | RESULT | | REASON ] [ CORRECTIVE MEASURE]

Overheat Thermosiat isactivates

Remove obstacles.Clean fan cage.

,, .. J Overnea; i nermo$;-a: -s

activatedRec'ace ^an Motor.Replace or cneCK P.C.B.

Flame Sensor Rod toucnesto Burner parts.

Carbon soot deocsitsat Flame Sensor Rod.

Gas shortage

Clean rtarre Sensor Rod withsteel wool scotchbnte orsane paper.

Coniaci gas supplier

Flame failure dunng ignitingmoae.

Refer SYMPTOM 41

RESULT I | CHECK4 | RESULT | | CHECKS | RESULT | [ REASON I CORRECTIVE MEASURE\ [ SYMPTOM I | CHECK1 | RESULT [ [ CHECK2 | RESULT |

Room temp. Setting 15 too low

failure of Circulation ^ar, Motor.

Air mlei ex warm air outletis cioggec or oartiatiy blockea

Manual Gas Valve :S notopen fully.

Failure of Gas Control Valve

Oifice is cogged

Gas inlet pressure \s too low

Failure of Room Temp.Sensor.

Poor location of RoomTemp. Sensor

Poor air circulation m areabeing treated.

Reset de&rea room temp.

Replace Circulation ran Motor.

Remove obstacles.

Open fully.

Replace Gas Control valve.

L-orrect doggmg.

Contact gas suopiier

Replace Room Terno.Sensor

Change location of RoomTemp. Sensor.

Use of caling fans and / orroom to room fansmay be necessary.

SYMPTOM | | CHECK1 | RESULT | | CHECK2 [ RESULT | | CHECK3 | RESULT | | CHECK4 | RESULT | | CHECKS | RESULT | | REASON | | CORRECTIVE MEASURE ]

4.

5.

when burnergnit9S.

gas type.

Is there srne'lof gas indoors ?

]J Correct U-

i ... iT NO |-

Is vent terminalinstallationproper?

ouidoors ?

H E 1 rL

i ~ i±L

i iIL1

i~ '_* thr̂ .Q "n Q*~ i"

Is unit set UD for gastype used ?

Flue pipe clearancesis not proper.

Rue pipe or exnaust pipe orair intake pipe is dogged.

Failure of Gas ControlValve.

main cock in the room.

Gas teaks from gassupply parts of unit.(Gas control valve orAutomate Gas Valve orGas Joint or Gas Piomgor Manual Gas Valve.)

Exhaust pipe toucningcurtain etc.

Burnt or snortedelectrical components.

Correc: installation.

ec cogg g

Replace Gas Control Valve.

for reoars.

Remove- rtanoretc

Replace parts,

SYMPTOM CHECK1 RESULT CHECK2) •

I No operation, l-p Does 88:88

displaywindow?

I Plug in AC cord. I

NOTE:If problem is found to be in PCB,do not attamp to repair, replaceand sand PCB thru your distributorto MPI tor repair.

l-| No. |— Is there 12Vdc. -I

J Yes U|-| tetheregas? L

|

Press the operationbutton switch toON position.

Disconnect connector marked CN1going to the SWITCH & LAMP ASSYand then jump T1 to 17 of CN1on PCB.

No gas.

Failure ol SWITCH &LAMP ASSY.

Failure of resonator.

Failure of resistor.(R40)

Failure of microprocessor.(CD

CORRECTIVE MEASURE

Replace fuse.

Replace Transfer me (1).

Contact gas supplier

Ropbca SWITCH 4 LAMP ASSY

', I SYMPTOM [ | CHECK1 | RESULT | | CHECK2 | RESULT | | CHECK3 | | RESULT | [ CHECK4 | | RESULT | | CHECKS | | RESULT | REASON CORRECTIVE MEASURE

I 1Doescombustionblower work

and igniting ?

j ~|

-f i1_± — |

between TP2andlC!3(@}?

pressure switchwork normally .

I \

L_± — 1

1 ••• 1n — ̂ — r~ Doesetectroaa arc ?

(\.sl)

at col of relay 1 r~

i Yr. ii — _ — i

L

----

-

-

J

(IC4)

1 Failure of triac.(IQD

1 Failure Of resistor(R1.R47)

I Failure of capacitor(C2)

!Failure of combustionblower

Incorrect wiring ofcomousnon blower

switch.

Rubber hose isblocked or disconnected-

Incorrect winng.

F ,

( iCi)

(RU2)

HReplace comousnonblower

•" 1 Correct wiring.

switch.

^^_ Ctear and orcorrect rubber hose.

1 Correct wirmg.

Ignition transformer open. H Replace ignition transformer.

REASON CORRECTIVE MEASURE

Failure of diode. (05)

Failure of microprocessor. HC1)

Failure olTR array. (1C 13)

Failure o< diode. (028 D29)

Failure of relay. (Rl_3. RL4.)

Failure of transistor. (Q3t

incorrect wiring ofgas solenoid valve.

Gas solenoid valveopen.

Correct wiring

Replace gas solenoid valve

Correct wiring.

