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Service Manual

1. ewe n EE B BRE UM D n Es mam Le Co y iii Leve yim TL T wax p tii i ELT Leve fap ____ C nrc gp rrr Qn o Tr ll Hii Hu DEL TG lI Lo p ES TT T ju Lo j HEEL ECL WIDE I TT T LL a HG DH D LUI gui l CT IEEE IET pae PREPA eu ____ rd 5 RI 47 4 ar ox E fy LE Jy 7 ms T S ant M 5 HIGH H MED L MED LOW 12 SET TEM PUMP PULSE ECONOMY PLUS EMPTY OVER HEAT AIR PRESSURE SW CLOCK SET RUN ON OFF AUTO IC 7 FM IC 12 ECONOMY PLUS OPERATION 5W PHOTO TRIAC PHOTO COUPLER LED INDICATO BURNER STATUS MONITOR LED SENSOR SW ROOM TEMP SELECTOR RELAY TRIAC e d gt 4 o UD DUE MEO wage gn maa w em gt M 422 OPERATION TIMING CHART eee ___ TEE TET pw eu ET PRE COM
2. Section 3 Operation gt 32 STEP4 Check for Cause of Overheating NOTE Overheating is usually caused by objects that impede free circulation Look for debris and other obstructions at front of heater at Circulation Fan at rear of the heater and at Fiue Pipe tip outside dwelling STEPS Remove Louver Assembly STEP6 Clean Heater Interior BEFORE PROCEEDING TO CLEAN HEATER BE SURE THAT HEATER INTERIOR IS COOL ENOUGH TO TOUCH With a clean lint free damp rag or other appropriate cleaning material wipe up all dust dirt and debris frorn exterior of cabinet including exterior of Com bustion Chamber and Heat Exchanger STEP7 Replace Louver Assembly STEPB Reconnect Monitor Heater Power Plug to the Wall Outlet STEPS Turn Heater ON STEP1O Reprogram Heater Microprocessor STEPTI Select Mode of Operation CAUTION after the completion of recovery procedure the heater overheats again something is wrong Do not operate heater until prob lem has been diagnosed and cor rected 3 14 RECOVERY FROM BLOWN FUSE All electrical components of the Monitor heater are protected against power overloads and electrical malfunctions by two 2 fuses and a 10 fuse Should fuse blow the recovery procedure is outlined below SYSTEMS Mat STEPI STEP2 STEPA STEPS STEPS STEP7 STEPB
3. Heated Air Delivery High 388 Cubic feet minute _ H Medium 388 Cubic feet minute L Medium 300 Cubic feet minute Low 300 Cubic feet minute High 176 Cubic feet minute H Medium 176 Cubic feet minute L Medium 113 Cubic feet minute Low 113 Cubic feet minute Vent Pipe Hole 2le inches Diameter 212 Diameter Dimensions Height 26 6 inches Height 25 6 inches Width 28 7 inches Width 20 9 inches Depth 13 8 inches Depth 12 4 inches Weight 82 Pounds empty 55 Pounds empty When Considering heat of condensation is lost then net efficiency 87 2 SPECIAL FEATURES AUTOMATIC IGNITION Memory 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 is restored indicator Lights Easy to see signals show when heater is in operation when timer is activated and when the burner is operating in low medium or high modes Choice of Fuel Supply Large tank gravity fed system large tank system with pump M 441 Built in capsule tank or connect to separate tank M 422 Multiple Heat Exchanger Extracts 87 of heat from burner Clean Operation Produ
4. Outdoor Fuel Tank Shut ofi Valve 34 Flare Connection Monitor 422 Fuel Filter OW T maximum 16 2 6m IELI 35 Flare Connection or Fusible Valve Connection XOD Copper Tubing NOTE Fuel tank must be a minimum 3 feet away from flue pipe Figure 2 12 TYPICAL FUEL LINE CONNECTIONS MONITOR HEATING SYSTEMS Section 3 Operation 3 1 INTRODUCTION Monitor an easy to operate vented kerosene heater Routine operation features high BTU output automatic adjustment of room temperature low fuel and power consumption and choice of automatic or manual heater operation This section provides all information necessary to operate the Monitor Heating System All operation procedures specified should be performed in the order in which they are described 3 2 OPERATING SPECIFICATIONS The following specifications apply to the operation of the Monitor 441 and the Monitor 422 Monitor 441 Rated Efficiency heaters 9395 Rated Efficiency as applied to central heating systems 8794 Power Consumption as follows as applied to kerosene HIGH MEDIUM HIGH MEDIUM LOW LOW IGNITION BURN BURN BURN BURN 340watts 62watts S8watts S watts A Circulation Fan Output 388 cubic min Fuel source Remote separate tank Potential heating area 900 3200 sq feet energy from the combustion process
5. Mode Fre purge Igniling 1 5 min 1 5 min Test Point NE plement jow 2 qun C F M OIf C F M Low m3 13 12V 30 32V 1 30 12V 30 12V 1309 5V 10 1 10 5V i 10 1 10 5V 1 10 TP 5 3 9V 3 9V 3 9V TP 6 me TP 7 A 12V min 1 2V min pulse at TP 8 5V 5V 5V 5V _ Operation Waiting until 77 Mode Medium High Medium Low Low OFF Postpurge programmed time Test point uu c comes on TP 3 12V 30 12V 130 12V 1 30 12V 1 30 12V 1 30 12V 1 30 12V 30 TP 4 110 1 10 110 5V 110 1 109 TP 6 pulse pulse pulse pulse pulse pulse TP 7 1 2V min 1 2V min 1 2V min 1 2V min OV ID OV variable 5V B 5V 5V 5V 5V 5V La AS MONITOR HEATING SYSTEMS Section 6 Troubleshooting X O Mc X Digital Display INDICATION OF FAILURE MODE The Reason of Indication At pre purge Flame rod is sensing flame when there should be none After power on power supply to the micro processer timing circuit is incorrect At starting of operation the circuit to drive Relay RL6 of Solenoid Pump is mal functioning When unit is shut off either manually or automatically
6. Fuse F2 open Replace fuse igniter open Replace ignite lt of micio Does combustion processor blower work 15 there 12Vdc between prepisga 1 2 and igniting SIS JEM Deme Failure of ian Failure of TR 5 Faitura of photo viac Failure of resistor ASH Failure of capacitor Failure of combustion Replace combustion inconect winng of Correct wiring Combustion blower Replace ait press of ac switch pressure switch Does pressure swich work NOt malty Clear and rubber hose Rubber hosa is bloked on discorrected Incortect wiring Correct wing 1 SYMPTOM RESULT CHECK2 RESULT RESULT RESULT 5 RESULT pump work Is there 160Vdc Yes at diode D2 Failure of tuel supply Failura of resistor 82 R9 Failure of capacitor C4 5 Failure of zener diode 701 Failure of diode D3 D5 Failure of trigger diode 3 Failure of thyristor 22 Failure of diode D2 Failure of microprocessor Failure of TR array Failure of diodelDI7 Failure of resistoqf53 Failure of photo Cit Failure nf transistor 06 011 CORRECTIVE MEASURE Check fuel supply parts CORRECTIVE ME
7. STEPTI 32 Turn Monitor OFF Unplug heater Remove louver assembly Remove front cover As the Front Cover of the Monitor 441 is connected to the Printed Circuit Board by Lead Wires pull the Front Cover to the front side slightly and remove the Connector cf the Lead Wires from the Printed Circuit Board and then remove the Front Cover Locate and replace fuse s Reattach front cover In case of the Monitor 441 be sure that the connector is connected to the printed circuit board Reattach louver assembly Plug heater power cord into wall outlet Turn Monitor ON Reprogram heater Program Automatic operation cycles applicable Select Automatic operation appli cable 78 15 OPERATION CONTROL SYSTEM M 441 OPERATION TIMING CHART POST E moe x CEEI TE E TION 1 un EH NN ui j lips uiui EEUU HEN y uet e ow IL Hi up d EE ewe NM dL meson ub Ee qur dcs imp trit utl E Lows o NA ILLE Co ntt ris ur Hills a LL LEE HH T mme Np uti EFE HEEL EL E EN TIT ww prd NI ductibus LET II ewe riori
8. and then jumper T pin and T6 pin on 16 lemperiature displayed in display window Does heater start 10 operate Fuse ff open Failure ol Trans former Failure of Diode 06 09 Faifurs of Capacitor Failure of 2 Faiture of Capacitor Failure micto processor 5 of compatater Cia Failure of resistor R29 32 Failure of Capacilor Failure swilch SW Failure of resistor 839 Failure of capacitor C201 Failure of operation circuit board Failure of resonator Failure of resistor 1859 Failure of microprocessor CORRECTIVE MEASURE Replace luse Replace transforme Replace operation circuit board TP3 DCI vl 5111 Oe 1 U sated Diodes 810281 n ETHER Dimensions Gpacitoc Resisior 7 OD i n 56 imm PET ee ee EA E os 5 5 Ci6 R23 s m view saa CONNECTION OF LEAD WIRES OPERATION TIMER SELECTOR TIME TEMP SET gt 25 gt TIMECO Panel Printed Wiring Board ECONOMY RUN AUTO PLUS BURNER STATUS e SET ROOM m md ied PM Lamp Printed Wiring Board Purnp Main Printed Wiring Board Pressure 0
9. 2 1 INTRODUCTION Installing the Monitor System at the user s location can be performed quickly and economically The Monitor 422 can be used as either an internally fueled Capsule tank or remotely fueled System The Monitor 441 mode is strictly a remotely fueled system and both are externally vented As such both need the installation of an externally vented intake exhaust system and if remotely fueled will need the installation of a remote fuel storage tank By completing each step of the easy to follow installation instructions each step should be com pleted in exact order specified the Technician is 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 the Monitor vented heating system in ciuding any electrical wiring and fuel supply equipment check local building electrical mechanical and fire codes The requirements of these codes must be followed to insure lawful installation and use The heater can be located almost anywhere within the dwelling provided that electrical fuel and ex haust specifications are met 2 2 PHYSICAL PLACEMENT OF HEATER In additio
10. 4 4 VERIFY IGNITER OPERATION Visually inspect igniter Operation HEATER IS OPERATIONAL DURING THIS INSPEC TION AVOID DIRECT CONTACT WITH ANV HEATED OR ELECTRICAL COMPONENT STEP Prepare for Inspection Remove Louver Assembly STEP2 Visual Inspection A 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 6 of this Service Manual to diagnose the probiem C An altemate inspection is to feel the igniter cover after the unit has been in the ignition stage for about 5 minutes should be warm CAUTION f igniter is broken do not operate the ON OFF switch button repeatedly STEP3 Reassembly of Heater Turn the heater OFF and repiace the Louver Assem biv 4 5 CLEAN FUEL CONSTANT LEVEL VALVE FIL TER Contaminants are trapped by the filter to prevent them from clogging the Fuel Constant Level Valve The filter itself has a great number of small pores Whenever a filter is tom or disfigured enlarged pores it should immediately be repiaced inspect and clean the filter as indicated by the procedure below CLOSE FUSIBLE LINK VALVE ON M 422 OR CLOSE SHUT OFF VALVE OF THE EXTERNAL FUEL TANK ON M 441 TO AVOID DRAINING ALL FUEL FROM TANKS NOTE Power should be OFF during the pertor mance of this procedure STEPI Disassembiv A Using a philli
11. 2 13 Fuel Tank Installation 2 14 Heater Installation Section 3 Operation a tuit t S MH ee Page 23 34 3 1 Introduction 3 2 Operating Specifications 3 3 Operating Con trols and Indicators 3 4 Pre operation Check List 2 5 Operation 3 6 Manual Heater Operation 3 7 Automatic Heater Operation 3 8 Reprogramming the Monitor Heater 3 9 Heat Sensor 3 10 Monitor Shutdown 3 11 Out of Fuel 3 12 Recovery from a Power Failure 3 13 Recovery from Overheat Condition 3 14 Recovery from Blown Fuse 3 15 Operation Contro system SECON 4 SER puma umen he mn n NU Yu rro man dS Page 35 38 _ 4 1 Introduction 4 2 Periodic Maintenance 4 3 Inspect Exhaust Air Piping 4 4 Verify gniter Operation 4 5 Clean Fuel Constant Level Valve Filter 4 6 Cleaning Fusible Link Valve Intake Fitting on M 422 4 7 Maintenance 4 8 Replacement of Fuses 4 9 Fuel Contamination MONITOR HEATING SYSTEMS Table of Contents Section 5 Servicing MM Page 39 41 5 1 introduction 5 2 Measurerment of Fuel Flow rate 5 3 Removal of Water Deposits and Contaminants from Fuel Constant Level Vaive and Fuel Lines 5 4 Cleaning the Burn Chamber amp Burner Pot 5 5 Cleaning the Fuel Iniet Section 6 Troubleshooting Si Page 43 56 Resistance Values component Voltage Readings Test Point Voltage Troubles
12. 6191 6118 6119 6196 6120 6121 6122 6123 6176 6124 6125 6068 6069 6126 6127 6181 6128 6129 6130 6131 6132 6201 6134 6135 6202 6168 6169 6203 6172 6173 6170 6187 6204 6137 6107 6184 MONITOR 22 SERVICE PARTS LIST MONITOR 22 SERVICE PARTS LIST DESCRIPTION SPILL TRAY LEG AIR SUPPLY HOSE A AIR SUPPLY HOSE B FUEL PIPE FUSIBLE VALVE CONSTANT LEVEL VALVE C LV STRAINER STRAINER GASKET SOLENOID PUMP PACKING SOLENOID PUMP OIL SUMP PIPE JOINT SEAL PACKING FUEL SUMP GASKET 1 BURNER BURNER CLOTH GASKET 2 GASKET 3 HEATER IGNITER BRACKET HEATER COVER PACKING IGNITER COVER FLAME DETECTIVE PLUG PLUG PACKING FL PLUG BRACKET GASKET 4 HEAT EXCHANGER ASSY GASKET 6 EXHAUST DUCT O RING P39 WINDOW GASKET WINDOW FRAME GASKET WINDOW PLATE WINDOW GLASS WINDOW BASE GASKET COMBUSTION CHAMBER COMBUSTION RING ASSY BURNER CAP BAFFLE ASSY CHAMBER GASKET CHAMBER CAP POWER TRANSFORMER PWB ASSY PWB SPACER CLIP PWB SPACER CLIP B MICROPROCESSOR RELAY A RELAY B BUZZER FUSE 250V 104 FUSE 250V 24 CAPACITOR 1 54 FD TR ARRAY M54563P IC3 PHOTO COUPLER IC9 11 CORD CONNERCTOR AIR LINE AIR PRESSURE SWITCH ITEM NO 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 79 76 7 79 80 81 B2 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 89 100 101 102 103 104 105 106 107 108 109 110
