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MONITOR HEATING SYSTEMS Service Manual

1. ARIE f min Auto operation moda Put in Marual Bum CORRECTIVE MEASURE 2 A Heeh H weiter final handia of fink vales or walas Fusibig link valve closed 21 Check wiring to plug K Yes d is Fuel constant Lal Valve Lover sat Make General Checks above la hum haad tao low Sage Secti n2 INSTALLATION is solenoid nump High la fuel lina length coment using u Lifter check Lifta installation srpecificanana urit placed horizontally 5 1 Poor flame sounds of G m bustion soo at fne rear of ine haator not a failure but apt to occur m r I Replace Fuel constant level of Fin constant evel valve Burner joint clogged Fusi Line Clean burner joint passageway into the Combustion Chamber naar base of Burner P t 1 Fugi not fad because of surfase tension of wi ter Discharge water Water gathering in fuel tank Failure of Solenoid Pump Replace Solanzid Pump Wiring failure Conect or reapince wires Straighten fuel ling to remove mir 1 pocket or correct fuel tina intttadlation A Push Fuel Constant Level Vane Fuel not entering inta fuel Set Lover 4 or 5 imat i Push Opaensiion Button to 2 Ffiefuel tank 3 Turn faber on Fuel shortage ji
2. HOSN3S 3lAV 13 NIE m YNVL 7903 Y HASWVHO NOLLSnSINOO 15 H3ONVHOX3 lV3H lt HIV HOOGLNO 33V LNI tL 3dld 3073 NOLLV I1OHIO HIV 4 AIR CIRCULATION FAN on HEAT 1 _ 5 6 cS z COMBUSTION CHAMBER 5 AY u dm FUEL TANK d iba x x lt i FLAME SENSOR A z O He es gt 0 COMBUSTION RING BURNER POT 34 i Z ees SOLENOID PUMP _IGNITER x gt lt FUEL VAPOR CONSTANT LEVEL VALVE Figure 1 3 ELEMENTS OF COMBUSTION SYSTEM MONITOR 40 MONITOR HEATING SYSTEMS Section 2 Installation 2 1 INTRODUCTION Installing the Monitor System at the user s location can be performed quickly and economically The Monitor 21 can be used as either an internally fueled capsule tank or remotely fueled System The Moni tor 40 model is strictly a remotely fueled system and borh 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 the exact order specified the Technician is directed through the installation process This section contains all relevant installation infor mation including In
3. Connected to the Combustion Chamber are the igniter located within the chamber a fuel line the Heat Exchanger and a Flame Sensor Within the Combustion Chamber are the Burner Pot the Combustion Ring Assembly and the Burner Cap Access to those internally located parts is facilitat ed by a removable Service panel A window on the panel lets the technician visually examine the com bustion process i e glowing igniter or proper flame color An airway in the Cabinet Base extends from the intake fan of the Combustion Blower to the hollow base of the Combustion Chamber This airway channels air to the Combustion Chamber The Flame Sensor is mounted with two 2 phillips head screws onto the wall of the Combustion Chamber 1 9 BURNER POT Designed specifically to support combustion the Burner Pot refer to Figure 1 2 contains a series of air holes an igniter tube to accommodate the igniter and a fuel inlet fitting interconnects the fuel line It is secured to a mounting plate near the bottom of the Combustion Chamber The Combustion Ring Assembly is seated on three 3 screws in the Burner Pot 1 10 COMBUSTION RING ASSEMBLY This assembly is a special structure designed to promote efficient combustion 1 11 BURNER CAP Secured by tabs and a screw on the Burner Pot the Burner Cap shapes the flame into its comfiguration and height 1 12 FIAME SENSOR Mounted on the outside wall of Combustion Cham ber t
4. 333 LOUVER 21 8123 EXHAUST DUCT 72 5334 CONTROL COVER 2 8178 O RING 039 13 5335 FRONT COVER 5215 OTL SUMP PIPE 74 6336 AMP PANEL 5154 JOINT SEAL SACKING 75 5154 SWITCH ASSY 25 8124 WINDOW GASKET 75 5155 LAMP ASSY 25 5125 WINDOW FRAME GASKET 77 5337 TOP COVER 27 ROFE WINDOW PLATE FRAME 6334 PESISTOR 28 ANRA WINDOW GLASS 79 6339 CABINET ASSY 29 6376 WINDOW GASKET 80 5157 M5092405 240 8317 CHAMBER GASKET 81 5158 RELAY A 31 5312 COMBUSTION CHAMBER ASSY 82 6169 RELAY 8 32 5319 COMBUSTION RING ASSY 83 6171 QUIZZER 33 63290 BURNER CAP Ra 6172 FUSE 250 10A 4 6321 CHAMBER CAP 85 5173 FUSE 250V 2A 25 6322 CONDENSER 2 5 86 5340 CAPACITOR 1 8MFD 35 53235 SLOWER ASSY 6341 CARTON BOX 37 5142 DAMDED SDILENOID assy RA 534 CIISHTON SET 8 6324 SUCTTON CASE A ASSY 3 1143 OWNERS GUTDE 0 6 44 SEN SACKING 90 6187 IC3 M54563P 53275 SWE VX33Y 31 BIRR 129 10 11 oHOTO Cole 79 at 5134 PWB SPACER CLIP 92 6190 BASE TRAY RETAINER 42 6135 PWE SPACER CLIP B 93 5194 WALL CLAMPS 43 6132 POWER TRANSFORMER 94 6195 IGNITER BRACKET 44 6326 AIR LINE 95 5196 FLAME ROD BRACKET 45 6343 PRESSURE SW 96 6197 SCREW SET FOR FLUE PIPE 46 6136 RUBBER BUSH 97 6344 STRAINED GASKET 47 6327 OVER HEAT PROTECTOR 98 5345 UNTON NUT 6152 FAN THERMOSTAT 99 5346 IGNITOR COVER 6137 CORD CONNECTOR 100 5347 WIRING GUARD 50 6032 JUNCTION BOX COVER 101 348 MOTOR FOR COMBUSTION u
5. 51 5139 POWER SUISPLY CORD 192 8216 TOUCH UP PAINT WHITE Cushion Set MONITOR 21 EXPLODED VIEW 77 Owners Guide MONITOR 21 SERVICE PARTS LIST MONITOR 21 SERVICE PARTS LIST e Me DESCRIPTION DESCRIPTION 1 6100 SPILL TRAY 50 6149 UNDER COVER 6101 AIR SUPPLY HOSE A 51 6150 LOUVER 3 6102 AIR SUPPLY HOSE B 52 6151 OVER HEAT PROTECTOR 4 6103 FUEL PIPEO 53 6152 FAN THERMOSTAT 5 6104 FUSIBLE VALVE 54 6153 FRONT COVER 6 6105 CONSTANT LEVEL VALVE 55 6154 SWITCH ASSY 7 6106 CONSTANT LEVEL VALVE STRAINER 56 6155 LAMP ASSY 8 6107 AIR LINE 57 6156 TOP COVER 9 6108 SOLENOID PUMP PACKING 58 6157 LAMP PANEL 10 6109 SOLENOID PUMP 59 6158 FUEL TANK COVER 11 6110 OIL SUMP PIPE 60 6159 FUEL TANK ASSY 12 6111 FUEL SUMP 61 6160 BLOWER GUARD 13 6112 GASKET 1 62 6161 CIRCULATION MOTOR 14 613 BURNER CLOTH 63 6162 RESISTOR 15 6114 GASKET 2 64 6163 AIR PACKING SET 16 6115 GASKET 3 65 6164 JOINT SEAL PACKING 17 6116 HEATER 66 6165 FLOAT SWITCH 18 6117 HEATER COVER PACKING 67 6166 CABINET ASSY 19 6118 FLAME DETECTIVE PLUG 68 6167 MICROPROCESSOR M50940 20 6119 PLUG PACKING 69 6168 RELAY A 21 6120 GASKET 4 70 6169 RELAY Z 22 6121 HEAT EXCHANGER ASSY 71 6170 CAPACITOR 1 5MFD 23 6122 GASKET 6 72 6171 BUZZER 24 6123 EXHAUST DUCT 73 6172 FUSE 250V 10 25 6124 WINDOW GASKET 74 6173 FUSE 250V 10V 26 6125 WINDOW FRAME GASKET 75 6174 CARTON BOX 27 6126 WINDOW BASE GASKET 76 6175 CUSHION SET 28 6127 COMBUSTI
6. Air Pressure Switch Connector J 0 Overheat Protector Open Damper Solenoid PCB 5 E 105 Solenoid Pump K on PCB 5 105 Circulation Fan High Speed GR to BK BK to RD 21 110 BL to BK BK to WH M 40 110 Circulation Fan Low Speed YL to RD GR to YL M 21 110 GR to WH BL to GR M 40 110 Igniter T B on PCB 110 Power Transformer H on 110 primary side Power Transformer Connector L 120 secondary side Connector M 11 Combustion Blower Fon 110 High Speed Combustion Blower F on PCB 92 21 Low Speed RL3 is OFF 88 40 Resistor G on PCB _ 18 21 22 M 40 MONITOR HEATING SYSTEMS Section 6 Troubleshooting TEST POINT VOLTAGE Pre purge Pre heat Test point tvi 30 infinitly variable Igniting 2 low med 55sec 12V 3097 SV 1095 infinitly variable Pre burning 1 1 5 min C F M Off 12V 309 infinitly variable Pre burning 2 1 5 min C F M Low 12V 4 3096 5V 10 1 2V min Waiting until programmed time comes on 12V 30 42 MONITOR HEATING SYSTEMS Section 6 Troubleshooting TO 43 GENERAL CHECKS la power avallable in wall outlet s power Plug inserted wall outlet Has there bean power interruption Display window shows 88188 Has Circulation Fan stopped fused in tank Tank valve Has Fuel Constant Level Valve Set Lever raised and lowered ls Operation Swit