Replace gas control vafve.

Contact gas suppler.

CHECKS CHECK4 REASON

FLAME ROD BYPASS CIRCUITFor testing purposes - A flame detector rod bypass circuit can be made up, consistingof 2 insulated alligator dips. 2-6" pieces of insulated copper wire, 1-'/4 watt 400 voltdiode, and 1-Y< watt 100KOHM resistor.These component are to be soldered together ri sequence as shown in diagram below(Note component sequence and polarity).Once the bypass circuit is made the unit is turned on. immediately after the prepurgecycle, when mode light comes on, the O and N pins are disconnected off the PCB andreplaced with the bypass circuit.The unit should then continue functioning as though it had a good flame inside the bumchamber.(WARNING, after all tests are completed, replace original flame rod wires as it is avital safety feature.)

CUPS CUPS

Failure of resister.(R5-R8)

Failure of transformer. (1)

Failure of capacitor.(C12-C14)

Failure of resistor.(R53, R9-R11)

CORRECTIVE MEASURE

Replace transformer. (1)

Correct wiring.

HCorrect installation.

CHECKS CHECK4 CHECKS REASON CORRECTIVE MEASURE

Connect lOKflresisterat fol pins, andthen, set temperaturefrom Low to High.

Is thereapprox 2.8VatTPB?

1

motor able tochange speed ?

1 1

1 1

-

-

'

L

-

-

-

-

-

-

-

ri-L

L

Failure of micro-prccessor. (IC1)

( Failure of operatKxialamplifier. (IC9I

Failure of diode. (D22. D23)

Failure of transistor. (Q2. Q4)

Failure of resistor. (R29-R32)

Failure of capaotor.(C19.C20,C40)

Failure of microprocessor. ;IC2)

Failure of photo tnac. (IC2)

Failure of TR array. (C13)

Failure of circulationfan motor

Failure of microprocessor. (IC1)

Failure of TR array (IC1 3)

Failure of photo Mac. (IC3. IC4]

Failure of triac. (Q1)

Failure of resistor. (R1 .R47.R48)

Failure of capacitor. (C2)

Failure of combustion blower.

Failure of resistor lor combustion blower.

Failure of damper solenoid.

(R35. R36)

Failure of capacitor.(038. 039)

. Replace circulationfan motor

H Replace combustionblower

H Rep&ce dampersotenad.

Section 5: Troubleshooting

INDICATION OF FAILURE MODE

Digital Display

C n iC u i

E 05

E OB

E !

The Reason of Indication

At pre-purge, Flame rod is sensingflame when there should be none.

After power on, power supply tothe microprocessor timing circuitis incorrect.

At starting of operation, the circuitto drive relay of Gas SolenoidValve is malfunctioning.

At starting of operation, circuit ismalfunctioning.

Trouble Point

Flame sensing circuit, groundedflame rod or pinched wire.

Timer clock circuit bad or powersource to unit above or belowacceptable levels.

Gas Solenoid Valve control circuithas a malfunction.

Gas Control Valve circuit on PCB.

51

MONITOR HEATING SYSTEMSection 6: Electrical System

WIRING DIAGRAM

GAS CONTROLVALVE

SWITCH AND LAMPP C B

'20V

SOHa

BLOWER MOTOR

JO,

MICROCOMPVJ

i PC.8

! i [ i 1

IP

R

E

— j l

1 1

1 ' ' 1

RESET TEMPSELECTOR

CAUTION:• Label all wires prior to disconnection when

servicing controls. Wiring errors can causeimproper and dangerous operation.Verify proper operation after servicing.

• If any of the original wire as supplied with theappliance must be replaced, it must bereplaced with a wire of at least a 105°Ctemperature rating.

CODEBkBlBrGOrRWYGr

COLORBlackBlueBrownGrayOrangeRedWhiteYellowGreen

BLOCK DIAGRAMRESET TEMPSELECTOfl

MARKBMERFFMFRFTOHTPSRC1-4R1-4SLSPSV1SV2TA1-4TFTHTR1TR2

PARTS NAMECOMBUSTION BLOWER MOTORELECTRODECURRENT FUSECIRCULATION FAN MOTORFLAME RODFAN THERMOSTATOVERHEAT THERMOSTATAIR PRESSURE SWITCHRECTIFICATION CIRCUITRELAYSOLENOIDSPARKERSOLENOID VALVE 1SOLENOID VALVE 2TRIACTHERMAL FUSETHERMISTORTRANSFORMER 1TRANSFORMER 2

QAS CONTROLVM.VE

Grounded inside chassis at bottom of unit.