13. 6205 6206 6207 6208 4004 6407 6408 6145 4014 4016 4006 4008 4805 6147 6148 6075 6330 6331 6347 6332 G409 6410 6411 6412 6154 6155 6337 6338 6413 6345 6194 6197 6414 6342 1148 8216 8217 8219 DESCRIPTION CAPACITOR 1 8 10 TR ARRAY M54583P IC3 PHOTO COUPLERIIC9 11 POWER TRANSFOPMER AIR LINE AIR PRESSURE SW RUBBER BUSH OVER HEAT THERMOSTAT FAN THERMOSTAT CORD CONNECTOR JUNCTION BOX COVER POWER SUPPLY CORD CORD BUSHING LEVEL GUIDE CARRYING HANDLE SENSOR ASSY SLIDE SWITCH ASSY SLIDE SWITCH COVER SLIDE SWITCH PANEL SLIDE SWITCH KNOB JOINT PIPE DAMPER E AIR DAMPER S AIR SUPPLY HOSE ASSY EXHAUST OUTLET CAP AIR PORT O RING PIPE HOLDER HOSE BAND AIR OUTLET CAP FLUE PIPE ASSY SLEEVE FLANGE SET FAN CIRCULATION MOTOR BLOWER GUARD WIRING GUARD UNDER COVER LOUVER CONTROL COVER FRONT COVER LAMP PANEL SWITCH ASSY LAMP ASSY TOP COVER RESISTOR CABINET ASSY UNION NUT WALL CLAMPS SCREW SET FOR FLUE PIPE CARTON BOX CUSHION SET OWNERS GUIDE TOUCH UP PAINT WHITE GLUE TOUCH UP PAINT GREY Screw Set for Flue Pipe int Carton Box 14 waa 12 Cushion Set 15 Glue 42 13 Owners Guide ida Faini 55 Moler f Wiring H For Fan MONITOR 22 EXPLODED VIEW PART NO 6200 5019 6101 6102 6103 6104 6105 6106 6189 6108 6109 6110 6164 6111 6112 6182 6113 6114 6115 6116 6185 6117
14. Switch Sensor Thermistor Over Heat Thermostat Slide Switch Solenoid Vaive j Fiame Detector Biower tor Combustion Blower for Fan Resistor Circulation Thermostat Junction Box figure 7 1 Monitora 41 59 MONITOR HEATING SYSTEMS Section 7 Electrical System Printed Circuit Wiring Diagram CONNECTION OF LEAD WIRES OPERATION TIMER SELECTOR TIME TIME TEMP SET Pane Printed Wiring Board RUN ME FUP BURNER STATUS TEMP SET ROOM LE ey _ Lamp Printed Wiring Board Short Terminal Main Printed Wiring Board Empty Lamp Switch Float Switch Ait Pressure Switch Sensor Thermistor Over Heat Thermostat _ Solenoid Vaive Blower for Combustion Power Corc Blower for Fan Resistor Circulation Junction Box figure 7 2 Monitor422 60 MANOMETER READINGS 21 22 422 Lo Lo Med _ 1 5 2 0 mm H2o Fan Lo Speed Damper Med Hi 3 2 3 6 mm H20 Fan Lo Speed Damper Hi 3 8 4 2 mm H2o Fan Hi Speed Damper O 40 41 441 Lo Lo Med 2 5 3 0 mm H2oe Fan Lo Speed Damper C Med Hi 5 8 6 4 mm H20 Fan Lo Speed Damper O Hi _ 6 8 7 4 mm H2o Fan Hi Speed Damper O Note These Readings are to be taken after the heater has fully warmed up Approximately 5 minutes on Hi fire The adjustmen can only be done on Low or Low Med 48 Low pressure side High cuts side Screw
15. amp BURNER POT Under nonmai running conditions soot will not deposit in great quantities inside the burner and a light covering of soot will not affect tne performance of the unit thus it need not be cleaned However if heavy soot built up does occur the unit should be Opened and cleaned The burner is assembled using gaskets to maintain its air tightness If these gaskets leak the extra air Can cause a serious soot problem and or exhaust gases to escape into the area being heated NOTE f any gaskets are tom when components are removed replace Disconnect power suppiy 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 lead connectors E Remove fuel piping from bum chamber F Remove igniter G Remove flame detective rod lead from PCB DO NOT REMOVE FROM BURN CHAMBER H Remove screw at top of bumer cap which attached it to cabinet Remove screw at back of cabinet from exhaust duct and remove the 4 screws holding the bum chamber to base L Rock chamber back and forth lightly raise about 1 2 and remove bum chamber and heat exchanger as one assembly from unit J Set chamber upside down and remove the 4 screws which secure the burner pot to the bum chamber Pull the bumer pot up and Out 2 On th
16. 111 112 113 114 113 116 PART NO 6136 6151 6152 6163 6139 4833 6037 6138 6186 6205 6206 6207 6208 6140 6141 6142 6143 6144 6160 6161 6180 6192 6193 4004 6209 6145 4014 4016 4006 4008 4805 6147 6148 6149 6210 6211 6154 6155 6156 6212 6158 6159 6179 6165 6178 6177 6162 6213 6345 6194 6214 6197 6215 6175 1148 8216 8217 8219 DESCRIPTION RUBBER BUSH OVER HEAT THERMOSTAT FAN THERMOSTAT AIR PACKING SET POWER SUPPLY CORD CORD BUSHING LEVEL GUIDE CARRYING HANDLE SENSOR ASSY SLIDE SWITCH ASSY SLIDE SWITCH COVER SLIDE SWITCH PANEL SLIDE SWITCH KNOB BLOWER ASSY BLOWER MOUTH PACKING DAMPER SOLENOID ASSY SUCTION CASE SEAL PACKING BLOWER GUARD CIRCULATION MOTOR FAN BLADE WIRING GUARD WIRING HARNESS FAN MOTOR JOINT PIPE AIR DAMPER S AIR SUPPLY HOSE ASSY EXHAUST OUTLET CAP AIR PORT O RING PIPE HOLDER HOSE BAND AIR OUTLET CAP FLUE PIPE ASSY SLEEVE FLANGE SET UNDER COVER LOUVER FRONT COVER SWITCH ASSY LAMP ASSY TOP COVER LAMP PANEL FUEL TANK COVER FUEL TANK ASSY FUEL TANK CAP FLOAT SWITCH FLOAT SWITCH PACKING OIL FILTER RESISTOR CABINET ASSY UNION NUT WALL CLAMPS BASE TRAY RETAINER SCREW SET FOR FLUE PIPE CARTON BOX CUSHION SET OWNERS GUIDE TOUCH UP PAINT WHITE GLUE TOUCH UP PAINT GREY
17. 6196 6313 6314 6122 6123 6176 6315 6164 6352 6353 6404 6124 6125 6405 6350 6317 6349 6356 6321 6322 6323 6406 6324 6144 6348 6362 6134 6135 6202 6168 6169 6203 6172 6173 MONITOR 41 SERVICE PARTS LIST DESCRIPTION SPILL TRAY LEG AIR SUPPLY HOSE A AIR SUPPLY HOSE B CONSTANT LEVEL VALVE C L V STRAINER STRAINER GASKET FUEL PIPE SOLENOID PUMP GASKET 1 BURNER BURNER CLOTH ROPE GASKET HEATER GASKET 3 IGNITER BRACKET HEATER COVER PACKING IGNITER COVER FLAME DETECTIVE PLUG PLUG PACKING FL PLUG BRACKET GASKET 4 HEAT EXCHANGER ASSY GASKET 6 EXHAUST DUCT O RING P39 OIL SUMP PIPE JOINT SEAL PACKING FUEL NOZZLE FUEL NOZZLE COVER BASE TRAY RETAINER WINDOW GASKET WINDOW FRAME GASKET WINDOW GLASS WINDOW BASE GASKET CHAMBER GASKET COMBUSTION CHAMBER COMBUSTION RING ASSY CHAMBER GAP CONDENSER 2 5 BLOWER ASSY DAMPER SOLENOID ASSY SUCTION CASE A ASSY SEAL PACKING MOTOR FOR COMBUSTION PWB ASSY PWB SPACER CLIP A PWB SPACER CLIP B MICROPROCESSOR RELAY A RELAY B BUZZER FUSE 250V 10A FUSE 250V 2A ITEM NO 55 56 57 58 59 60 61 62 Od 64 65 66 67 68 69 70 71 72 T3 74 75 76 fi 78 79 80 81 82 83 84 85 86 87 88 89 90 DI 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 PART NO 6340 6187 6204 6132 6326 6343 6136 6327 6152 6137 6032 6138 4833 6037 6138 6186
18. 6269 6178 6177 6162 6270 6345 6194 6214 6197 6271 6175 1154 8216 8217 8219 6216 DESCRIFTION OVER HEAT THERMOSTAT FAN THERMOSTAT AIR PACKING SET POWER SUPPLY CORD CORD BUSHING LEVEL GUIDE CARRYING HANDLE SENSOR ASSY SLIDE SWITCH ASSY SLIDE SWITCH COVER SLIDE SWITCH PANEL SLIDE SWITCH KNOB BLOWER ASSY BLOWER MOUTH PACKING DAMPER SOLENOID ASSY SUCTION CASE SEAL PACKING BLOWER GUARD CIRCULATION MOTOR FAN BLADE WIRING GUARD WIRING HARNESS FOR FAN MOTER JOINT PIPE AIR DAMPER S AIR SUPPLY HOSE ASSY EXHAUST OUTLET CAP AIR PORT O RING PIPE HOLDER HOSE BAND AIR OUTLET CAP FLUE PIPE ASSY SLEEVE FLANGE SET UNDER COVER LOUVER FRONT COVER SWITCH amp LAMP ASSY TOP COVER LAMP PANEL FUEL TANK COVER FUEL TANK ASSY FUEL TANK CAP FLOAT SWITCH FLOAT SWITCH PACKING OIL FILTER RESISTOR CABINET ASSY UNION NUT WALL CLAMPS BASE TRAV RETAINER SCREW SET FOR FLUE PIPE CARTON BOX CUSHION SET OWNERS GUIDE TOUCH UP PAINT WHITE GLUE TOUCH UP PAINT GREY FUEL NOZZLE Touch up Paint Grey Touch up Paint White Glue Screw Set for Flue Pipe 03 Cushion Set Owners Guide MONITOR 41 EXPLODED VIEW 4 MSS f MONITOR 41 SERVICE PARTS LIST ITEM NO PART NO 6400 5019 6301 6302 6303 6304 6344 6305 6306 6357 6401 6363 6358 6311 6115 6402 6354 6403 6355 6119
19. Burner Pot The metered flow of fuel is carried to the Burner Pot by a copper fuel line 1 21 EXTERNAL FUEL TANK The Monitor 422 gives the user the option of either using the intemal capsule tank or hooking up to an extemal fuel tank Fuel for the Monitors can be stored in and fed from an external storage tank The tank which generally is dealer installed should contain a shutoff vaive a fuel filter and a vent installation of the tank should conform to local regulations and to the specifica tions and guidelines documented in this Service Manual Capsuie tank cannot be used in Connecticut and Massachusetts 1 22 FUSIBLE LINK VALVE Basically the Fusible Link Valve is amp safety mecha nism that cuts off fuel to the heater in the event of an overheat condition at the valve The fusible link valve is mounted as a standard item on the Monitor 422 Located outside the rear of the Heater Cabinet the Fusible Link Valve is a spring loaded device that cuts off the supply of fuel to the heater when the temperature level at the valve exceeds a predefined maximum limit An iniet on the bottom of the valve allows fuel to pass into the heater The handie which can also manually be opened or closed sits on a spring loaded stem which contains a low melting point alloy The fusible link valve can be externally mounted on the Monitor 441 if required 1 23 FUEL CONSTANT LEVEL VALVE This valve has an automatic sh
20. Combustion Fan wotk properly Check for obstructions such as wasps nests in exhaust or Supply piping ts damper installed according to specifications Does extend to whole aea ol burner Does Dampet Solenoid work properly See Symptom 25 above Yes Is igniter installed property Switch Set temperature to High and Low 5 6 Check outside end of Flue Pipe for flow of and exhaust ts Air Damper installed according 10 specifications a Yos Flama extends Flame does not extend Failure of Damper Solenoid Assy Fuel solenoid pump matlunctioning intake or exhaust line clogged Combustion fan failed Clogged air supply or exhaust piping Nol as specified Too much flow ignitor mounted incorrectiv Combustion Ring is Installed improperly Combustion Ring is broken Ait isaks from Igniter Cover Supplies only small amount of fuet due to dust or bubbles in Fuet delivery parts Failure of solenoid pump as specified CORRECTIVE MEASURE Replace Damper Solenoid Assy Replace solenoid pump Install Ak Damper according to specifications Clean out and exhaust ducts 4 Replace Combustion Blower Assambly H Remove obstructions Conect specified Mount Damper if needed Mount properly Instal
21. Economy Plus mode 3 7 AUTOMATIC HEATER OPERATION Automatic operation is established by programming the time temperature settings for specific times On a daily basis a maximum of four time temperature settings can be programmed it subsequently it should be desired to switch to manual mode of operation the changeover can be made at any time Proceed with automatic mode of operation in the following manner STEPI Program Clock for Current Time A Press the TIMER SELECTOR push button switch at which time the CLOCK SET indicator light will illuminate B Press HOUR push button switch to program current hour on the Clock IMPORTANT Be sure to set clock for AM or PM as appropriate NOTE Both hour and minute digits on Display Window are advanced in increments of one by pressing the appropriate push button switch one time for each digit digits can also be advanced repetitively by pressing and holding the appropriate push button switch C Press MINUTE push button switch to program the current minute s on immediately after programming current time in terms of hours and minutes press the SET push button switch STEP2 Program the 161 Time Temperature A Pressing the TIMER SELECTOR push button switch will illuminate the 1st indicator light B Press TIME push button switch MONITOR HEATING SYSTEMS Section 3 Operation Press HOUR and MINUTE push button switches to program 1st desired
22. is there ov pins On Cr cuit board Change fuse plug in Dower cord Yes Incorrect wiring of flame sensor or Ground Flame sensor tod touches lo burner parts of Combustion Failura of Ait Pressure Switch Failure of Solenoid Pump Has constant level valve safaty tripped Blower motor Failure of Circuit Board Incorrect Sool adhering to combustion chamber interior Failure of sotencid Pump Failure of Igniter Failure of Circuit Board Incorrect wiring Is there at plug failure of Circuit Board Fuse open Short circuit of lead wire Failure ol Circuit Board is Auto operation mode CORRECTIVE MEASURE Replace or check Circuit Bosrd Correct wiring Correct oc Change _ Replace Pressure Switch Replace Solenoid Pump Rasal the fuat constant level valve neret Raplace Combustion Blower Molor of check Circuit Board Correci wing Clean genlly with brush etc Solenoid Pump Replace Igniter check Circuit Board wirlng of igniter relay on PCB replace board Replace o check Circuit Board Change fuse o change Replace ot check Board Put in Manunt Burn Mode CORRECTIVE MEASURE SYMPTOM CHECK1 RESULT CHECK2 RESULT CHECK3 I RESULT CHECK4 RESU
23. lock bracket the short stop and substitute the long stop B Attach lock bracket to left hand side of upper Adjust to proper position and secure with window frame Use the two wood screws screws and washers previously removed provided Before securing the stop to the window remove the protective backing and firmly stick NOTE the lock bracket prevents the lower the stop packing onto the underside of the window from sliding upward notch the Stop bracket into the upper window frame NOTE Windows with deep sills may require the C Slip lock into lock bracket use of an extra intake and exhaust elbow to provide clearance for flue pipe hook up IMPORTANT Window can be locked by turning piece of the air intake line can be cut to locking lever to right to open turn join the two intake elbows together locking lever to left and remove lock from bracket Deep Window Sill One Exhaust Elbow Two intake Elbows Figure 2 6 MONITOR HEATING SYSTEMS Section 2 Installation 2 10 INSTALLING AN EXTENSION KIT installing an Extension Kit requires the construction of an air line and the exhaust line The air line is connected between the Air Supply Elbow at the rear of the heater and the air inlet port on the Fiue Pipe Similariy the exhaust line is connected between the joint pipe at the rear of the heater and the exhaust port on the Flue Pipe IMPORTANT The PVC air line is longer than the exhaust line a