7. From this point heater operation is as follow exam ple 6 00AM 9 00AM 5 00PM 10 00PM 80 FI 68 F Example 3 8 PEPROGRAMMING THE MONITOR HEATER On occasion it may be necessary to reprogram the Monitor Heprogramming is performed as specified below MONITOR HEATING SYSTEMS Section 3 Operation STEPI Reprogramming Current Time if necessary Set the TIMER SELECTOR slide switch to position CLOCK SET Press HOUR and MINUTE push button switches to program new current time Set applicable time by watching Clock display Press SET push button switch IMPORTANT If SET push button switch is not pressed current time will revert to previously programmed time STEP2 Reprogramming Automatic Operation Set TIMER SELECTOR switch to appropriate position ist 2nd or 4th Press TIME push button switch C 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 Display Window Press SET push button switch F Press TEMP push button switch G Press CLEAR push button switch Set Temper ature displayed on Window will disappear H Using UP and DOWN push button switches program new desired temperature by watching the Display Window Press SET push button switch 3 9 HEAT SENSOR Heat Sensor is located on the rear of the cabinet It is recommended to leave the sensor in its origin
8. been completely installed and is working properly A Cut the two plastic ribbons that hold the ship ping carton together B Remove the top C Remove from the shipping carton the Cardboard drilling Template and the Owner s Guide 10 NOTE The Dealer should complete the Registra tion Card at time of customer purchase and return it to Monitor Products Inc as soon as possible D Remove the spill tray from shipping carton and remove the plastic bag Remove the plastic bag covering the hearer F Remove the plastic bag 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 materials H Firmly grasp cabiet handles 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 Flue Pipes Window Kits Extension Kits and other accessories that may be required for non standard installations MONITOR HEATING SYSTEMS Section 2 Installation Frontal Clearance combustible 4 Wall Any construction 24 60cm above Flue Pipe or more must not come 3 pij within 24 60cm 14 Of front obstacle 24 60cm or more or more Front Obstacle Flue Pipe 8 20cm or more
9. 2 Strainer m i Strainer ee ee Cover ME Sele J A Sl C M I aj E I aH ji Drain Guide Container Figure 4 1 CLEAN FUEL CONSTANT LEVEL VALVE 33 MONITOR HEATING SYSTEMS Section 4 Maintenance A MA FRYE III OTE SE IEEE ES OEM WARNING UNPLUG THE HEATER POWER TO THE HEATER SHOULD BE OFF DURING THE PERFORMANCE OF THIS PROCEDURE STEPI Close off Fuel Supplv A Shut off fuel at the Storage Tank or remove fuel from the fuel sump tank with siphon and svringe if using the capsule fuel tank B Manually turn handle to close Fusible Link Valve NOTE Place paper towels underneath the Fusible Link Valve to catch anv spilled fuel STEP2 Clean Valve A Loosen hex nut on Fusible Link Valve inlet fitting at rean 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 inlet 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 Turn ON fuel at Fusible Link Valve and at storage tank or fuel sump tank C Check for leaks 4 7 CORRECTIVE MAINTENANCE The two procedures below are remedies for
10. Clean Combustion Chamber every 3 years Vacuum all carbon deposits from interior of chamber Inspect air holes in Burner Pot Use a small stiff brush or a short length of soft copper wire to clean any blocked holes Clean Igniter Check air line that interconnect Combustion Blower and Air Pres sure Switch Check for carbon build up in fuel inlet going into burn chamber every year CAUTION If any obstruction is felt remove igniter before proceeding 4 3 INSPECT EXHAUST AIR LINES Verify that all exhaust and air lines are free of leaks and loose connections as specified below STEPI Remove Protective Cloth Remove cloth insulation cover s from all exhaust lines STEP2 Inspection of Exhaust Air Lines A Visually inspect both air and exhaust lines for obvious cracks leaks or loose connections Black carbon deposits may be evidence of these leaks Be sure that all lines are installed tightly and securely especially at joints C Turn heater ON D Carefully apply a small amount of soapy water with a paint brush to the surface areas of the air exhaust lines Any leaks that may exist will be readily identified by the appearance of bubbles STEP3 Return to Operating Condition Turn heater OFF Scrape any carbon deposits from igniter Replace air line that is worn broken or brittle Disconnect copper fuel line from burn chamber and clear fuel inlet line by reaming with a phillips h
11. Section 7 Electrical System Printed Circuit Wiring Diagram CONNECTION OF LEAD WIRES TIME a SELECTOR TIME rive Teme SET si TEMP E Panel Printed Wiring Board BURNER STATUS TEMPSET ROOM AM RUN AUTO E Emm PM Lamp Printed Wiring Board TIT mr RE oca AC120V Main Printed Wiring Board Pressure Senes Thermistor Flame Detector EN sus Over Heat Thermostat Solenoid Valve Power Transformer ieda Resistor Junction Box BL Blo Heater Blower for Circulation Combustion Thermostat figure 7 1 Monitor 40 52 MONITOR HEATING SYSTEMS Section 7 Electrical System Printed Circuit Wiring Diagram CONNECTION OF LEAD WIRES OPERATION SELECTOR SELECTOR TIMED rS I Panel Printed Wiring Board SET ROO Lamp Printed Wiring Board Short i Terminal AC120V Main Printed Wiring Board Empty Lamp Switch Float Switch Over Heat Thermostat Solenoid Valve G E A 116 o Power Power Transformer Cord AE Resistor Blower for Blower for Circulation Combustion Thermostat figure 7 2 Monitor 21 53 MONITOR HEATING SYSTEM Section 7 Electrical System Schematics 54 or FAN THERMOSTAT FI 2A FUSE e 120v MH RI 330K 171 RI R5 R7 eau RIG R
12. Unplug heater 2 Remove mir flow obairugtions and or determine causa of overheating 3 Aeplace cover and restart hantar Overheat condition Air p sent line Loradi fuai fina Rapace sono pump of sotandid pump Wiring failura Corect Wiring Fallura of solenoid pump Replace solenoid pump Failure of circuit board Raplaca or check circuit Board Mot as speciflad as specified Loose llus pipa Allow heater to coo compietery tighten all connection TUM zontally property obstructions Replace achenok pump much as waspa nesta in exhaust or air supply piping Fesi solendid pump malfunctioning stall Air Damper according to specifications Abnormal intake or exhaust line clogged Out Bir and ducts Combustion fan failed Replace Combustion Bimas Glogged air supply or exhaust piping Hamove obstructions Correct as specified E 8 12 fi much air flow Mouni Air Damper Is igniting time too long Usually 0 5 1 igniter mounted incorrectly cc Mount properly kerosene M aT ee cna a H arema bo z whole ama of butter Combustion Ring ig broken Replace Combustion F ng Assembly running gasket correctiy install Air leaks from igniter Gowe