55

MONITOR HEATING SYb i tMParts List

NO

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

16

19

20

20-1

20-2

20-3

20-4

21

22

23

24

25

26

27

28

29

30

31

32

PARTS NAME

ADJUSTABLE LEG

TRAY

AIR SUPPLY HOSE A

AIR SUPPLY HOSE B

AIR UNE B

ORING(PIO)

AUTOMATIC GAS VALVE ASSY

GAS CONTROL VALVE

GAS INLET JOINT

ORINGIP11)

GAS PIPE JOINT

ORINGIS16)

RETURN PIPE

0 RING (P4)

GASKET 1

BURNER CHAMBER ASSY

WINDOW PACKING

MCA PLATE

MCA HOLDER

PLUG BASE ASSY

FLAME DETECTIVE PLUG ASSY

IGNmON ELECTRODE ASSY

PLUG HOLDER

PLUG PACKING

GASKETS

GASKET 6

COMBUSTION CHAMBER ASSY

GASKET 7

CHAMBER CAP ASSY

GASKETS

HEAT EXCHANGER ASSY

GASKET 9

EXHAUST DUCT ASSY

O RING (P39)

GASKET 2

AIR PRESSURE SWITCH

PARTS NO.

5019

6602

6301

6302

6603

6604

6605

6607

6608

6609

6610

6611

6612

6613

6614

6615

6616

6617

6618

6619

6620

6621

6622

6623

6624

6625

6626

6627

6628

6313

6629

6122

6630

6176

6631

6632

OTY

4

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

REMARKS NO.

33

34

35

36

37

38

39

40

41

42

43

44

45

46

47

48

49

50

51

52

53

54

55

56

57

58

59

60

61

62

63

64

65

66

67

68

PARTS NAME

AIR LINE A

IGNITION TRANSFORMER

PRESSURE DETECTIVE PIPE

BURNER ASSY

MIXING PLATE ASSY

BURNER PORT ASSY

FLAME HOLDER

BURNER PACKING

ORIFCE HOLDER

ORIFCE GUIDE

GASKET 4

BLOWER ASSY

BLOWER MOTOR

BLOWER CAPACITOR

SOLENOID

SUCTION CASE A ASSY

SEAL PACKING

PWB SPACER CUP A

PW8 SPACER CUP B

PWB ASSY

CABINET ASSY

RUBBER BUSH

STRAIN REUEF BUSHING

POWER SUPPLY CORD

CARRYING HANDLE

SENSOR ASSY

SUDE SWITCH ASSY

SLIDE SWITCH PANEL

KNOB

METAL WIRE WAY B

METAL WIRE WAY A

FAN ASSY

CIRCULATION MOTOR

BLOWER GUARD ASSY

UNDERCOVER

LOUVER ASSY

PARTS NO.

6633

6634

6635

6637

6638

6639

6640

6641

6642

6643

6644

6645

6348

6322

6406

6324

6144

6461

6462

6646

6647

6136

4833

6648

6138

6186

6649

6207

6208

6455

6455

6075

6453

6454

6332

6409

OTY

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

2

14

1

1

2

1

1

2

1

1

1

1

1

1

1

1

1

1

1

REMARKS

NOTE : TO OBTAIN PARTS. CONTACT YOUR DEALER OR.

MONITOR PRODUCTS. INC P.O. BOX 3408, PRINCETON. NEW JERSEY 08543

57

MONITOR HEATING SYSTEMParts List

MO.

69

70

71

72

73

74

75

76

77

78

79

80

81

82

83

34

85

86

87

88

89

90

91

92

93

94

95

96

97

98

99

100

PARTS NAME

CONTROL COVER

FRONT COVER

LAMP PANEL

SWITCH & LAMP ASSY

FAN THERMOSTAT

OVERHEAT THERMOSTAT

THERMAL FUSE

TOP COVER

WALL CLAMP

VENT CONNECTOR

PIPE HOLDER

AIR SUPPLY HOSE ASSY

FLUE PIPE ASSY

SCREW CAP ASSY

OUTSIDE FLANGE

OUTSIDE PACKING

EXHAUST OUTLET CAP

AIR PORT 0 RING

AIR OUTLET CAP

HOSE BAND

AIR DAMPER NAT S

AIR DAMPER NAT E

AIR DAMPER LP S

AIR DAMPER LP E

ORIFICE (NAT GAS)

ORIFICE (LP GAS)

GAS PIPE ASSY

OWNER'S GUIDE

MANUAL GAS VALVE

MANIFOLD TEST PLUG

ORIFICE (2-6000FT NAT)

ORIFICE (2-6000FT LP)

PARTS NO.

6650

6457

6458

6651

6152

6463

6652

6337

6194

4004

4006

6145

6147

6148

6148

6146

4014

4016

4«05

4008

6653

6654

6655

6656

6657

6658

6659

6660

6601

—

6661

6662

QTY

1

1

1

1

1

1

1

1

2

1

1

1

1

1

1

1

1

1

1

2

1

1

1

1

1

1

1

1

1

1

1

1

REMARKS NO. PARTS NAME PARTS NO. OTY REMARKS

NOTE : TO OBTAIN PARTS. CONTACT YOUR DEALER OR.

MONITOR PRODUCTS, INC P 0 BOX 3408. PRINCETON. NEW JERSEY 08543

58

Documents

Service Manualmonitorproducts.com/wp-content/uploads/Service manuals...MONITOR GF500 Vented Heating System Service Manual • The information contained herein is proprietary to Monitor