24. push button switch is pressed to position ON Figure 3 1 Item2 AUTO indicator Light Lights when heater runs in automatic mode AUTO RUN and appropriate BURNER STA TUS indicators are illuminated simultaneously if heater is burning Figure 3 1 ttem3 ECONOMY PLUS Lights when heater runs in Economy Plus Indicator Light mode Figure 3 1 tem Empty Indicator Light in case of using the cartridge tank when the fue is empty EMPTY indicator Light biinks This Light is not provided with Monitor 441 Figure 3 1 Rem5 BURNER STATUS Light in accordance with heat output as fol indicator Lights o jows Heat Output Light Pattem High Bindicators ON Medium High Sindicators ON Medium Low 4indicators ON Low 2indicators ON 29 MONITOR HEATING SYSTEMS Section 3 Operation FIGURE AND ITEM NO CONTROL OR INDICATOR FUNCTION Figure 3 1 TEMP indicator Light Lights when heater is running and Digital Window is showing the temperature Figure 3 1 Item7 AM indicator Light Figure 3 1 8 PM Indicator Ligh Figure 3 1 9 E Digital Display Indicates SET and ROOM temperature when heater is running and indicates time when heater is Off indicates time and temperature for automatic operation setting Figure 3 2 10 TIMER SELECTOR The automatic function allows the program push button switch ming of different temperatures for different times of the day Two three or four settings
25. that heater is level this inspection reveals any system deficiencies correct the problems before operating the heater 3 5 OPERATION Operation of Monitor heater can be controlled manually by the user or run automatically by the microprocessor Paragraphs 3 6 through 3 10 provide the details of heater start up operation and shutdown The controis and indicators iliustrated by Figure 3 1 and 3 2 are used to operate the system and to monitor the heater s performance MONITOR HEATING SYSTEMS Section 3 Operation 3 6 MANUAL HEATER OPERATION Operation of the heater is under the direct control of the user heater wil not operate automatically The heater will however automatically respond to changes in room temperature signaled by the Heat Sensor to maintain the temperature of the room at a comfortable level NOTE Resetting the Fuel Constant Level Valve is necessary oniv if the heater is being start ed for the first time hasn t been used for an extended period of time or if tank has run empty priming is unnecessary skip to step 2 Prime the Heater Gently press and release the Fuel Constant Level Reset Lever four or five times STEP2 Select Manual Operation If heater operation is in AUTO mode press the AUTO push button switch and change Auto to Manua mode STEP3 Select Temperature Setting Press the TEMP push button switch and press either the UP or DOWN push button switch to set
26. the digital set room temperature indicator to the desired temperature and then press the SET push button switch IMPORTANT In case no temperature is set tem perature wili automatically be set at the setting temperature seiected by using the slide selector for the reset temperature STEP4 Turn Monitor On Press the ON OFF push button switch to position ON The RUN indicator light illuminates to indicate that power has been applied to the instrument and the heater is cvcied for manual mode of operation INSTRUCTIONS FOR ECONOMY PLUS MODE 1o engage the economy plus mode simply press down the button labeled Economy Plus to disengage press again NOTE Operation switch must be ON and in MANUAL mode This feature minimizes the ON and OFF cycling of the unit by allowing it to overshoot the set temperature by 12 degrees instead of the nomnal 4 degrees The advantages of this feature are to increase the overall efficiency of the unit by 29 1 Decreasing electrical consumption by decreasing the frequency of ignition cycles 2 Reducing heat loss during the prepurge and postpurge cycles 3 Reducing inefficient combustion associated with start up and shut down 4 Prolonging component life by decreasing expan sion and contruction of internal parts NOTE This feature could be compared to driving an automobile in stop and go traffic regular mode versus highway driving with cruise contro engaged
27. time IMPORTANT Be sure to set the ciock AM or PM as appropriate D Immediately after programming the 1st desired time press the SET push button switch This step must be completed within fifteen seconds after programming the time E Press TEMP pust button switch F Press UP and or DOWN push button switch es to program 1st desired temperature G immediately after programming the 1st desired temperature Press the SET push button switch This step must be completed within fifteen seconds after programming the temperature STEP3 Program the Remaining Times By pressing the TIMER SELECTOR push button switch again the 2nd Indicator Light will iliuminate 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 lock into memory Should heater power be interrupted by a power fallure or by disconnection of the power cord beyond 5 minutes heater reverts to MANUAL operation and all AUTO programming is erased 4 Select Automatic Operation Press AUTO push button switeh The AUTO in dicator light will illuminate STEPS Turn Monitor ON Press ON OFF push button switch to position ON The RUN indicator light will illuminate to indicate that power has been applied to the heater From this point heater operation is as foliow exam ple 5 00PM 10 00PM BO F 6 00AM 9 00AM 76 F SEE 64 F Ex
28. vented through the intake fan of the Combustion Blower to hollow base of the Combustion Chamber This airway A deterioration of air pressure at the Air Pressure channels air to the Combustion Chamber Switch is an abnormal condition the heater is shut The Flame Sensor is mounted with two 2 phillips head screws onto the wall the Combustion Chamber 2 MONITOR HEATING SYSTEMS Section 1 Description Pot is cut flame extinguishes after all fuel currently in the line has been consumed and the Burner Status Indicators blink This safety mechanism can be triggered by several conditions Leak or loose connection in air line Leak loose or broken tubing which connects the Air Pressure Switch with the Combustion Blower Clogged or blocked Air ire Blocked or clogged Pipe intake port of Combustion Blower is blocked Combustion Blower is inoperabie l 20 FUEL DELIVERY SYSTEM Fuel Delivery is a very important aspect of the Monitor s operation The fuel flow must be maintained at a level corre sponding to the bum mode so that combustion can be conducted efficiently Fuel moves by gravity flow from the external fuel Storage tank or the capsule fuel tank to the Fuel Constant Level Valve The Solenoid Pump meters the flow of fuel from the Fuel Constant Level Valve to the
29. with tuse out 0 1 Fuse IDA read with fuse out 0 01 0 01 solenoid Pump coil 688 695 WARNING DISCONNECT HEATER FROM POWER SOURCE BEFORE MAKING ANY RESISTANCE TESTS MONITOR HEATING SYSTEMS Section 6 Troubleshooting Monitor 422 441 Component Voltage Readinas COMPONENT READING TAKEN AT AC DC Thermistor Q on PCB Sensor disconnected E Thermistor Q on POB Sensor connected 1 5 3 2 Air Pressure Switch Connector J 110 Overheat Protector Closed Air Pressure Switch Connector J 0 Overheat Protector Open Damper Solenoid on PCB 105 Solenoid Pump Kon PCB pulse Circulation Fan High Speed RD to BK M 422 110 WH to BK M 441 110 Circulation Fan Low Speed RD to BK M 422 93 WH to BK M 441 9 igniter B on PCB 110 Power Transformer AC 120V 110 primary side Power Transformer AC 120V 120 secondary side AC 12V 12 Combustion Blower F on PCB 110 1 High Speed i Combustion Blower F on PCB 92 422 Low Speed Q1 is OFF BBIM 441 Resistor G on PCB 18 M 422 22 M 441 x Pulse can only be measured with a high impedance digital volt meter MONITOR HEATING SYSTEMS Section 6 Troubleshooting Monitor 22 41 Component Voltage Readings COMPONENT Thermisior Thermistor Air Pressure Switch Overheat Protector Closed Air Pressure Switch Overheat Protector Open Damper Solenoid Solencid Pump Circulation Fan High Speed Circulation
30. 1 44 6252 45 6134 46 6135 47 6253 48 6203 49 6172 50 6173 51 6256 52 6187 53 6204 54 6137 55 6107 55 6184 57 6135 DESCRIPTION SPILL TRAY LEG AIR SUPPLY HOSE A AIR SUPPLY HOSE B FUEL PIPE FUSIBLE VALVE CONSTANT LEVEL VALVE C L V STRAINER STRAINER GASKET SOLENOID PUMP PACKING SOLENOID PUMP OIL SUMP PIPE JOINT SEAL PACKING FUEL SUMP GASKET 1 BURNER BURNER CLOTH GASKET 2 GASKET 3 HEATER IGNITER BRACKET HEATER COVER PACKING IGNITER COVER FLAME DETECTIVE PLUG PLUG PACKING FL PLUG BRACKET GASKET 4 HEAT EXCHANGER ASSY GASKET 6 EXHAUST DUCT O RING P39 WINDOW GASKET WINDOW FRAME GASKET WINDOW PLATE WINDOW GLASS WINDOW BASE GASKET COMBUSTION CHAMBER ASSY COMBUSTION RING ASSY BURNER CAP BAFFLE ASSY CHAMBER GASKET CHAMBER CAP POWER TRANSFORMER PWB ASSY PWB SPACER CLIP A PWB SPACER CLIP B MICROPROCESSOR BUZZER FUSE 250V 104 FUSE 250V 2A 1 8 u FD TR ARRAY 54563 104 PHOTO COUPLER IC12 CORD CONNECTOR AIR LINE AIR PRESSURE SWITCH RUBBER BUSH ITEM NO 58 59 60 61 62 63 64 65 66 67 MONITOR 422 SERVICE PARTS LIST MONITOR 422 SERVICE PARTS LIST PART NO 6273 6260 6163 6139 4833 6037 6138 6186 6278 6206 6207 6208 6140 6141 6142 6143 6144 6261 6262 6180 6263 6264 4004 6209 6145 4014 4016 4006 4008 4805 6147 6148 6149 6210 6265 6266 6267 6268 6158 6159 6178
31. 15 released in the form of heat and vaporized water Normally heating systems discharge water from combustion to the atmosphere without condensing it This 93 efficiency rating means that assuming the water cannot be condensed 83 of the heat produced by the combustion process is recovered Assuming the water can be conoensed the effi ciency is 87 NOTE Actual effective heating area depends upon numerous factors such as type and severity of climate type of dwelling construction condition of dwelling and thickness and effectiveness of dwelling insulation Table 3 1 lists Monitor 441 performance specitica tions at various user selected heat output settings Table 3 1 HEATER PERFORMANCE SPECIFICATIONS Specification Rating Heater Output hr 19 500 31 500 40 000 wm liema es bumime eel 206 Continuous use burntime 5 gal tank 31 3hrs 20hrs 15 7hrs 5 gatari mss Continuous use bumtime 55 gal tank B hrs day burntime 275 gal tank me Continuous use bumtime 275 gal tank 71 6days MONITOR HEATING SYSTEMS Section 3 Operation Monitor 422 Circulation Fan Output 176 cubic feet min Rated Efficiency as applied to kerosene Fuel source 1 32 U S gal separate tank heater 8392 optional Rated Efficiency as applied to central heating Pot
32. 7 TEMPERATURE SENSOR The sensor which is capable of sensing room tem perature within a range of 42 F to 96 F be left mounted on the back of the heater cabinet or be wall mounted Approximately 6 about 200 cm of No 20 AWG Wire is supplied with the sensor to facilitate wall mounting the sensor in a favorable location 1 28 SAFETY MECHANISMS Several safety mechanisms have been built into the Monitor Heating System These devices protect the user against personal injury protect the heater against damage and shutdown the heater f a malfunction occurs t 29 CLOTH COVERED EXHAUST PIPE insulating cioth covers are to be placed over all metal surfaces of the Exhaust Line during installa tion Since combustion bv products are vented at ele vated temperatures the Exhaust Pipe will become hot during operation The insulating cloth covers protect the user from bum hazards associated with accidental contact with these heated metal Sur A n P nA 4 A 2 During installation make sure that all Exhaust Lines are tight Do not operate the heater without the insulating Covers t 30 AIR CIRCULATION FAN GUARD This guard is an integral part of the fan assembly The guard protects the user against physical injury which could occur from accidental contact with revolving metal fan blade 1 31 FUSE 2 amp and 10 125VAC fuses protect the heater from damage resu
33. ASURE Replace handle of fusible link valve DI Open valve RESULT SYMPTOM RESULT CHECK2 RESULT CHECK3 RESULT 4 15 soleno Yes pump operating Nu luc feed ignition Fusible link valve closed on M 422 in luct ling Check waler Topped saletv on Fuel constant Reset Fuel constant level level valve valve Burner joint clogged Fuel Line m Clean burner joint 5 passageway into the Combustion Chamber near bass of Burner Pot Yes Fuel not ed because of surfasa tension water Discharge water Water gathering in fue tank Failure of Solenoid Pump Replace Solenoid Pump Wiring laiture Correct or replace wires Check wwing to pluy Straighten fuel line lo remove an Yes pocket consect fuel line installation 3 T soon alter Level Valve Sat Lever 4 5 times ignition 1 sal t Push Operation Button to Yes Fuel shortage gt 2 tank 3 Turn haate on 1 Unplug heater 2 Ramove obstructions and or determine cause of 3 Flepinca cover and restart heater Overheat condition Ait present lina Correct fuel line Flame does nol increase when sel al Make Generat Checks above head too low ISae Section2 INSTALLATION i