13. and must not contain combustible materials in the heater s immediate vicinity Interior or exterior gravity fed 55 100 or 275 gallon tank Pressure Reducer Lifter circulates fuel from remote storage tank Figure 2 9 ALTERNATIVE SOURCES OF FUEL STORAGE 19 MONITOR HEATING SYSTEMS Section 2 Installation Outdoor Fuel Tank Shut off Valve s Flare Connection Monitor 40 WALI p 9 o w Fuel Filter maximum 2 6m 16 Lenan ath Flare Connecti he Se ts 3 7 OD Copper Tubing Outdoor Fuel Tank Shut off Valve Flare Connection d L As Monitor 21 T dE Fuel Filter 16 3 Flare Connection 0 47 ine XE Fusibie Li Lin OD Copper Tubing Valve Connection Figure 2 10 TYPICAL FUEL LINE CONNECTIONS 20 MONITOR HEATING SYSTEMS Section 3 Operation 3 1 INTRODUCTION Monitor is 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 des
14. e The fuel tank should be located no closer than 6 feet to a source of heat The fuel tank should have an opening for filling on the top and a vent with a weather proof cap on the side One some tanks the vent and fill spout use the same opening 55 100 and 250 gallon tanks must contain e Shut off valve at tank outlet e Disposable fuel filter protects heater against condensation and other impurities e Fueling inlet protected by weather proof cap e Ventilation outlet e Clearance of at least 6 from any source of heat Allowable Height Dimensions e Bottom of tank at least 16 above floor holding heatere maintains sufficient pressure e of tank maximum of 8 above floor holding heater prevents excessive line pres sure e Position of Lifter more than 8 above fuel inlet of heater requires pressure reduction valve RECOMMENDATION Pipe fittings in the fuel supply to the Monitor heating systems should be sealed with pipe thread tape The supply line from the tank to the Monitor Kerosene Lifter must be absolutely air tight 275 gallons and bigger tanks should have a 2 5 P S max pressure reducer to avoid excessive pressure at heater inlet 2 16 HEATER INSTALLATION The Monitor heaters can be physically situated on carpeting or other combustible flooring with com plete safety The selected heater site must be accessible to an electrical outlet must support free air ciculation both internal and external
15. perature within a range of 42 F to 96 F can be left mounted on the back of the heater cabinet or be wall mounted Approximately 6 7 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 if a malfunction occurs 1 29 CLOTH COVERED EXHAUST PIPE Insulating cloth covers are to be placed over all metal surfaces of the Exhaust Line during installa tion Since combustion by products are vented at ele vated temperatures the Exhaust Pipe will become hot during operation The insulating cloth covers protect the user from burn hazards associated with accidental contact with these heated metal sur faces masma During installation make sure that all Exhaust Lines are tight Do not operate the heater without the insulating covers 1 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 amp 125VAC fuses protect the heater from damage resulting from power overloads In the event of a power surge or internal wiring hazards the fuse opens and power to the heater is
16. 13 TYPICAL MONITOR LIFTER PUMP INSTALLA For more detailed information look under Kerosene TIONS Lifter manual MONITOR KEROSENE LIFTER CAN BE POSITIONED BEHIND UNIT MONITOR KEROSENE LIFTER MONITOR KEROSENE LIFTER GRAVITV Figures 2 7 17 MONITOR HEATING SYSTEMS Section 2 Installation 2 14 USES FOR THE ELBOW ADAPTER KIT Convert trom Monitor 20 30 to 21 40 using an elbow adapter Kit part 8213 and utilizing existing flue pipe installation PARTS LIST EXPLODED Name No Ref of in No Part Unit 1 Exhaust Pipe Clamp 2 Exhaust Elbow 3 Exhaust Joint 4 Joint Supporter 5 Heat Insulation Cover 6 Self Tapping Screws 7 Hose Clamp this part comes with Monitor Heater 8 Air Damper this part comes with your Monitor Heater 9 Flue Pipe this part comes with Monitor Heater your your Remove Monitor 20 30 heater and flue pipe Install Monitor 21 40 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 OO gt Figure 2 8 18 Remove metal cap on side mounted exhaust port of flue pipe and replace into the port the Monitor 21 40 is now ready to be positioned into place NOT
17. C 95 F Off Physically assembled with a protective wire cage for the Monitor 40 and metal mesh cage for Monitor 21 the entire fan assembly is secured to a bracket on the rear of the Heater Cabinet A metal conduit at the rear of the heater protects the fan wiring from damage 1 19 AIR PRESSURE SWITCH This switch consists of a rubber diaphragm which senses changes in air pressurelit is connected to the Combustion Blower and normally open micro switch Should an abnormal pressure differential exist the switch opens to disable the circuitry that controls MONITOR HEATING SYSTEMS Section 1 Description the supply of fuel Since the flow of fuel to the Burner Pot is cut off the 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 Line Blocked or clogged Flue Pipe Intake port of Combustion Blower is blocked Combustion Blower is inoperable 1 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 burn mode so that combustion can be conducted efficiently Fuel moves by gravity flow from the external fuel storage
18. Heater Interior WARNING 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 from exterior of cabinet including exterior of Com bustion Chamber and Heat Exchanger STEP7 Replace Louver Assembly STEP8 Reconnect Monitor Heater Power Plug to the Wall Outlet STEP9 Turn Heater ON STEP10 Reprogram Heater Microprocessor STEP11 Select Mode of Operation CAUTION If 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 amp fuses and a 10 amp fuse Should fuse blow the recovery procedure is outlined below STEPI Turn Monitor OFF STEP2 Unplug heater STEP3 Remove louver assembly STEP4 Remove front cover MONITOR HEATING SYSTEMS Section 3 Operation NOTE As the Front Cover of the Monitor 40 is STEP7 Reattach louver assembly connected to the Printed Circuit Board by Lead Wires pull the Front Cover to the front STEP8 Plug heater power cord into wall outlet side slightly and remove the Connector of the Lead Wires from the Printed Circuit STEP9 Turn Monitor ON Board and then remove the Front Cover STEP10
19. The Monitor 40 combustion blower has a two stage intake fan Burner modes control fan speeds and the solenoid damper in the blower casing Those functions are as follows Table 1 1 COMBUSTION AIR CONTROL Burn Mode Fan Speed Solenoid Damper High High Off Open Medium High High Off Open Medium Low On Close Low Low On Close 1 17 HEAT EXCHANGER An inlet at top of the Heat Exchanger permits the heated air to travel from the Combustion Chamber into the exchanger An outlet at the bottom of the exchanger permits combustion by products to be vented to the Flue Pipe While moving through the Heat Exchanger the hot air within the exchanger heats the outside metal walls The hot metal walls in turn heat air that is pushed past the exchanger and is circulated into the room An air baffle directly in front of the exchanger deflects the heated air upwards and out through the louver assembly A pair of Over Heat Protector Switches protect the heater from damage due to excessive heat built up 1 18 AIR CIRCULATION FAN Both Monitor circulation fans are driven by two speed motors and are designed to circulate the heated room air If the heater is running in low and medium low burn modes the fan also runs at low speed in medium high or high burn modes the fan advances to high speed Operation of the fan is controlled by the micro processor and fan thermostar switch 52 C 126 on 35