34. BUS LLL PTT mi PTT TION een dH LTD LET m HE SEHE HH HIR __ as HTT TT ON BY ROOM THERMO E POST UT NL oe o NI JU Tp mms nu ewe PRE PURGE PRE HEAT LA ha HIGH 12 F 4 SET TEMP OVER HEAT AIR PRESSURE 5 CLOCK TEMP RL HEATER IC 7 FM BUZ2ER IC10 SL IC 11 PUMP PULSE SON CLOCK PHOTO COUPLER BURNER STATUS LED INDICATOR ROOM TEMP MONITOR LED OPERATION SW SENSOR 5W SELECTOR PHOTO TRIAC PRE HEAT ett HH MONITOR HEATING SYSTENS Section 4 Maintenance 4 1 INTRODUCTION cally in order to sustain the efficiency of the Monito Heater maintenance is divided into two classifica Heating Systems tions periodic maintenance is required to maintain the heater in good operating condition corrective maintenance is necessary to repair a malfunetion At the time of the demonstration or installation heater maintenance should be discussed with the user emphasize that a clean heater and proper fuel are the keys to optimum heater operation and 4 2 PERIODIC MAINTENANCE performance The Maintenance Schedule provide
35. D ES MONITOR HEATING SYSTEMS Service Manual MONITOR 422 MONITOR 441 MONITOR 22 MONITOR 4i MONITOR 21 MONITOR 40 MONITOR HEATING SYSTEMS Table of Contents Section 1 Description M Page 1 7 1 1 Specifications 1 2 Special Features 1 3 Safety Features 1 4 Description 1 5 Spill Tray 1 6 Heater Cabinet l 7 Combus tion System 1 8 Combustion Chamber 1 9 Burner Pot 1 10 Combus tion Ring Assembly 1 11 Burner 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 Pressure Switch 1 20 Fuel Delivery System 1 21 Extemal Fuel Tank 1 22 Fusibie Link Valve 1 23 Fuel Constant Level Valve 1 24 Solenoid Pump 1 25 Electrical System 1 26 Microprocessor 1 27 Tempera ture Sensor 1 28 Safety Mechanism 1 29 Cloth Covered Exhaust Pipe l 30 Air Circulation Fan Guard 1 31 Fuse 1 32 Overheat Protector Switches 1 33 Slide Selector For the Reset Temp Section 2 Inetalisti ti xssssexesaxzexxuxxcuuxkwe n 9 21 2 1 Introduction 2 2 Physical Placement of Heater 2 3 Drilling Requirements 2 4 Power Requirements 2 5 Fuel Tank Require ments 2 6 Temperature Sensor Wiring Requirements 2 7 Building Codes 2 8 Un packing 2 9 Heater Installation 2 10 Installing an Extension Kit 2 11 Typical Monitor Litter Pump Installations 2 12 Uses for the Elbow Adapter Kit
36. E WHILE POWER S ON STEP1 Removal of Fuse A Unplug heater Remove Louver Assembly and Front Cover B Remove the fuse from fuseholder on the Printed Circuit Soard 38 STEP2 A Installation of New Fuse Install a new fuse into the fuseholder The fuse must be a 250 V 2 amp or a 250 V 10 amp type as marked on the printed circuit board Do not use oversized fuses the Front Cover and the Louver Assembly and piug the heater into the wall outiet IMPORTRNT Whenever the heater is unplugged the Microprocessor must be repro grammed when power is restored 4 9 FUEL CONTAMINATION Fuel contamination is often difficult to diagnose even though it will adversely affect heater operation and performance The best course of action to take when fuel contamination is suspected is to examine all of the system s fuel filters beginning with the fuel storage tank If a Monitor Kerosene Lifter is part of the fueling system examine and ciean that unit s filter as well as the filter located in the Fuel Con stant Level Valve When it has been determined that water or some other contaminants have infiltrated the fuei tne following action must be taken 1 BEFORE PROCEEDING FURTHER UNPLUG THE HEATER STEPI Remove Contamination A Shut OFF the fue supply at the storage tank or at the Fusible Link Vaive B Drain otf the contaminants from the fue storage tank or the fue sump tank M 422 Fill with fresh cl
37. ENT FREEZING IN COLD CLIMATE 20 50cm or more 24 Front Obstacie SNOW SURFACE or GROUND Figure 2 4 FLUE PIPE CLEARANCES INSTALLATION OF FLUE PIPE WINDOW KIT A window kit makes it possible to vent the heater from dwellings in which through the wall venting is neither practical nor possible The Window Kit is available in two sizes The Short Window Kit accommodates windows from 20 to 32 wide the Long Window Kit accommodates windows from 31 to 50 wide NOTE The procedure below describes how Window Kit is installed in a double hung window The Window Kit can also be in stalied in a vertical sliding type window Install the Window Kit in the manner outlined below STEP 1 install Fiue Pipe in Window KIt A Push the rubber seal into the Fiue Pipe hole on the window kit frame The hole on the seal should be positioned at the exterior side of the frame B Using the four 4 Phillips head screws fasten the spacer to the frame C With the arrow on the Fiue Pipe pointing UP align the screw holes on the Fiue Pipe with those on the Spacer Secure with three 3 phillips head screws MONITOR HEATING SYSTEMS Section 2 Installation A A VISIONE OMIM M n E dM FIC PLE MM ada qr a d we STEP 2 instal Window in the Window IMPORTANT Prior to installation ciean the win Gow fram
38. Fan Low Speed Igniter Power Transformer primary side Power Transformer secondary side Combustion Blower High Soeed Comcustion Blower Low Speed Resistor READING TAKEN AT Q Sensor Zisconnectec Q on PCB Sensor connected Connector J Connector J on PCB K on PCB GR to BK BK to RD M 21 BL to BK BK to WH 40 YL to RD GR to YL M 21 to WH BL to GR IM 401 Bon PCB H on PCB Connector L Connector M F on PCB F on PCB RLS is OFF on 42 AC 110 110 110 110 110 110 120 110 AAM 22 88 41 18 22 221M 41 ing Troubleshooti MONITOR HEATING SYSTEMS Section 6 TEST POINT VOLTAGE Pre purge Igniting Pre buming 1 Preparallon Test Point L Pre heal low med 2 min C F M Off x UM GEN s UNE Pre burning 2 C F M Low Operalion Mode 5V 10 12V 30 Wailing until L Posi purge programmed lime comes on Medium High Medium Low svo 5 10 10 5V 10 5V 10 10 12V 30 12V 30 12V 30 12V 30 12V 3096 Operalion Mode Test point OW 65 MONITOR HEATING SYSTEMS Section 6 Troubleshooting TEST POINT VOLTAGE Operation Pre burning 1 Pre burning 2
39. LT CHECKS RESULT I temperatura jew is solenoid pump f display normal able to change Change ol burn moda High Lowi inptoper Failute ol microprocessor fuel low rate Failure of photo coupter iCt2 Failure of TA array IC 6 Connect resis Failure of solenoid tor at IO pins and Replace solenoid pump then set temperature kom Low to High Failure of microprocessor 18 circulation fan n ICI molot able ta change speed Failure of photo biac uc Failure of TA Replace circulation fan motor Failure ol circulation fan motor x Vas of microprocessor Failure of TR array 106 Failure of photo triac 28 9 Failure of tiac QU Faiturs of resistor R51 52 Failure of capacitor 8 N Replace combostion blower Failure of combustion blower Failure of resistor for combustion blower Replace damper solenoid Failure of damper solenoid Failure of resistor R12 813 of capacitor C10 Failure of mico G mmm SEIT Failure of tans n Replace transformer Failure of capacitor 16 at Failure of resistor R22 R24 at C2 pini f tor IC3 Failure of resistor 271 failure of diode 013 FLAME ROD 8YPASS CIRC
40. NANTS FROM FUEL CONSTANT LEVEL VALVE AND FUEL LINES NOTE Disconnect the Monitor from power supply unplug before proceeding 1 Use a syphon pump and a syringe to drain off any fuel in the fuel sump in case of capsule tank use on the Monitor 422 H using Separate tank on the Monitor 422 shut off fusible link valve On the Monitor 441 shut off valve of separate tank Bend a piece of sheet metal or cardboard into a U shape and place it under tne fuel constant level vaive strainer cover to drain bad fuel into a l 2 liter pan Figure 4 1 Remove strainer cover and drain With strainer cover removed inspect clean and or replace strainer if damaged Remove drain port screw and drain Replace strainer Cover and screw Open fusible link valve or shut off valve to refill system with fresh crystal clear ker osene _ Repeat steps 1 3 until all contaminated fuel is drained off i Remove fuel feed pipe from burner pot and solenoid pump and drain fuel into pan Once lines are clear reconnect fuel feed pipe tum operation switch ON and start a test run m o o gt F NOTE Removing and retightening bumer fuel connection must be done when a burner cools down completely If it is done when a 3g UO _ ___ ___ ___ _ gt a CMM ACCU burner is hot the welding on the fuel joint may break Fixing Torque for nut 30 40kg cm 26 3Slb in 5 4 CLEANING THE BURN CHAMBER
41. OTE Economy Plus mode is accepted only in the MANUAL mode 3 4 PRE OPERATION CHECK LIST After heater installation but prior to Monitor heater start up inspect the system for operational teadi ness The following check list specifies those items that should be inspected on a routine basis lt lt lt 4 lt ta N Check that the Monitor heater is plugged into wal outlet 120 Vac 60 Hz Verify that adequate supply of kerosene is availabie in fuel tank Confirm that fue is free of water or other contaminants Check fue tank for good operating condition it must be free of rust corrosion and or leaks inspect Fue Line for signs of leaks toose connections cracks air pockets or blockages Confirm that Fuel Vaives on Fuel Tank and Fusible Link Vaive are open so fuel fiow freely Outside dwelling check area immediately around Fiue Pipe for combustibles or obstruc tions to free air circulation inspect Air Line for cracks loose connections or blockage Check Exhaust Line for cracks loose connec tions or blockage At rear of heater verify that air flow to the Air Circulation Fan is not blocked 28 Inspect dwelling interior and confirm that imme diate area near heater is free of combustible and objects that might interfere with free air fiow Make certain that Heat Sensor is not exposed to drafts direct sunlight nor direct heat from the Monitor v Confirm
42. R HEAT THERMOSTAT FAN THERMOSTAT CORD CONNECTOR JUNCTION BOX COVER POWER SUPPLY CORD CORD BUSHING LEVEL GUIDE CARRYING HANDLE SENSOR ASSY SLIDE SWITCH ASSY SLIDE SWITCH COVER SLIDE SWITCH PANEL SLIDE SWITCH KNOB JOINT PIPE AIR DAMPER E AIR DAMPER 5 AIR SUPPLY HOSE ASSY EXHAUST OUTLET CAP AIR PORT O RING PIPE HOLDER HOSE BAND AIR OUTLET CAP FLUE PIPE ASSY SLEEVE FLANGE SET FAN CIRCULATION MOTOR BLOWER GUARD WIRING GUARD UNDER COVER LOUVER CONTROL COVER FRONT COVER LAMP PANEL SWITCH amp LAMP ASSY TOP COVER RESISTOR CABINET ASSY WALL CLAMPS SCREW SET FOR FLUE PIPE CARTON BOX CUSHION SET OWNERS GUIDE TOUCH UP PAINT WHITE GLUE TOUCH UP PAINT GREY A 272 Ny NA 2 Z s 4 NY gt gt Wiring Harness or Fan Moter MONITOR 422 EXPLODED VIEW 09 Screw Sel lor Flua Pipa Carton Box 09 Cushion Set 42 Owners Guide Touch up Paint While 12 Touch up Paint Grey NO NO 1 6200 2 5019 3 6101 4 6102 5 6108 6 6104 7 6105 B 6106 9 6189 10 6108 11 6250 12 6110 13 6164 14 6111 15 6112 16 6182 17 6113 18 6114 19 6115 20 6277 21 6195 22 6117 23 6191 24 6118 25 6119 26 6196 27 6120 28 6121 29 6122 30 6123 31 6176 32 6124 33 6125 34 6068 35 6069 36 6126 37 6127 38 6181 39 6128 40 6129 41 6130 42 6131 43 625
43. Set lor Flue Pipe Touch up Paint While Canton Box 03 Glue 09 Cushion Set Touch up Paint Grey Owners Guide WONDURKRON JO PART NO 6400 5019 6172 6173 6452 6187 DESCRIPTION SPILL TRAY LEG AIR SUPPLY HOSE A AIR SUPPLY HOSE B CONSTANT LEVEL VALVE C L V STRAINER STRAINNER GASKET FUEL PIPE SOLENOID PUMP GASKET 1 BURNER BURNER CLOTH ROPE GASKET HEATER GASKET 3 IGNITER BRACKET HEATER COVER PACKING IGNITER COVER FLAME DETECTIVE PLUG PLUG PACKING FL PLUG BRACKET GASKET 4 HEAT EXCHANGER ASSY GASKET 6 EXHAUST DUCT O RING P39 OIL SUMP PIPE JOINT SEAL PACKING FUEL NOZZLE FUEL NOZZLE COVER BASE TRAY RETAINER WINDOW GASKET WINDOW FRAME GASKET WINDOW GLASS WINDOW BASE GASKET CHAMBER GASKET COMBUSTION CHAMBER COMBUSTION RING ASSY CHAMBER CAP CONDENSER 2 5 uFD BLOWER ASSV DAMPER SOLENOID ASSY SUCTION CASE A ASSY SEAL PACKING MOTER FOR COMBUSTION PWB ASSY PWB SPACER CLIP A PWB SPACER CLIP B MICROPROCESSOR BUZZER FUSE 250V 10A FUSE 250V 2A CAPACITOR 1 5 u FD TR ARRAY 54563 IC4 ITEM NO 55 56 57 58 59 60 SBEIFSGRO MONITOR 441 SERVICE PARTS LIST n MONITOR 441 SERVICE PARTS LIST PART NO 6204 6251 6326 6145 6197 6459 1153 8216 8217 B219 DESCRIPTION PHOTO COUPLER IC12 POWER TRANSFORMER AIR LINE AIR PRESSURE SWITCH RUBBER BUSH OVE
44. UIT For testing purposes flame detector rod bypass can be up consisting of 2 insulated alligntor clips 2 6 pieces of insutated copper wire 1 1 47 watt 400 volt diode and 1 1 47 wan 100k OHM resistor These components are to be soldered together in sequence as shown diagram below note component sequence and polarity Once the bypass is made the unit is turned on immediately after the prepurge preheat cycle when mode light comes on the O and N pins are disconnected off the PCB and replaced with the bypass The should then continue functioning as Yes i Failure of microprocessontCI of capacitor C29 Failure of tansistor Q7 though R had a good flame inside the burn chamber and service tests such fuel flow can be checked fNote WARNING after all tests sre completed replace original Name rod wires as a vital safety feature Failura of resistor 1833 Pal Q Failure of wiring for Conect wiring flame sensor and ground incon ect installation p Coreci installation of sensor rod SYMPTOM CHECK1 RESULT CHECK2 RESULT RESULT CHECK4 RESULT 5 RESULT CORRECTIVE MEASURE of micro Is ied is there 129 processor be at Coil of relay MLS piehear Failte of TA 6 of relay
45. V 1 6 1 6 Power Transtormer Secondary AC 120V 647 647 Damper Solenoid connector 1 1 4 600 4 600 Resistor Connector 68 91 Circulation Fan M A22 RD amp BK M 441 WH amp 235 115 Circulation Fan M 422 BK amp YL M 441 BK BL 247 5 2585 Combustion Blower M 422 BK 4 BK M 441 WH 8 GR 22 78 Combustion Blower M 441 GR 8 OR 92 Thermistor connector Q Q at 77 F 10 000 10 000 Fuse 2A read with fuse out 0 1 0 1 Fuse 10A read with tuse out 0 01 0 01 Solenoid Pump 565 565 DISCONNECT HEATER FROM POWER SOURCE BEFORE MAKING ANY RESISTANCE TESTS MONITOR HEATING SYSTEMS Section 6 Troubleshooting IA Monitor 22 41 Resistance values APPROX OHMS COMPONENT M 22 M 41 igniter connector B 16 8 12 7 Power Transtormer Primary connector H 97 97 Power Transformer Secondary connector L L 824 824 Power Transformer Secondary connector M M 1 3 1 3 Damper Solenoid connector 4 600 4 600 Resistor connector G G 68 91 Circulation Fan M 41 WH amp BK M 22 RD amp BK 310 120 Circulation Fan M 41 WH amp GR 22 80 amp YL 365 190 Circulation Fan M 41 BL amp M 22 GR amp BK 270 260 Circulation Fan M 41 BL amp GR M 22 GR 8 YL 210 200 Combustion Blower M 41 WH amp M 22 BK 8 22 78 Combustion Blower M 41 GR 4 OR 92 Thermistor connector Q Q at 77 10 000 10 000 Fuse 2A read
46. ample 5 8 REPROGRAMMING THE MONITOR HEATER On occasion it mav be necessary to reprogram the Monitor 5 Reprogramming is performed as specified below 30 STEPI Reprogramming Current Time if necessarv A Press TIMER SELECTOR push button switch to illuminate the CLOCK SET indicator light Press HOUR and MINUTE push button switches to program new current time Set applicable time by watching Clock display C Press SET push button switch IMPORTANT SET push button switch is not pressed current time will revert to previously programmed time STEP2 Reprogramming Automatic Operation A Press the TIMER SELECTOR push button switch to illuminate the appropriate indicator light 1st 2nd 3rd or 4th Press TIME push button switch Press CLEAR push button switch Time dis played on window will disappear Using HOUR and MINUTE push button switches program new desired time by watch ing the Dispiay Window Press SET pust button switch Press TEMP push button switch Press CLEAR push button switch Set Temper ature displayed on Window will disappear Using UP and DOWN push button switches program new desired temperature by watching the Disptay Window Press SET push button switch m X 3 9 HEAT SENSOR Heat Sensor is located on the rear of the cabinet It is recommended to leave the sensor in its original mounted position However shouid relocation be necessary choose a location for the sensor that
47. at protector switches They will combustion chamber by three 3 phillips head shut down the heater to protect it from damage in Screws the event of excessive heat build up The overheat protector switches reset automatically after cooling 1 14 COMBUSTION AIR SYSTEM down The Combustion Air System channels air to and 1 8 COMBUSTION CHAMBER from the heater This tall cylinder is positioned on the Heater Base Outside air is drawn into the heater by the Combus It is secured to the base by phillips head screws tion Blower through an airway to the Combustion Connected to the Combustion Chamber are the Chamber igniter located within the chamber a fuel line the A Combustion Blower draws the intake air into the Heat Exchanger and a Flame Sensor through a Fiue Pipe This air enters the Combustion Combustion p Assembly and the Bumer 10 Support combustion Remaining air is heated and Cap M 422 Access to those intemally located is drawn into the Heat Exchanger parts is facilitated by a removable Service panel As the heated air passes through the Heat Exchan A Window on the panel lets the technician visually ger an Air Circulation Fan blows room air past the examine the combustion process i e glowing igniter Exchanger and out again into the room heat or proper color ing passing air by convection Exhaust vapors exit An airway in the Cabinet Base extends from the ing from the Hear Exchanger are
48. can be used Figure 3 2 11 CLOCK SET Allows programming of current time when Indicator Light illuminated NOTE Prior to programming current time Digital Display shows 88 88 IMPORTANT Once current time has been programmed press the SET pushbutton switch within 60 seconds Otherwise ciock dis play will revent to previously programmed time if any Figure 3 2 12 1st indicator Light Allows programming of first automatic time and temperature selection when illuminated When programmed heater automatically oper ates at specified time and temperature i e 6 OO am 70 F if set for AUTO providing that heater has been set for automatic mode of operation TIME TEMP HOUR UP MINUTEDOWN and SET push button switches are used to pro gram first operated time and temperature IMPORTANT Once time and temperature be pressed with in Tt5seconds Otherwise time and tempera ture will revert to previously programmed time If any When this Light iliuminates 1st presentiv pro grammed time and temperature displayed J J Figure 3 2 item13 2nd indicator Light Allows programming of second automatic x time and temperature selection when illumi nated 26 MONITOR HEATING SYSTEMS Section 3 Operation FIGURE AND ITEM NO CONTROL OR INDICATOR FUNCTION Figure 3 2 14 3rd indicator Light Programs 3rd au
49. cts of combustion are vented outside Consumes No Room Air Air for combustion is drawn from outside Easy Installation Complete instructions inciuded in this guide 3 SAFETY FEATURES SAFE 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 in the electrical circuitry or disruption of the power supply NO EXHAUST IN ROOM Products of combustion are discharged outdoors FLUE PIPE Outside air is drawn through amp pipe within a pipe venting system This process preheats combustion air and regains heat from exhaust gases 1 4 DESCRIPTION The Monitor heaters are composed of tne following MONITOR HEATING SYSTEMS section 1 Description a Spill tray a cabinet a combustion system an air 1 9 BURNER POT circulation system a fuel delivery system electrical Designed specifically to support combustion the and electronics systems and a variety of safety Burner Pot refer to Figure 1 2 contains a series of mechanisms air holes an igniter tube to accommodate the 15 SPILL TRAY igniter and a fuel inlet fitting interconnects the fuel The Spill Tray line is secured to mounting plate near the Protects the floor kom damage resulting from bottom of the Combustion Chamber fuel spillage The Combustion Ring Assembly is seated on three Provides a secure tip resistant heater base 3 scre
50. d in Tabie 4 1 describes the tasks that must be performed periodi Tabie 4 1 SUGGESTED MAINTENANCE ACTIVITIES Activity Material Remarks Check all fuel pipes for leaks and 3 8 OD copper tubing Fuel piping must be secure and loose connections free of leaks Repiace tubing when necessary Inspect exhaust piping for leaks or All exhaust pipes must be covered loose connections by a cloth insulation cover If cloth cover shows signs of discoloration at joints check o rings Check fuel for water and or other Fuel color should be crystal clear contamination if fuel is contaminated see Cor If the capsule tank is used on the rective Maintenance procedure Monitor 422 the capsule tank filter paragraph 4 9 should be checked cleaned or replaced as well as the constant level valve strainer Inspect Fuel Pipe for obstruction inspect electrical wiring for WARNING cracks signs of deterioration bare wires and or loose connectors UNPLUG HEATER BEFORE PRO CEEDING HEATER MUST ALSO BE COOL BEFORE STARTING Ciean heater Clean lint free cioth and a mild Wipe down exterior of heater cabi non abrasive household cleaning net Vacuum heater interior if agent USE ONLY NON necessary PETROLEUM DISTILLATE CLEANERS Clean Air Circulation Fan Monthly Vacuum fan cage Wipe fan blades Inspect air piping for leaks or loose 2 Look for cracks wear or signs of connections deterioratio
51. d with normal heater 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 illuminates and flashes a buzzer will sound for twenty seconds The burner mode is changed to Low automatically and then the heater wil shut off after 30 minutes The remaining burning time is indicated at the Display Window Refueling Turn Heater OFF Press ON OFF switch and wait 15 minutes for the heater to Cool STEP2 Lift Out the Capsule Fuel Tank Open the tank cover and lift out the capsule fuel tank Turn the tank upside down and remove the fue cap STEP3 Fill the Capsule Fuel Tank Fill the capsule fuel tank with fresh crystal clear kerosene by using a siphon STEP4 Reinstall the Capsuie Fuel Tank Replace and tighten the fuel cap To insure proper fuel flow be sure the cap is secured correctly SAIS RG FW yO CT CC EE ST ST EC Install the tank with tne arrow pointing forward and Close the tank cover STEPS Turn Heater Press ON OFF switch to ON Proceed with normal heater operation 342 RECOVERY FROM A POWER FAILURE For the power interruption of up to 5 minutes the set memory is kept and will resume operation automatically with fhe set memory For power interruptions beyond 5 minutes heater wil resume operation after a 3 minutes cool down period in the MANUAL mode and maintain room temp
52. e Monitor 441 A Remove louver assembly B Remove front cover and wire connectors C top cover D Remove heat shield that covers combustion chamber E Remove service panel F Fiame detector rod For a more thorough cleaning use the same procedure as for the M422 above MONITOR HEATING SYSTEMS Section 5 Servicing 3 Turn counter ciockwise to remove combustion ring If ring does not turn puli up slightly to loosen retaining clips 4 Use wire brush to clean inside of combustion chamber Vacuum and wipe clean with a waste cloth 5 H tar is present on the burner bottom remove igniter the tar by using a flat bladed screw driver or ner wire brush then clean the area by using vacuum cleaner etc NOTE Make sure all air inlet openings are ciear 6 When cleaning the inside of the bumer pot remove the igniter and change the burner cloth Figure 5 3 Figure 5 4 by the following procebure Burner Cloth C Apply glue at all 4 corners of Burner Cioth as Shown in Figure 5 5 7 On the Monitor 422 A Apply glue P No8217 on the burner bottom as shown in Figure5 1 Approx 3 8 Figure 5 1 Figure 5 5 B Put the burner cioth on the burner bottom afterwards press and straighten out the burner cloth so that it is glued flat and even NOTE The Bumer Cioth is not symmetrical in on the burner bottom shape therefore make sure to place it in B Onthe Monitor 441 the c
53. e of all dust dirt and debris Raise the lower window 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 to loosen the large set screw on the frame in order to do so D Slightiv lift window kit frame Slide the L Adapter under the and position it at the gt point where the inner and outer frame meet Expand the frame to fit the window tightly Adjust the position of the L Adapter if neces sary Tighten the set screw to secure the frame Secure the L Adapter to the window sill with two 2 wood screws Lower the window firmly down upon the top of the Window Kit frame Measure the width of the upper outer window which is located in the outer track Cut a length of the Rubber Packing to this size Remove the protective backing and firmly mount it onto the underside of the outer win dow MONITOR HEATING SYSTEMS Section 2 Installation A AN A UTEM STEP 3 Install Window Lock D Two adjustable position stops are supplied to A special window lock replaces the usual ciam accommodate various window sash thicknes shell lock ses If short stop is too small remove two To install the window lock proceed as follows retaining screws and brackets which hold the A Tum locking lever to left and disengage lock short stop to the underside of the lock Remove from
54. ean fuel STEP2 Clean the Heater fuel constant level valve filter and filter compartment B Remove the Louver Assembly and Solenoid Pump on the constant level valve Clean the Solenoid Pump filter STEP3 Reinstall Cleaned Components A Replace the components correctly and install new gasket B Turn on the fue at the storage tank and at the fusibie link vaive and apply power to the heater f probiem still exists and contaminated fuel is suspected it can be checked by A Shutting off the fuel supply at the storage tank and at the fusible link valve B Drain off fuel at constant level vaive C Disconnect fue line at back of heater and hook up a 5 gallon quick tank with proven good fuel D Testrun heater to see if problem clears up with use of new fuel N MONITOR HEATING SYSTEMS Section 5 Servicing 5 1 INTRODUCTION Servicing is required when the Monitor Heater is not running at proper efficiency This section covers possible Causes Corrective procedures for effi loses Signs of improper heater efficiency and performance would be Yellowish lazy Smoke from fiue pipe exhaust Heavy soot and carbon build up in combustion chamber Lowered heat output 5 2 MEASUREMENT OF FUEL FLOW RATE Fuel flow rates are preset and sealed These rates should not and we recommend they do not be readjusted 5 3 REMOVAL OF WATER DEPOSITS AND CONTAMI