20. and than jumper T2 pin and T7 pin on temperatura dinplanedi in diaplay window Mowe the Timer Sela ctor knob t the CLOCKJ TEMP position Fuse Fi open Failure of Trans of Dioda Bid DTI Failure of Capacitor Failure of Failure of Capacitor oro Failure of micro processor ICT Failure of compar ta uz Failure of resistor R22 23 24 321 Failure of diode 202 Failure of Copector G21 of reeistor Ai 18 R202 Fallura of capacitor ICIS Failure of operation board of nesonaior I 4 Failure of capacitor con 321 Failure of resistor Failure of micro processor 01 CORRECTIVE MEASURE Alapiace fuse transformer Finpi a Diode Replace capacitor Replace it Fisplaca capacitor epla e microprocessor Replace comparata Replaces nesaior Replace zener diode Raplace capacitor Replace resistor Replace capacitor Faplaca operation circuit board 2g Replace capacitor Repleog Replace microprocessor 2 is igniter red on preheat during prepurge and igniting 118 there 12Vdc at coil of ratay REA during pre MEASURE 18 i Tn Replace igniter Replace combustion correct wiring Fa
21. cut off The electrical outlet into which the heater is con nected should be protected by at least a 15 amp fuse or circuit breaker 1 32 OVERHEAT PROTECTOR SWITCHES Connected in series two 2 normally closed Over heat Protector Switches safeguard the heaters against damage due to overheating The Monitor 21 switches are rated 110 C 230 F The Monitor 40 switches are rated 115 C 239 F Should a Monitor overheat internal temperatures rise beyond 110 C 230 F on the Monitor 21 115 C 239 F on the Monitor 40 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 reser after cooling dowm Once the heater has cooled to 80 C 176 F the system can be restarted To restart the Monitor proceed as follows Press ON OFF Switch to OFF Allow heater to cool Troubleshoot the cause of the overheat Press ON OFF switch to ON Proceed with normal operation m O O m gt MONITOR HEATING SYSTEMS Section 1 Description LZ HOLINOW W31SAS NOILSNSWOD 40 51 3 2 1 91bi4 3ATVA I3A31 LNVLSNOO HOdVA Tans HOLIMS 3unss3Hd HIV x JANS Tana H3LINDI QION310S i JIZZON gt O A75 mum 10 M 4 f T GION3 1OS L L DNIH NOLLSPhIBINOO b a H3AAO18 NOLLSASWOD x lt d V YHE
22. gasket Test run heater to see if problem clears up with Turn on the fuel at the storage tank and at the use of new fuel fusible link valve replace all covers and apply 35 MONITOR HEATING SYSTEMS Section 5 Servicing 5 1 INTORODUCTION Servicing is required when the Monitor Heater is not running at proper efficiency This section covers possible causes and corrective procedures for effi ciency loses Signs of improper heater efficiency and performance would be Yellowish lazy flame Smoke from flue pipe exhaust Heavy soot and carbon build up in combustion chamber Lowered heat output 5 2 MEASUREMENT OF FUEL FLOW 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 CONTAMINANTS 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 21 2 using separate tank on the Monitor 21 shut off fusible link valve On the Monitor 40 shut off valve of separate tank 3 Benda piece of sheet metal or cardboard into a U shape and place it under the fuel constant level valve strainer cover to drain bad fuel into a 1 2 liter pan Figure 4 1 A Remove strainer cover and drain With strainer cover removed inspect clean and o
23. heater start up inspect the system for operational readi ness The following check list specifies those items that should be inspected on a routine basis X Check that the Monitor heater is plugged into wall outlet 120 Vac 60 Hz Verify that adequate supply of kerosene is available in fuel tank Confirm that fuel is free of water or other contaminants Check fuel tank for good operating condition it must be free of rust corrosion and or leaks Inspect Fuel Line for signs of leaks loose connections cracks air pockets or blockages Confirm that Fuel Valves on Fuel Tank and Fusible Link Valve are open so fuel can flow freely Outside dwelling check area immediately around Flue 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 Inspect dwelling interior and confirm that imme diate area near heater is free of combustible and objects that might interfere with free air flow Make certain that Heat Sensor is not exposed to drafts direct sunlight nor direct heat from the Monitor Confirm that heater is level if this inspection reveals any system deficiencies correct the problems before operating the heater 26 3 5 OPERATION Operation of Monitor heater can be controlled manually
24. tank oe _ Setting Medium Medium rere 0 25 Continuous use burntime 55 gal tank 19 1days 14 3days 9 2davs 286 5days 214 8days 137 5days 95 5days 71 6days 35 9days 8 hrs day burntime 275 gal tank Continuous use burntime 275 gal tank 5 2days 3 9days 2 5davs 21 Tama zw MONITOR HEATING SYSTEMS Section 3 Operation Monitor 21 Circulation Fan Output 176 cubic feet min Rated Efficiency as apply to kerosene heater Fuel source 1 32 U S gal separate tank 93 optional Rated Efficiency as apply to central heating Potentional heating area 600 2000 sq feet systems 87 Power Consumption as follows Table 3 2 lists Monitor 21 performance specifica tions at various user selected heat output setting HIGH MEDIUM HIGH MEDIUM LOW LOW IGNITION BURN BURN BURN BURN 250watts 52watts Siwatts 50watts 50watts Table 3 2 HEATER PERFORMANCE SPECIFICATIONS Setting Medium Medium Specification Heater Output hr L W or w ss ww 8 hrs day burntime 1 32 gal tank 2 4 1 3davs Continuous use burntime 1 32 gal tank Continuous use burntime 55 gal tank a27days 22000 22 MONITOR HEATING SYSTEMS Section 3 Operation 3 3 OPERATING CONTROLS AND INDICATORS Several controls and indicators are used to operate the heater and to monitor its perf
25. 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 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 21 gives the user the option of either using the internal capsule tank or hooking up to an external 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 valve 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 1 22 FUSIBLE LINK VALVE Basically the Fusible Link Valve is a 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 21 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 inlet on the bottom of the valve allows fuel to pass into the heater The handle 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 40 if require
26. 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 WARNING DO NOT REPLACE FUSE WHILE POWER 1 STEPI Removal of Fuse A Unplug heater Remove Louver Assembly and Front Cover 34 B Remove the fuse from fuseholder on the Printed Circuit Board STEP2 Installation of New Fuse A Install a new fuse into the fuseholder The fuse must be a 250 V 2 amper or a 250 V 10 amper type as marked on the printed circuit board Replace the Front Cover and the Louver Assembly and plug the heater into the wall outlet 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 svstem s fuel filters beginning with the fuel storage tank If a Monitor Kerosene Lifter is part of the fueling system examine and clean 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 fuel the following action must be taken WARNING BEFORE PROCEEDING FURTHER U