55. een combustion ring and bumer pot before reassembiing See Figure 5 6 Flame Detector Rod T ELS Combustion E Chamber Combustion Ring Assy i i Gap M 441 016 more 422 3mm 0 12 or more E Burner Pot Figure 5 6 For minor adjustments of flame detector rod without disassembling 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 combustion ring Tightening the bottom screw first will cock the rod inward towards the combustion ring 5 5 CLEANING THE FUEL INLET 2 Push a piece of wire about the same size as When cleaning the combustion chamber and the tne 1 0 of fuel inlet pipe into the fuel inlet burner pot the fuel iniet nozzle should also be nozzle cieaned This can be done as follows 3 obstruction is felt twist wire back and forth to brake up soot and carbon so that wire ulti 1 Disconnect copper fuel line at burn chamber mately penetrates igniter shield On M 422 also check air holes surrounding fue iniet for blockage and clear if necessary 41 MONITOR HEATING SYSTEMS Section 6 Troubleshooting Monitor 422 441 Resistance values APPROX OHMS COMPONENT M 422 441 igniter connector B B 16 8 12 7 Power Transtormer Primary AC 120V 125 125 Power Transformer Secondary 12
56. entional heating area 600 2000 sa feet systems 87 Power Consumption as follows Table 3 2 lists Monitor 422 pertormance specifica tions at various user selected heat output setting HIGH MEDIUM HIGH MEDIUM LOW LOW IGNITION BURN BURN BURN BURN 250watts S2watts Siwatts SOwatts SOwatts Tabie 3 2 HEATER PERFORMANCE SPECIFICATIONS Specification tw Veo mg IT mama maa naes a lem iaa BE Erie Sp Continuous use bumtime 55 gal tank 2 NOTE Capsule tank cannot be used in Connecticut and Massachusetts 24 MONITOR HEATING SYSTEMS Section 3 Operation 3 3 OPERATING CONTROLS AND INDICATORS Several controis and indicators are used to operate the heater and to monitor its performance as follows 6 ECONOMY RUN AUTO PLUS EMPTY BURNER ST A SET ROOM iud gem EE AM 7 1 2 3 4 5 7 8B Figure 3 1 INDICATORS U 12 13 14 15 OPERATION pt sie OR CLOCK ON OFF AUTO ist and ard ath th TIME TEMP SET TIME ___ HOUR MINUTE SET CLEAR Tl T 19 20 Figure 3 2 CONTROLS FIGURE AND ITEM NO CONTROL OR INDICATOR FUNCTION Figure 3 1 Item RUN indicator Light Light to indicate that power has been apilied to heater illuminates when operation ON OFF
57. erature according to the setting temperature selected by using the SLIDE SELECTOR for the reset temperature at the lower right hand side of the Cabinet When the TIME push button switch is pressed or the TIMER SELECTOR push button switch is pressed to iliuminate the CLOCK SET indicator light the Display Window will show 88 88 indicating the need to reset the clock and re program the heater for automatic operation REMARK in order to display reset temperature it should be set before the heater is plugged in and energized New reset temperature selected after plugged in will take effect only after a power loss 3 13 RECOVERY FROM OVERHEAT CONDITION The Monitor is protected against damage resulting from an overheat condition by two Monitor 422 115 C Monitor 441 automatic reset thermostats in the event of an overheat the thermostats are triggered to cut off the flow of kerosene to the Burner Pot the flame ts extinguished automatically and user is alerted to the overheat condition by blinking of the Burner Status indicators To recover from an overheat condition proceed as Outlined below Turn OFF Heater STEP2 Allow Monitor Heater to cool NOTE Be sure that heater is cool to touch A period of 30 to 45 minutes should be sufficient to permit heater to cool completely STEP3 Unpiug Heater Disconnect heater power cord from wall outlet SORT 254
58. es and delivery systems are illustrated Figure 2 12 Since fuel storage tank installation techniques vary from place to piace often dependent upon cable codes a particular installation procedure cannot be specified However certaiB criteria govern the fuel hook up of the Monitor Use the following check list as a guide to the fuel storage facilities USE ONLY CRYSTAL CLEAR KEROSENE NEVER USE GASOLINE WHITE GAS CAMP FUEL OR OTHER FLAMMABLE LIQUIDS USE OF SUCH FUELS CAN RESULT IN AN EXPLOSIVE FIRE AND CAUSE SEVERE INJURY Fueling Options Available Fueling of the Monitor Heating Systems can be accomplished in one of 3 ways 1 Capsule Tank on the Monitor 422 2 Gravity Fed Large Capacity Extemal Tank Practical for large heating needs where bulk delivery of kerosene is available This system should be installed by a qualified plumber or fuel supply technician Large Capacity External Tank with Pump For large heating needs where a gravity fed system is not practical An electric pump the Monitor Kerosene Lifter especially designed for use with Monitor heating systems if a pumping system is used to supply fuel the inlet pressure to the heater must not exceed2 5psi 3 MONITOR HEATING SYSTEMS Section 2 Installation JA LM MER EROR INE DEM OR i SETS To install a large capacity gravity fed externa tank 5 100 and 250 gallon tanks must contain follow the instruc
59. flame rod does not detect out within 300 seconds Trouble Point Flame sensing Circuit grounded flame rod or pinched wire MM 4 Timer clock circuit bad or power source to unit above or below acceptable levels Solenoid Pump control circuit has a malfunction Driving circuit of RL6 or excess fuel in burner pot SYMPTOM GENERAL CHECKS is power available in wall outlet Is power Plug inserted in wall outlet Has there been a power interruption iDisplay window shows 88 88 Has Circulation Fan stopped is Iuel m tank Tank valve open Has Fuel Constant Level Valve Set Lever raised and lowered Is Operation Switch on Is operation mode on Manual Is set temperature in High position is Fusible Link Valve open RESULT CHECK2 RESULT CHECK3 RESULT CHECK4 RESULT CHECKS RESULT i of Circuit Board i Operation lamp ht Yes 13 igniter red Check visually through the Combustion Chamber viewing window of feel igniter coveriafier3 5 minutes prepu preheat it should be warm to the touch Is Disptay Win 17 Is there flama 3 Disconnact wiring for Solenoid Pump Check Fuse Fn Yes red t Operation Switch OFF 2 Remove igniter Does Combustion Yes Blower motor operate ts wiring cortect
60. hooting Diagrams Mechanical Troubleshooting Diagrams Electrical Indication of Failure mode Section 7 Electrical System s960v505e52000509090000002000000000000025009200000000 9090900009 005000000009 Page 58 66 Schematic Monitor 441 Printed Circuit Board Wiring Diagram Monitor 422 Printed Circuit Board Wiring Diagram MONITOR HEATING SYSTEMS Section 1 Description 4 1 SPECIFICATIONS Model Monitor 441 Monitor 422 Fuel Type Crystal Clear K 1 Kerosene Crystal Clear 1 Heater Efficiency 93 93 Heat Rating High 43 000 BTU hour High 22 000 BTU hour H Medium 33 900 BTU hour H Medium 17 400 BTU hour L Medium 21 000 BTU hour L Medium 11 700 BTU hour Low 16 200 BTU hour Low 9 600 BTU hour Heater Output High 40 000 BTU hour High 20 400 BTU hour H Medium 31 500 BTU hour H Medium 16 200 BTU hour L Medium 19 500 BTU hour L Medium 10 900 BTU hour Low 15 000 BTU hour Low 8 900 BTU hour Fuel Tank Separate Not supplied with heater 1 32 Gallons Separate tank optional Fuel Consumption High 0 319 Gallon hour H Medium 0 25 Gallon hour Medium 0 16 Gallan hour Low 0 12 Gallon hour High 0 164 Gallon hour H Medium 0 13 Gallon hour L Medium 0 09 Gallon hour Low 0 07 Gallon hour Power Source 120 Volts AC 60 Hz 120 Volts AC 60 Hz Power Consumption Ignition 340 Watts Operation 8O Watts Average ignition 250 Watts Operation 55 Watts Average
61. is not in the path of direct suniight drafts or the flow of warm air from the heater Loosen the screw and release the sensor from the rear of the cabinet Fasten the sensor to the wall with the screw 3 10 MONITOR SHUTDOWN A simple one step procedure is utilized to shutdown the Monitor Press ON OFF push button switch to position OFF the RUN indicator will extinguish IMPORTANT heater has shut down it can not be restarted until post purge cy has been completed if ON OFF switch is lett in position ON Monitor operation will automatically restart upon completion of MONITOR HEATING SYSTEMS Section 3 Operation 3 11 OUT OF FUEL During either manua or automatic operation of heater fuel in the tank may be depieted The Monitor in case of using external fuel tank is known to be out of fuel when all of the following symptoms are present Burner Status indicator lights blink Absence of flame visually verified through view plate on wall of Combustion Chamber Turn Heater OFF Press ON OFF switch to OFF STEP2 Fill Fuel Tank A Close shut off valve at outlet of Fuel Tank B Drain Fuel Tank from bottom if possibile to remove all condensation debris and old fuel C Fill Fuel Tank with fresh crystal clear kerosene D Upon completion of stepC open shut off vaive which was closed in stepA above STEP3 Turn Heater ON Press ONOFF switch to ON Procee
62. k Joint 18 Phenolic Probe or insulated Screwdriver 19 Supply of 125V 2 and 10 Amp fuses 20 Floor mat to cover carpeting 21 Quart size pan for draining fuel 2 4 POWER REQUIREMENTS THE MONITOR POWER CORD MUST BE PLUGGED INTO A DIRECTLY ACCESSIBLE WALL OUTLET DO NOT USE AN EXTENSION CORD TO MAKE THIS ELECTRICAL CONNECTION Line current to the system should be 120 VAC at 60 Hz The electrical system should be protected against current overload by means of at least a 15 fuse or circuit breaker NOTE The wall outlet should supply electricity for the Monitor system oniv Do not connect any other electrical appliance to it in some installations it may be best to hard wire the heater to the house circuits competent licensed electrician should do this MONITOR HEATING SYSTEMS Section 2 instailation 2 5 FUEL TANK REQUIREMENTS INSTALLATION OF ANY REMOTELY LOCATED FUEL TANKS MUST COMPLY WITH ALL LOCAL STANDARDS AND OR BUILDING CODES Heater fuel crystal clear kerosene oniy can be stored in remotely located storage tanks ranging from 55 gallon drums to 275 gallon tanks When using large tanks a pressure regulator with a max of 2 5 PSI should be installed near heater inlet in some installations it may be better to install permanent fuel tank plumbing licensed Plumber should do this 2 5 TEMPERATURE SENSOR WIRING REQUIRE MENTS A wall mounted temperature Sensor ga
63. l Combustion Ring property Replace Combustion Ring Assembly Replace gasket correcity install Cover fnstruct customer about filter and 6341 laver Raplace solenoid pump i Correct as specilied The Overheat i Curtain or other obstruction covers circulation air inlet Thermostat is curtain too iles activated close to the Keep curtain from unit rear of unit 3 E Does circula Yes Obstacle covers circulating Remove obstacle lion fan operate air oullet properly EM Failure of P C B Replace or check P C B Circulation fan failed Replace Fan Motor incorrect wiring Repair or replace wiring Clean guard Circulation Fan Guard dusty D MB i ous blink it f problem is found be in PCB jo not attempl lo repair replace to lor repair i and sand PCB thru your distrib Cart 2 ini amu asa GA lt 5 5 at wes lt lt 15 12Vdc M 422 Press the operation button smich 0 ON position 1 2 Yes Is empty LEO On 422 Yes Al plug AC does oulput of turn into High from Low Remove the connector of operation cit cuit board from
64. ls Firmly grasp cabiet handies one on each side of heater cabinet and lift heater off the card board shipping base Check for parts as listed in Monitor Owners Guide IMPORTANT Only the standard size Flue Pipe is shipped with the heater The Moni tor dealer will also stock Medium Fiue Pipes Window Kits Extension Kits and other accessories that may be required for non standard installations MONITOR HEATING SYSTEMS Section 2 Installation 2 9 HEATER INSTALLATION in choosing a location for your heater the following guidelines must be considered e The heater MAY be installed on combustible floors e The area around the heater should be free of obstacies that might interfere with the free flow of ait Allow the clearances shown in Figure 2 1 e The heater must not be installed in a combustible fireplace An AC wall outlet must be within reach of the heater s power cord Extension cords must not be used e The area outside where flue pipe will emerge should be free of foliage fuel storage tanks and flammabie objects Air should circulate freely in the area Allow the clearances shown on follow ing page e The wall where flue pipe hole will be cut should be free of plumbing pipes electrical wires studs air ducts and other obstacles NOTE After using the installation template as a guide for drilling the flue pipe hole the Monitor Fiue Pipe can be normally installed according t