27. 3 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 1 30 Air Circulation Fan Guard 1 31 Fuse 1 32 Overheat Protector Switches Section 2 Installation 6 nnn Page 9 20 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 Installation of Flue Pipe Window Kit 2 10 Installing an Extension Kit 2 11 Typical Monitor Lifter Pump Installations 2 12 Uses for the Elbow Adapter Kit 2 13 Fuel Tank Installation 2 14 Heater Installtion Section 3 Operation 21 30 3 1 Introduction 3 2 Operating 3 3 Operating Con trols and Indicators 3 4 Pre operation Check List 3 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 Section 4 iii ika 31 35 4 1 Introduction 4 2 Periodic Maintenance 4 3 Inspect Exhaust Air Lines 4 4 Verify Igniter Operation 4 5 Clean Fuel Constant Level Valve Filte
28. DED TOOL KIT FOR MONITOR HEATER SERVICE TECHNICIANS 1 2 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 2 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 Needlenose Cutting Lock Joint 18 Phenolic Probe or Insulated Screwdriver 19 Supply of 125V 3 Amp fuses 20 Floor mat to cover carpeting 21 Quart size pan for draining fuel 2 4 POWER REQUIREMENTS WARNING 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 ampere fuse or circuit breaker NOTE The wall outlet should supply electricity for the Monitor system only Do not connect any other electrical appliance to it CAUTION In some installations it may be best to hard wire the heater to the house circuits A competent li
29. E Be sure the exhaust elbow is firmly fixed on the flue pipe with a joint supporter Insert air suppoy elbow opening over flue pipe air intake flange and secure with hose clamp G NOTE The Standard Air Damper is installed over the flue pipe air intaka flange To locate flue pipe air intaka flange see your Monitor Owner s Guide Elbow adapter kits may also be used to raise a flue pipe hige enough to clear certain base board heat ing systems 2 15 FUEL TANK INSTALLATION Pictorial views of alternative types of storage facil ities and delivery systems are illustrated Figure 2 10 Since fuel storage tank installation techniques vary from place to place often dependent upon appli cable codes a particular installation procedure cannot be specifed However certain criteria govern the fuel hook up of the Monitor Use the following check list as a guide to the fuel storage facilities WARNING 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 21 2 Gravity Fed Large Capacity External 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 te
30. F by microprocessor 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 cycled for manual mode of operation 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 If 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 STEPt Program Clock for Current Time A Position TIMER SELECTOR slide switch at position CLOCK SET B Press HOUR push button switch to program current hour on the Clock IMPORTANT Be sure to 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 Press MINUTE push button switch to program the current minute s on Clock D Immediately after programming current time in terms of hours and minutes press the SET push button switch E Place TIMER SELECTOR slide switch in posi tion CLOCK TEMP and verify that time dis played on Clock is the current tim
31. Ground or slab surface Overhead Clearance s Non combustible 24 60cm combustible Som 24 60cm IER mp a or more Body 30cm Clamp x gt lass Flue Pipe Ground or slab surface Side Clearance Side obstacle Body Clamp 18 45cm or more Flue Pipe 60cm 24in 13 5cm 13 5cm 15cm 25cm 10in 100cm 39in 100cm 39in Figure 2 1 FLUE PIPE CLEARANCES 1 MONITOR HEATING SYSTEMS Section 2 Installation HOW TO PREVENT FREEZING IN COLD CLIMATE Exhoust Elbow 24 60cm or more Et 2 Front Obstacle or 20 50cm or more SNOW SURFACE or GROUND Long JExtension kit Figure 2 2 FLUE PIPE CLEARANCES 12 MONITOR HEATING SYSTEMS Section 2 Installation NOTE After using the installation template as a guide for drilling the flue pipe hole the Monitor Flue Pipe can be normally installed according to 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 Back of Hea to the Flue Pipe of Heater Fuel Inlet Floor The center of The Joint Pipe Back of Heater Fuel Inlet Floor Figure Figure 2 3 13 2 9 INSTALLATION OF FLUE PIPE WINDOW KIT A window kit makes it possible to vent the heater from dwelling
32. IS CI xxx Ll po Jmm 23 M54565P l 1315017 UK 22K 22K iam 26 GIR IHTTP V US AX RIZ LM R30 59 51 IS2076A DIM s Het 10012 M34518P GIR P V US Q1 013 _ S 0vDC A 220 inva MONITOR HEATING SYSTEM EXPLODED VIEWS AND PARTS LIST 55 WOINITOR 40 Carton Box Cushion Set jf MONITOR 40 EXPLODED VIEW 43 MONITOR 40 SERVICE PARTS LIST mo PART DESCRIPTION ITEM PART DESCRIPTION NO NO __ NO 1 6300 SPILL TRAY 52 4833 CORD BUSHING 56 6185 LEG 53 6037 LEVEL GUIDE 2 5301 AIR SUPPLY HOSE A 54 6138 CARRYING HANDLE 4 5302 AIR SUPPLV HOSE 8 55 5185 SENSOR ASSY 5 5303 CONSTANT LEVEL VALVE 55 4004 JOINT PIPE 25 5304 CANSTANT LEVEL VALVE STRAINER 57 5328 ATR DAMPER 5305 FUEL PIDE 58 6329 AIR DAMDEP 5 9 5305 SOLENOID PLIMD 59 145 ATR SLODI V HOSE ASSY 2 6307 GASKET 1 50 4014 EXHAUST OUTLET 0 6309 BURNER 5 1 4016 AIR PORT n BING 11 6309 GASKET 2 62 4006 DTPE HOLDER 12 6210 GASKET 2 53 4008 13 5311 HEATER 54 4805 ATR OUTLET 14 5115 GASKET 3 65 5147 FLUE PIDE ASSY 15 6117 HEATER COVER PACKING 66 6148 SLEEVE FLANGE SET 15 6312 FLAME DETECTIVE PLUG 67 6075 17 6119 PLUGPACKING 58 6330 CIRCULATION MOTOR IB 6313 GASKET 4 50 5331 BLOWER GUARD 19 6314 HEAT EXCHANGER ASSV 70 332 UNDER COVER 20 6122 GASKET 6 71
33. NPLUG THE HEATER STEPI Remove Contamination A Shut OFF the fuel supply at the storage tank or at the Fusible Link Valve B Drain off the contaminants from the fuel storage tank or the fuel sump tank M 21 Fill with fresh clean fuel STEP2 Clean the Heater A Clean fuel constant level valve filter and filter compartment Remove the Louver Assembly and Solenoid Pump on the constant level valve Clean the Solenoid Pump filter On the Monitor 21 remove the Front Cover Cover Front Bracket Top Bracket Combustion Chamber Cap Baffle Service Panel and the Flame Sensor and then remove the Burner Cap and Combustion Ring from the Burner Pot On the Monitor 40 remove the Front Cover Top MONITOR HEATING SYSTEMS Section 4 Maintenance y sr Cover Front Bracket Service Panel and the power to the heater Flame Sensor and then remove the Burner Cap and the Combustion Ring from the Burner Pot H problem still exists and contaminated fuel is D Using clean paper towels thoroughly wipe the suspected it can be checked by bottom of the Burner Pot the Burner Cap the A Shut off the fuel supply at the storage tank and Combustion Ring and the Flame Sensor Rod at the fusible link valve B Drain off fuel control valve STEP3 Reinstall Cleaned Components C Disconnect fuel line at back of heater and hook A Replace the components correctly and install up a 5 gallon quick tank with proven good fuel new