65. lting from power overloads in the event of a power surge or internal wiring hazards the fuse opens and power to the heater is cut off The electrical outlet into which the heater is con nected should be protected by at least a 15 fuse or circuit breaker 1 32 OVERHEAT PROTECTOR SWITCHES Connected in series two 2 normally ciosed Over heat Protector Switches safeguard the heaters against damage due to overheating The Monitor 422 switches are rated 110 C 230 F The Monitor 441 switches are rated 115 C 239 F Should a Monitor overheat internal temperatures rise beyond 110 C 230 F on the Monitor 422 115 C 239 F on the Monitor 441 either or both switches will open to shut down the heater After extinguish ing the flame the Burner Status indicators continue to blink The Overheat Protector Switches will auto matically reset atter cooling down Once the heater has cooled to 90 C 194 F the system can be restarted To restart the Monitor proceed as follows A Press ON OFF Switch to OFF B Allow heater to cool C Troubieshoot the cause of the overheat D Press ON OFF switch to ON Proceed with normal operation 33 SLIDE SELECTOR FOR THE RESET TEMP Once power is restored after power interruption by power failure or by disconnecting heater plug from wall outiet heater will resume operation in the MANUAL mode and maintain room temperature according to the setting temperature selected b
66. n replace if necessary inspect rubber Air Hose at rear of heater Clean fuel constant level Valve Clean Kerosene Refer to paragraph 4 5 Procedure filter Inspect fusible link Valve is described in paragraph 4 6 input fitting Check Leveling Guide Ciean only if necessary Verity that heater is level inspect flue pipe for obstruction If blocked clean and vacuum or corrosion If corroded badly replace 35 MONITOR HEATING SYSTEMS Section 4 Maintenance Activity Material Remarks inspect Combustion Ring Flame Clean all carbon deposits Replace Sensor Rod and Burner if excessively worn warped or Clotn Suggested frequency every cracked years NOTE f any gaskets are torn when Components removed the gasket must be replaced Clean Combustion Chamber every Vacuum all carbon deposits from years interior of chamber inspect air hoies in Burner Pot Use a small stiff brush or a short length of soft Copper wire to ciean any blocked holes The M422 may need air holes reamed with a torchtip cleaner if partially block on a 5 to 7 year basis Clean lgniter Scrape any carbon deposits from igniter Check air piping that interconnect Replace air piping that is worn Combustion Blower and Air Pres broken or brittle sure Switch Check for carbon build up in fuel Disconnect copper fuel piping from iniet going into bum chamber every bum chamber a
67. n to the space taken up by the heater interior space must aiso be reserved for free air circulation Remove all combustibles from the heat ing area Unless building or fire codes dictate otherwise the Monitor system be placed on any floor surface including carpeting or other combustible material and provide safe operation 2 3 DRILUNG REQUIREMENTS Through the wall Pipe installation requires that a21 7 65mm hole be drilled through the dwelling wali interior to exterior The hole must be pitched downward toward the outside at an approximate angle of 2 about per foot The appropriate wall area in which hole will be drilled must contain no internal obstacles such as piping wiring air ducts or studs jin U U RECOMMENDED TOOL KM FOR MONITOR HEATER SERVICE TECHNICIANS 1 22 Phillips Head Screwdriver 2 Steel Tape Measure 3 Felt Tip Pen or Pencil 4 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 pipe 7 Rubber Clipping Tool 8 Long Drill Bit 9 22 Standard Screwdriver 10 Adjustable Wrenches various sizes 11 Copper Tubing Cutter 12 Copper Tubing Flaring Tool 13 V O M Volt OHM Meter with shielded probes 14 Level 15 Plumber s Pipe Thread Tape 16 Small assortment of Self Tappeng Screws 17 Assorted Pliers Slip Joint Needienose Cutting Loc
68. nd clear fuel iniet year line by reaming with a solid piece of wire such as copper bailing wire or coat hanger which should be able to go in approximately 3 without obstruction NOTE Removing ana retightening burner fuel connection must be done when the bumer cools down com pletely ff it is done when the burner is hot the weld ing on the fuel joint may break Fixing torgue for nut 30 40kg cm 26 4 3 INSPECT EXHAUST AIR PIPING securely especially at joints Verify that all exhaust and air pipes are free of leaks Tum heater ON and loose connections as specified below Carefully apply a small amount of soapy water with a paint brush to the surface areas of the STEPI Remove Protective Cloth air exhaust piping Remove cloth insulation cover s from all exhaust Any leaks that may exist will be readily pipes identified by the appearance of bubbles STEP3 Return to Operating Condition A Visually inspect both air and exhaust piping for Tum heater OFF obvious cracks leaks or loose connections Dry all pipes with paper towels Black carbon deposits may be evidence of Repair any leaks that have been found if these leaks and o rings may need to be necessary replace the tubing replaced Replace cloth insulation covers B Be sure that all pipes are installed tightiy and 36 O 9 1 gt MONITOR HEATING SYSTEMS Section 4 Maintenance
69. nd may need to be cut to size Be sure however to thor oughly deburr all rough edges Figure 2 7 COMPONENTS OF EXTENSION KIT ITEMZ DESCRIPTION MEM DESCRIPTION 1 PIPE Air suppiv 6 PIPE CLAMP Bottom 2 JOINT Air line 7 SCREW Legs mounting 3 ELBOW amp Air line B SCREW Pipe Clamp 4 LEG Wall standoff g BOND Adhesive 5 PIPE CLAMP Top MONITOR HEATING SYSTEMS Section 2 Installation Max lengths and bends allowable using extension kits Extension kits are available in four different lengths For exact dimensions refer to the accessories catalog 1614 Ft Max 13 FtMax Figure 2 8 MAX LENGTHS AND BENDS ALLOWABLE USING EXTENSION KITS 17 MONITOR HEATING SYSTEMS Section 2 Installation 2 11 TYPICAL MONITOR LIFTER PUMP INSTALLA For more detailed information look under Kerosene TIONS Lifter manual NOTE The same minimum and maximum pump heights must be maintain as is with other fuel tanks Figure 2 12 MONITOR KEROSENE LIFTER CAN BE POSITIONED BEHIND UNIT MONITOR KEROSENE LIFTER MONITOR KEROSENE LIFTER GRAVITV Figures 2 2 18 MONITOR HEATING SYSTEMS Section 2 Installation E 2 12 USES FOR THE ELBOW ADAPTER KIT Convert trom Monitor 20 30 to 422 441 using an eibow adapter Kit part 8213 and utilizing existing flue pipe installation PARTS LIST EXPLODED Name No Ref of in No Part Unit 1 Exhaust Pipe 2 Exhaust Elbo
70. o the Illustration procedure in the Monitor Manual Just in case the template was misplaced the ap proximate flue pipe hole location measurements are as follows Tha center of The Joint Pipe opening which connects to the Fiue Pipe Back of Heater Fuel Floor The center of The Joint Pipe Back of Heater Floor MONITOR HEATING SYSTEMS Section 2 Installation FLUE PIPE CLEARANCES pipe installations shouid provide for venting to an unconfined space through which there is a free flow o outdoor air Clearances to adjacent walls or obstacles must compiy with the requirements shown below Frontal Clearance Combustible Wall ZNCAUTION 24 60cm 8 Any construction Do not attach anything onto the outiet or more above Fiue Pipe of the fiue pipe 52 must not come _ 14 within 24 SOcm of front obstacle Front Obstacie Ground or slab surface Overhead Clearance Non combustible Wall Combustible 24 60cm or more 13 5cm Body 2 E Clamp Heater Py 7 7 Pipe Side Clearance MONITOR HEATING SYSTEMS Section 2 installation Exhaust Elbow in areas of heavy snow falls ground surface clearance must be increased according to average snow falis to prevent flue pipe from being buried HOW TO PREV
71. oreign materiais from clogging the iniet This is accomplished as follows WARNING UNPLUG THE HEATER POWER TO THE HEATER SHOULD BE OFF DURING THE PERFORMANCE OF THIS PROCEDURE STEPI Close off Fuel Supply A Shutoff fuel at the Storage Tank or remove fuel from the fuel sump tank with siphon and syringe if using the capsule fue tank B Manualiy turn handle to close Fusible Link Valve NOTE Place paper towels undemeath the Fusible Link Valve to catch any spilled fuel STEP2 Clean Valve Loosen hex nut on Fusibie Link Valve iniet A fitting at rear of the heater Disconnect the copper tubing which delivers the fuel from the storage or the fuel sump tank B Using a small straight piece of wire carefully and slowly ream out the iniet fitting on the Fusible Link Valve Avoid scratching the inside wall of the fitting With a cotton swab wipe the interior area of the inlet fitting STEP3 Reconnect Fuel Line A Reconnect the copper tubing to the intake fitting and tighten the hex nut B Tum ON fuel at Fusible Link Valve and at storage tank or fuel sump tank Check for leaks 4 7 CORRECTIVE MAINTENANCE The two procedures below are remedies for very generalized types of operating difficulties 4 8 REPLACEMENT OF FUSES A short circuit or similar electrical malfunction could cause the fuse to blow Troubleshoot the cause of the blown fuse Replace the fuse as follows DO NOT REPLACE FUS
72. orrect position so that the wider side A Apply giue arround the burner cloth as of the cioth is at left side of the igniter shown in Figure 5 2 Shield as shown in Figure 5 5 9 Combustion ring may deform and deteriorate ABE after several years use and should be cleaned and inspected before reinstallation tf combus tion ring is warped has cracked or is deteriorat Cie ing excessively it should be replaced lt V 10 When reassembiing the unit check that com VIEL Figure 5 2 bustion ring is positioned with the correct side B As shown in Figure 5 3 and 5 4 insert the up and is sitting squarely on all three support Bumer Cloth narrow between the Nozzie screws M 422 pins M 441 inside the burner Collar and the Igniter Shield then push the pot u Burner Cloth using your fingers ora screw T Reassemble by reversing the procedure foll driver so that it slips in under the Nozzie owed during disassembly Collar Afrerwards press and straighten out the Bumer cloth so that it is glued flat and NOTE Use of the economy plus feature can even on the Burner bottom minimize service calls and extend NOTE in some cases pulling out the Fuel Nozzie ponent life and Collar may make this procedure easier An easy out can be inserted into nozzie to help break loose and remove it MONITOR HEATING SYSTEMS Section 5 Servicing NOTE Make sure the position of flame detector rod is centered betw
73. ps head screwdriver unscrew the screws hoiding the rounded diamond shaped cover plate at the bottom of the Fuel Constant Level Valve Remove the cover plate NOTE Position a six inch U shaped piece of metal or cardboard under strainer Cover to drain fuel into a pan B Carefully remove the rubber gasket which is located behind the cover plate STEP2 inspection and Cleaning A Pul the filter straight out of the fuel reservoir B lf the filter is dirty but undamaged rinse the filter in fresh clean kerosene to remove all particles Replace damaged filters C To drain off upper portion of fuel constant level valve back out phillips head screw which is located slightly above and to the left of filter cover plate See Fig4 1 D H upper portion drain is dirty or containing water then remove pump and inspect and clean its Screen STEPS Reassembly A 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 screw holes in the gasket and cover piate C Wipe up any spilled fuel Strainer Cover Drain Guide Container M422 Figure 4 1 CLEAN FUEL CONSTANT LEVEL VALVE MONITOR HEATING SYSTEMS Section 4 Maintenance 4 6 CLEANING FUSIBLE LINK VALVE INTAKE FTT TING ON M 422 At periodic intervais the fitting on the Fusible Link Valve should be cleaned to prevent any accumula tion of f
74. s tual line length e Hf using Lifler check Lifter instaltauon specilicakons uni placed houzontally is solenoid pump High mode Failure of solenoid pump solenoid pump Wiring failure 4 Conect Wiring Failura of solenoid pump Replace solenoid pump Failure of circuit board Replace e check circuit board Not as specifled xi Correct as specified Abnormal sounds ol com Abnormal buston soot at the rear of the hoalo Loose flue pipe Allow heatar cool completely tighten all connection 1718 failure but 14 apt ta occur SYMPTOM CHECK RESULT CHECK2 RESULT CHECK3 RESULT 4 RESULT CHECKS RESULT i Smoke pio duced when sal High 7 Combuslion noise made soon after Igniting Combustion Chamber Window gets smoky atter tunning is u umt placed hon zontally is lius pipe too long ot have loo many bends See Section2 INSTALL igniting lime 100 long Usually 0 5 1 min fa fuel a pure kerosene is Heater mounted horzontally 4 external fue tank too tow Section2 INSTALL install Air Damper if needed 1See Symptom 5 above l is there an obstruction in Air miake System U HI the Combustion Abnormal Does