34. OFF switch to ON Proceed with normal heater operation The Monitor 21 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 will shut off after 30 minutes The remaining burning time is indicated at the Display Window Refueling STEP1 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 fuel cap STEP3 Fill the Capsule Fuel Tank Fill the capsule fuel tank with fresh crystal clear kerosene by using a siphon STEP4 Reinstall the Capsule Fuel Tank 28 Replace and tighten the fuel cap To insure proper fuel flow be sure the cap is secured correctly MONITOR HEATING SYSTEMS Section 3 Operation install the tank with the arrow pointing forward and close the tank cover STEPS Turn Heater ON Press ON OFF switch to ON Proceed with normal heater operation 3 12 RECOVERY FROM A POWER FAILURE The Monitor is equipped with an automatic reset feature which restores the manual mode of opera tion following interruption of power to the heater Note however that a power failure automatically triggers a Cooling and purge cycle routine operation will automatical
35. ON CHAMBER ASSY 77 1142 OWNERS GUIDE 29 6128 BURNER 78 6176 O RING P39 30 6129 BAFFLE ASSY 79 6177 OIL FILTER 31 6130 CHAMBER GASKET 80 6178 FLOAT SWITCH PACKING 32 6131 CHAMBER CAP 81 6179 FUEL TANK CAP 33 6132 POWER TRANSFORMER 82 6180 FAN BLADE 34 6133 PWB ASSY 83 6181 COMBUSTION RING ASSY 35 6134 PWB SPACER CLIP A 84 6182 BURNER 36 6135 PWB SPACER CLIP 85 6183 JUNCTION BOX COVER 37 6136 PUBBER BUSH 86 6184 AIR PRESSURE SW 38 6137 CORD CONNECTOR 87 6185 LEG 39 6138 CARRYING HANDLE 88 6186 SENSOR ASSY 40 6139 POWER SUPPLY CORD 89 6037 LEVEL GUIDE 44 6140 BLOWER ASSY 90 6068 WINDOW PLATE 42 6141 BLOWER MOUTH PACKING 91 6069 WINDOW GLASS 43 6142 DAMPER SOLENOID ASSY 92 4004 JOINT PIPE 44 6143 SUCTION CASE 93 4805 AIR OUTLET CAP 45 6144 SEAL PACKING 94 4006 PIPE HOLDER 46 6145 AIR SUPPLY HOSE ASSY 95 4008 HOSE BAND 47 6146 AIR DAMPER 96 4014 EXHAUST OUTLET CAP 48 6147 FLUE PIPE ASSY 97 4016 AIR PORT RING 49 6148 SLEEVE FLANGE SET 98 4833 CORD BUSHING 58
36. Reprogram heater STEP5 Locate and replace fuse s STEPtI Program Automatic operation cycles if STEP6 Reattach front cover applicable In case of the Monitor 40 be sure that the connector is connected to the printed STEP12 Select Automatic operation if appli circuit board cable 30 MONITOR HEATING SYSTEMS Section 4 Maintenance 4 1 INTRODUCTION Heater maintenance is divided into two classifica tions periodic maintenance is required to maintain the heater in good operating condition corrective maintenance is necessary to repair a malfunction 4 2 PERIODIC MAINTENANCE The Maintenance Schedule provided in Table 4 1 describes the tasks that must be performed periodi cally in order to sustain the efficiency of the Monitor Heating Systems 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 performance Table 4 1 SUGGESTED MAINTENANCE ACTIVIES Activity Material Check all fuel lines for leaks and 3 8 OD copper tubing loose connections Inspect exhaust lines for leaks or loose connections Check fuel for water and or other contamination f the capsule tank is used on the Monitor 21 the capsule tank filter should be checked cleaned or replaced Inspect Fuel Pipe for obstruction Inspect electrical wiring for cracks signs of deterioration bare wires and or lo
37. al mounted position However should relocation be necessary choose a location for the sensor that is not in the path of direct sunlight 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 Once heater has shut down it can not be restarted until post purge cy cle has been completed If ON OFF switch is left in position ON Monitor operation will automatically restart upon completion of post purge 3 1 OUT OF FUEL During either manual or automatic operation of heater fuel in the tank may be depleted 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 STEP1 Turn Heater OFF Press ON OFF switch STEP2 Fill Fuel Tank A Close shut off valve at outlet of Fuel Tank B Drain Fuel Tank from bottom if possible 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 valve which was closed in stepA above STEP3 Turn Heater ON Press ON
38. ay window will not be accepted and will revert to previously programmed time and or temperature Erases programmed time and temperature When cleared time and or temperature previ ously programmed and displayed disappear s from window IMPORTANT Both current time and auto matically programmed time s temperature s will have to be reprogrammed if electrical operation is inter rupted bv power failure or bv disconnecting heater plug from wall outlet If this occurs the heater will go into MAN UAL mode of operation and maintain initial set tempera ture 72 F ON position push button is in japplies power 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 All circuits except for Clock and Air Flow are shut down MONITOR HEATING SYSTEMS Section 3 Operation FIGURE AND ITEM NO CONTROL OR INDICATOR FUNCTION AUTO push button switch Figure 3 2 Item21 Places heater in automatic mode of operation AUTO indicator lights to confirm automatic operation Assuming that the heater has been properly programmed heater will operate automatic ally When pressed again AUTO indicator goes out and then heater will operate in MANUAL mode During manual operation the user turns heater ON and OFF at will 3 4 PRE OPERATION CHECK LIST After heater installation but prior to Monitor
39. 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 controls and indicators illustrated by Figure 3 1 and 3 2 are used to operate the system and to monitor the heater performance 3 6 MANUAL HEATER OPERATION Operation of the heater is under the direct control of the user heater will not operate automatically The heater will however automaticallv respond to changes in room temperature signaled bv the Heat Sensor to maintain the temperature of the room at a comfortable level NOTE Resetting the Fuel Constant Level Valve is necessary only 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 STEPI Prime the Heater Gently press and release the Fuel Constant Level Valve Reset Lever four or five times STEP2 Select Manual Operation lf heater operation is in AUTO mode press the AUTO push button switch and change Auto to Manual mode STEP3 Select Temperature Setting Press the TEMP push button switch and press either the UP or DOWN push button switch to set the digital set room temperature indicator to the desired temperature and then press the SET push button switch MONITOR HEATING SYSTEMS Section 3 Operation IMPORTANT In case no temperature is set tem perature will automatically be set at 72
40. censed electrician should do this MONITOR HEATING SYSTEMS Section 2 Installation 2 5 FUEL TANK REQUIREMENTS WARNING INSTALLATION OF ANY REMOTELY LOCATED FUEL TANKS MUST COMPLY WITH ALL LOCAL STANDARDS AND OR BUILDING CODES Heater fuel crystal clear kerosene only 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 CAUTION some installations it may be better to install permanent fuel tank plumbing A licensed Plumber should do this 2 6 TEMPERATURE SENSOR WIRING REQUIRE MENTS A wall mounted temperature Sensor gauges 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 If sensor is to be mounted re motely be careful not to place it in direct sunlight on uninsulated exterior walls 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 govern the installation and use of a vented heater and related fueling systems Prior to installation check and comply with all codes 2 8 UNPACKING Save all shipping materials until the Monitor has
41. ch on operation mode on Manual sat temperature High position la Fusibile Link Valve smeron n REASON 4 ti j F H IL ue px eM Crear Ban lamp flame incorrect wiring of Flame sensor Or Ground MEASURE Replace or check Circult Board Correct wiring Flame sensor rod touches Corect or Change to burner parts Failure of Air Pressure Swier Replace Pressure Failure of Solenoid Pump Replace Solenoid Pump s wiring of Combustion eorect Biower motor Replace Combustion Blower Replace check 1 Board cu inc msct wiring Correct wiring Yau Soot adhering to combustion l la Igniter Ya chamber auc Clean genthy with brush etc Failure of Circuit Board 8 4 Failure of solanold Pump Fiapla a Solenoid 1 Operation Switch OFF Replace Igniter 2 Remove igniter 3 Disconnect wirlng for Solenoid Pump Failure of igniter is hera nov are on cir Fallura of Circuit Board cuit board check Circuit Board incomect wiring Failure of igniter relay on ls thare MOV at plug replace board Fallura of Cirouit Board dew 4 Fuse open Short circuit of lead wire Correct or change Failure of Circuit Board Replace or check
42. chnician 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 is used to supply fuel the inlit pressure to the heater must not exceed 2 5 psi 3 MONITOR HEATING SYSTEMS Section 2 Installation To install a large capacity gravity fed external tank follow the instructions below Use of a qualified installer is recommended e Installation height of the bottom of the fuel tank should be 16 inches or more above the floor surface on which the heater stands This insures that inlet fuel pressure will be sufficient The top of the fuel tank should be no higher than 8 feet above the floor under the heater This insures that inlet fuel pressure will not be excessive The horizontal length of piping should not exceed 100 feet and should be free of sharp bends or obstructions Piping should include no inverse U type bends to avoid air locks which could block the fuel supply e Only inch OD copper tubing should be used The tubing should be bent carefully to avoid crimping A fuel filter is recommended for use on the fuel line near tank and a shut off valve should be installed at the tank e Flare connections should be used at the fusible link valve connection on the heater and at the fuel filter to be installed at the tank
43. cribed 3 2 OPERATING SPECIFICATIONS The following specifications apply to the operation of the Monitor 40 and the Monitor 21 Monitor 40 Rated Efficiency as applied to kerosene heaters 93 Rated Efficiency as applied to central heating systems 87 Power Consumption as follows HIGH MEDIUM HIGH MEDIUM LOW LOW IGNITION BURN BURN BURN BURN 340watts 65watts 62watts 58watts 58watts Circulation Fan Output 388 cubic feet min Fuel source Remote separate tank Potential heating area 900 3200 sq feet The energy form the combustion process is released in the from 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 93 of the heat produced by the combustion process is recovered Assuming the water can be condensed 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 40 performance specifica tions at various user selected heat output settings Table 3 1 HEATER PERFORMANCE SPECIFICATIONS specification Fuel Consumption gal hr 8 hrs day burntime 5 gal tank Continuous use burntime 5 gal tank 8 hrs day burntime 55 gal
44. d l 23 FUEL CONSTANT LEVEL VALVE This valve has an automatic shutoff safetv mecha nism and a Fuel Set Lever The safety mechanism prevents fuel 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 21 and 40 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 As 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 controls 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 muximum 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 fr
45. e STEP2 Program the 1st Time Temperature A Slide TIMER SELECTOR slide switch to posi tion 1st B Press TIME push button switch C Press HOUR and MINUTE push button Switches to program 1st desired time IMPORTANT Be sure to set the clock AM or PM F 27 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 push button switch Press UP and or DOWN push button switch es to program ist desired temperature G Immediately after programming the ist 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 With the TIMER SELECTOR slide switch in the appropriate positions program the 2nd 3rd 4th times as described above Be sure to press the SET push button switch after each time 1 programmed IMPORTANT Should heater power be interrupted by a power failure or by disconnec tion of the power cord heater reverts to MANUAL operation and all AUTO programming is erased STEP4 Select Automatic Operation Press AUTO push button switch The AUTO in dicator light will illuminate STEP5 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
46. ead screw driver which should be able to go in approximately without obstruction B Dry all lines with paper towels Repair any leaks that have been found if necessary replace the tubing D Replace cloth insulation covers 4 4 VERIFY IGNITER OPERATION Visually inspect Igniter Operation WARNING HEATER IS OPERATIONAL DURING THIS INSPEC TION AVOID DIRECT CONTACT WITH ANY HEATED OR ELECTRICAL COMPONENT STEP1 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 problem MONITOR HEATING SYSTEMS Section 4 Maintenance STEP3 Reassembly of Heater Turn the heater OFF and replace the Louver Assem bly 4 5 CLEAN FUEL CONSTANT LEVEL VALVE FIL TER Contaminants are trapped by the filter to prevent them from clogging the Fuel Constant Level Valve The filter itself has a great number of small pores Whenever a filter is torn or disfigured enlarged pores it should immediately be replaced Inspect and clean the filter as indicated by the procedure below I WARNING CLOSE FUSIBLE LINK VALVE ON M 21 OR CLOSE SHUT OFF VALVE OF THE EXTERNAL FUEL TANK ON M 40 TO AVOID DRAINING ALL FUEL FROM TANKS NOTE Power should be OFF during the
47. er from injury and the heater from damage This section describes the heaters and their compo nents Since a number of components have multiple func tions a component may be described more than once 1 2 PHYSICAL SPECIFICATIONS Listed below are the physical specifications that apply to the Monitors Monitor 40 Height 26 6 67 5cm Width 28 7 73cm Depth 13 8 35cm Weight 82 Ibs 37kg Flue Pipe Hole 2 65mm diameter Monitor 21 Height 25 6 65cm Width 20 9 53cm Depth 12 4 31 5cm Weight 55 16 25kg Empty Flue Pipe Hole 2 65mm jdiameter 1 3 FUNCTIOMNAL DESCRIPTION An overview of the functional operation of the Monitors is diagrammed by Fiqure 1 1 and is de scribed as follows Monitor operation always begins with a pre purge and a pre heat which must be completed before ma amm ama m R mer Dm ite 3 L qu a Ea mm one by visually examining a series of indicators on the Control Panel A Temperature Selector Control permits the user to set the temperature to the level desired in the room Upon commencing heater shutdown a post purge is run All heating operations cease except for the air circulation fan and the combustion fan which con tinue The post purge continues for three minutes after a flame goes out At this point heater operation stops completely Auromatic operation of the Monitor 40 and Monitor 21 is co