75. tance cause the inlet valve to stick or prevent it from opening the Fuel Set Lever is utilized to free the valve and to admit fuel to the reservoir CAUTION Care must be taken to prevent dust diri or other debris from clogging or blocking the valve debris collects on the sest of the inlet valve it may cause tripping of the safety iever and will require cleaning MONITOR HEATING SYSTEMS Section 1 Description 1 24 SOLENOID PUMP The Solenoid Pump is mounted on the Fuel Con stant Level Valve controlied by microcessor and four modes High Medium High Medium Low Low fuel flow is delivered to the Burner Pot 125 ELECTRICAL SYSTEM Electrical power is supplied to the Monitor to run the Microprocessor and the other electrically energized component Electrical operation of the Monitor can be thought of as having the following eight 8 distinct phases plug in 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 be found in Section 7 of this Service Manual 1 26 MICROPROCESSOR Principally consisting of a 64 pin Integrated Circuit the Microprocessor provides safety timings controls relays and provides clock and thermostat functions for the Monitor heater A component layout of the Printed Circuit Board is found in Section 7 of this Service Manual 1 2
76. ter must be absolutely air tight 275 e A fuel filter is recommended for use on the fuel gallons and bigger tanks should have 2 5 P S line near tank and a shut off valve should be max pressure reducer to avoid excessive pressure installed at the tank at heater inlet e Flare connections should be used at the fusible link valve connection on the heater and at the 2 14 HEATER INSTALLATION fuel filter to be installed at the tank The Monitor heaters can be physically situated on e The fuel tank should be located no closer than carpeting or other combustible flooring with com 6 feet to a source of heat plete safety The selected heater site must be e The fuel tank should have an opening for filling accessible to an electrical outlet must support free on the top and a vent with a weather proof cap on the side On some tanks the vent anc fill spout use the same opening air ciculation both internal and extemal and must not contain combustible materials in the heaters immediate vicinity exterior gravity fed 55 100 or 275 gallon tank Lifter circulates fuel from remote storage tank Figure 2 11 ALTERNATIVE SOURCES OF FUEL STORAGE MONITOR HEATING SYSTEMS Section 2 Installation Shut off Valve Outdoor Fue Tank 3 Flare Connection Monitor 441 Fuel Filter i 36 Threaded Connection 3 OD Copper Tubing
77. tions below Use of a qualified e Shut off valve at tank outlet installer is recommended e Disposable fuel filter protects heater against condensation and other impurities e installation height of the bottom of the fuel tank e Fueling inlet protected by weather proof cap should be 16 inches or more above the floor e Ventilation outlet surface on which the heater stands This e Clearance of at least from any source insures that inlet fuel pressure will be sufficient Allowable Height Dimensions The top of the fuel tank should be no higher Bottom of tank at least 16 above floor holding than feet above the floor under the heater heater maintains sufficient pressure This insures that inlet fuel pressure will not be e Top of tank maximum of 8 above floor excessive holding heater prevents excessive line pres e The horizontal length of piping should sure above 2 5 psi exceed 100 feet anc should be free of sharp e Position of Lifter more than 8 above fuel iniet bends or obstructions of heater requires pressure reduction valve e Piping should include no inverse U type bends to avoid air locks which could block the fuel RECOMMENDATION supply Pipe fittings in the fuel supply to the Monitor heating e Only inch OD copper tubing should be used systems should be sealed with pipe thread tape The tubing should be bent carefully to avoid The supply line from the tank to the Monitor crimping Kerosene Lif
78. tomatic heater operation as same as 1st indicator Light Figure 3 2 ttem15 4th indicator Light Programs 4th automatic heater operation as Same as 1st indicator Light Figure 3 2 ttemi6 TIME push button This switch is used to set time and change switch display over Figure 3 2 17 TEMP push button This switch ts used set temperature and switch change display over in 2 degree increments Figure 3 2 Item18 HOUR UP Programs time or temperature MINUTE DOWN NOTE Each time push button switch is repetitive action pressed the digit advances in incre push button switch ments of one digit push button is pressed and held the digits are advanced repetitively Figure 3 2 19 SET push button switch Sets time and or temperature If this control is not pressed after time and or temperature have been programmed the time and or temperature programmed as indicated by display window will not be accepted and will revert to previously programmed time and or temperature Figure 3 2 20 CLEAR push button switch any programmed time and temperature When cleared time and or temperature previ ously programmed and displayed disappear s from window IMPORTANT Both current time and matically programmed time s temperature s will have to be reprogrammed electrical operation is inter rupted by power failure or by disconnecting heater plug from wall outiet beyond 5 tain room tempera
79. ture accord ing tothe setting temperature you ve selected by using the slide selector for the reset temperature at the lower right hand side of the cabinet Y 58 585588 a m r lt s Figure 3 2 ttem21 ON OFF push button ON position push button is in japplies power switch to the unit When this occurs the RUN indica tor lights to indicate that heater operation has begun OFF position push button is out remove power from the heater circuits except for Clock and Air Flow are shut down MONITOR HEATING SYSTEMS Section 3 Operation FIGURE AND ITEM NO CONTROL OR INDICATOR FUNCTION Figure 3 2 Item22 AUTO push button switch Places heater in automatic mode of operation AUTO indicator lights to confirm automatic operation Assuming that the heater has been properly programmed and heater is in ON position heater will operate automatically When pressed again AUTO indicator goes out and then heater will operate MANUAL mode During manual operation the user tums heater ON and OFF at will When AUTO is disengaged the unit will operate manual temperature determined by the AUTO setting for that time of day Figure 3 2 ttem23 ECONOMY PLUS push button switch Places heater in Economy Plus mode of operation ECONOMY PLUS indicator lights to confirm Economy Plus operation When pressed again ECONOMY PLUS indicator goes out and then Economy Plus mode will be cancelled N
80. uges room temperature and automatically regulates the heating Cycles of the Monitor System The standard sensor wire is 6 long and can be left mounted on the back of the cabinet as shipped If this is not practical the sensor can be mounted on a wall CAUTION H sensor is to be mounted re motely be careful not to place it in direct sunlight on uninsulated exterior walis in drafty areas etc as this will create an inaccurate temperature reading 2 7 BUILDING CODES Fire regulations electrical and other local building codes may govem the installation and use of a vented heater and reiated fueiing systems Prior to installation check and comply with all codes 2 8 UNPACKING Save all shipping materials until the Monitor has been compietely 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 purchase and retum it to Monitor Products Inc as soon as possible Remove the spill tray from shipping carton and remove the plastic bag Remove the plastic bag covering the hearer Remove the plastic Dag containing the heater parts and set it aside Remove the Flue Pipe from the rear of the heater When ready to install separate Flue Pipe from cardboard packing materia
81. utoff safety mecha nism and a Fuel Set Lever The safety mechanism prevents fue from flooding or overflowing from the fuel reservoir The Fuel Set Lever resets the float so the Fuel Constant Level Valve can resume opera tion The fuel reservoir is a tank which contains a float _ assembly a safety mechanism and a priming lever Both the Monitor 441 and 422 fuel control valves are basically the same however they are of different size and material and can not be interchanged Fuel enters the Fuel Constant Level Valve through an inlet at the bottom of the reservoir 5 the level Of fuel rises it passes through a filter which removes most particles and foreign matter from the fuel flows up through an open inlet valve and enters the tank IMPORTANT The Fuel Constant Level Valve filter should be cleaned or replaced peri odically Time intervals will depend on purity and quality of fuel Within the Valve a float mechanism controis the level of fuel that will be permitted to the reservoir As the fuel level drops the float drops down to increase the inlet valve opening to admit more fuel into the valve When the fuel level reaches its maximum volume the float rises to shut the inlet valve in the event that fuel within the reservoir rises to an abnormally high level a float within the reservoir rises to trip a safety lever This safety lever drops to prevent fuel from entering into the reservoir Should a foreign subs
82. w 1 3 Exhaust Joint 1 4 Joint Supporter 1 5 Heat Insulation Cover 1 6 Self Tapping Screws 2 7 Hose Clamp this part comes with B Air 9 Fiue Pipe this part comes with A E C your Monitor Heater Damper this part comes with Monitor Heater your your Monitor Heater Remove Monitor 20 30 heater and flue pipe install Monitor 422 441 flue pipe into sleeve Slide the exhaust elbow onto the exhaust port opening on the rear of the heater To locate exhaust port opening see your Monitor Owner 5 Guide Secure the exhaust elbow by attaching the exhaust pipe clamp to the heater cabinet with two self tapping screws Cover the adjustable exhaust pipe with heat insulation cover Figure 2 10 19 F Remove metal cap on side mounted exhaust port of flue pipe and replace into the port the Monitor 422 441 is now ready to be positioned into place NOTE Be sure the exhaust elbow is firmly fixed on the flue pipe with a joint supporter G insert air supply elbow opening over flue pipe air intake flange and secure with hose clamp NOTE The Standard Air Damper is installed over the flue pipe air intake flange To locate pipe air intake flange see your Monitor Owner s Guide Elbow adapter kits may also be used to raise a flue pipe high enough to clear certain base board heat ing systems 2 13 FUEL TANK INSTALLATION Pictorial views of alternative types of storage facil iti
83. ws or pins in the Burner Pot Metal retainers 2 secure the heater to the Spill M Tray 110 COMBUSTION RING ASSEMBLY The legs are positioned with in the circular indenta This assembly is a special structure designed to tions promote efficient 156 HEATER CABINET 1 11 BURNER CAP A steel Cabinet hoids and protects all internal Secured by tabs and a screw on the Burner Pot the components Burner Cap shapes the flame into its configuration number ma primary parts are assembled to form and height M 422 only this housing 1 12 FLAME SENSOR 1 7 COMBUSTION SYSTEM Mounted on the outside wall of Combustion Cham The Combustion System is responsible for the per the Flame Sensor always supervises the flame production of heat which is circulated into the room in the Combustion Systems a mixture of fuel and air 1 13 IGNITER is bumed to produce heat Air is drawn from outside Located within the igniter tube of the Burner Pot the the dwelling into the Combustion Chamber At the igniter is designed to pre heat the Burner Pot and to same time fuel is metered from a storage cavity into vaporize and ignite the air fue mixture to start the this same Combustion Chamber Within the cham combustion process _ ber the air fuel mixture is ignited to produce heat igniter is secured a bracket and screw to the The Monitor combustion systems are safeguarded igniter tube The cover plate is secured to the by a pair of overhe
84. y using the selector for the reset temperature at the lower right hand side of the cabinet j AIR CIRCULATION FAN FLUE PIPE T 1 2 INTAKE OUTDOOR AIR SS c h EXHAUST COMBUSTION CHAMBER f K AIR DAMPER AY ET FUEL TANK V H COMBUSTION FLAME SENSOR A HE N BLOWER P 1 tl COMBUSTION RING L SOLENOID DAMPER BURNER POT TriHd 7 NOZZLE SOLENOID PUMP IGNITER FUEL VAPOR AIR PRESSURE SWITCH CONSTANT LEVEL VALVE Figure 1 1 ELEMENTS OF COMBUSTION SYSTEM MONITOR 441 uondiuoseq SIN3 LSAS HO LINOIN L uon2es AIR CIRCULATION FAN FLUE PIPE 1 INTAKE OUTDOOR AIR HEAT EXCHANGER M TENE c EXHAUST COMBUSTION CHAMBER gt f AIR DAMPER FUEL TANK FUEL TANK CAPSULE EXTERAL x ENSOR Ln XXE IS J iliza COMBUSTION RING BURNER 2 lt saqi COMBUSTION BLOWER od SOLENOID DAMPER NOZZLE SOLENOID PUMP IGNITER AIR PRESSURE SWITCH n FUEL SUMP FUEL VAPOR CONSTANT LEVEI VALVE Figure 1 2 ELEMENTS OF COMBUSTION SYSTEM MONITOR 422 NOTE Capsule tank cannot be used In Connecticut and Massachusetts L jdu2seq SWSLSAS DNILVSH YOLINOW MONITOR HEATING SYSTEMS Section 2 Installation

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