48. es One side of the Flue Pipe contains a T shaped fitting consisting of four ports This side is mounted on the interior wall of the dwelling The pipe side of the Flue Pipe is vented outside the dwelling The Flue Pipe Assembly consists of two concentric tubes Outside air is drawn through the cylindricai space between the tubes Combustion by products are vented through the inner tube As the cool air enters it is heated by the hot air that is exiting the system A large bore flexible hose connects the air inlet port on the Flue Pipe with the Combustion Blower a cloth covered metal pipe connects the Combustion Blower with the exhaust outlet on the Flue Pipe IMPORTANT If extension kits are utilized use the correct damper as follows Extension kit M 40 M 21 Up to 3 elbows with Extra Short Extensior kit Length 11 7 5 damper 5 damper Up to 3 elbows with Short Extension Kit Length 11 20 S damper 5 damper Up to 3 elbows with Medium Extension Kit Length 20 38 E damper unused Up to 3 elbows with Long Extension Kit Length 38 73 E damper unused 1316 COMBUSTION BLOWER The combustion blower on the Monitor 21 is a dual function fan The intake fan draws in outside air thru the flue pipe for internal combustion The cooling fan which runs on a common shaft with the intake fan circulates air inside the heater cabinet to keep internal compo nents cool
49. flame sensor 2 On the Monitor 40 A Remove louver assembly B Remove front cover and lead wire con nectors C Remove top cover Remove front bracket to cover combustion chamber Remove service panel F Remove Flame sensor 3 Remove burner cap 4 Turn counter clockwise to remove combustion ring 5 Use wire brush to clean inside of combustion chamber Vacuum and wipe clean with a waste cloth NOTE Make sure all air inlet openings are clear 6 If burner cloth on the bottom of burner is deformed replace it Combustion ring may deform and deteriorate after several years use and should be cleaned and inspected before reinstallation If combus tion ring is warped has cracked or is deteriorat ing it should be replaced When reassembling the unit check that com bustion ring is positioned with the correct side up and is sitting squarely on all three support screws inside the combustion chamber Reinstall burner cap and flame sensor to cor rect position r MONITOR HEATING SYSTEMS Section 5 Servicing 5 5 CLEANING THE FUEL INLET 2 Push a phillips head screw driver about the When cleaning soot from combustion chamber the same size as the I D of fuel inlet pipe into the fuel inlet pipe should also be cleaned This can be fuel inlet pipe done as follows 3 If obstruction is felt twist screw driver back and forth to brake up soot and carbon so that 1 Disconnect copper fuel line at burn chamber screwdriver
50. he Flame Sensor always supervises the flame 1 13 IGNITER Located within the igniter tube of the Burner Pot the Igniter is designed to pre heat the Burner Pot and to vaporize and ignite the air fuel mixture to start the combustion process The Igniter is secured by a bracket and screw to the igniter tube The cover plate is secured to the combustion chamber by three 3 phillips head Screws 1 14 COMBUSTION AIR SYSTEM The Combustion Air System channels air to and from the heater Outside air is drawn into the heater by the Combus tion Blower through an airway to the Combustion Chamber Combustion Blower draws the intake air into the through a Flue Pipe This air enters the Combustion Chamber at the Burner Pot and mixes with the fuel support combustion Remaining air is heated and is drawn into the Heat Exchanger As the heated air passes through the Heat Exchan ger an Air Circulation Fan blows room air past the Heat Exchanger and out again into the room heat ing passing air by convection Exhaust vapors exit ing from the Hear Exchanger are vented through the Flue Pipe A deterioration of air pressure at the Air Pressure Switch is an abnormal condition the heater is shut down by the malfunction MONITOR HEATING SYSTEMS Section 1 Description 1 15 FLUE PIPE Flue Pipes are available in three 3 sizes This provides the flexibility to meet the installation requirements for dwelling of various wall thicknes s
51. icator Light Figure 3 1 8 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 9 TIMER SELECTOR Displays set and current room temperature CLOCK TEMP when heater is ON position Displays current time after time has been programmed when heater is OFF Prior to programming 88 88 is displayed on clock NOTO During routine heater operation the selector switch is normally set to this position Figure 3 2 Item10 CLOCK SET Programs current time on Clock by use of position HOUR and MINUTE push button switches NOTO Prior to programming current time Digital Display shows 88 88 IMPORTANT Once current time has been programmed press the SET pushbutton switch with in 60 seconds Otherwise clock dis play will revert to previously programmed time if any Figure 3 2 Item11 1ST Position Programs first automatic heater operation When programmed heater automatically oper ates at specified time and temperature i e 6 OO a m 7O F if set for AUTO providing that heater has been set for automatic mode of operation TIME TEMP HOUR UP MINUTE DOWN and SET push button switches are used to pro gram first operated time and temperature IMPORTANTO Once time and temperature have been programmed the SET push button switch must be pressed with in 15seconds Otherwise time and te
52. ilure af registar for combustion blower correct wiring pressura switch ure switch Clear and or rubber hose Incorrect wiring Correct wiring there 12006 ALG during pumi work dunng igniting igniting Failure of diode Replace diode ipe Failure of solenald Beng C H zz supply parts processor Failure of Replace solenoid pump I Replace microprocessor Failure of diode Raplace fina DTS Failure of IC CS Replace K Failure of resistor Replace resistor Failure of transistor ETUR i of dinde Replace diode there LiVde at IC2 E pin stop healer operation and connect equivalent flame circuit between flame sensor rod H pin and ground Ef pin Equivalent flame circuit la there marid than 1 2Vdc at 02 m pini ia there OV at 2 9 I Failure of resistor Ra FIS R A201 of rans Fima Fa open Failure of capacitor C15 Failure of resistor 0 201 56 571 Failura of compare tor Failure of resistor Failure of diode 10181 Fallure of capacitor Failure of Failure of microprocessor of wiring for Marna sensor and ground inzorraci installation ai ama sansor red x CORRECTIVE MEASURE asin
53. ly be resumed following purge cycle A switch to manual mode is automatic because the absence of power to the microprocessor wipes out the programmed memory To recover from a power failure automatic mode of operation proceed as listed below STEP1 Program Current Time STEP2 Program Automatic Time Temperature operation cycles STEP3 Return to Automatic operation 3 13 RECOVERY FROM OVERHEAT CONDITION The Monitor is protected against damage resulting from an overheat condition by two 110 C Monitor 21 115 C Monitor 40 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 is 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 STEP1 Turn OFF Heater STEP2 Allow Monitor Heater to cool NOTE Be sure that heater is cool to touch A period of 30 to 45 minutes should be sufficient to permit heater to cool completely STEP3 Unplug Heater Disconnect heater power cord from wall outlet STEP4 Check for Cause of Overheating NOTE Overheating is usually caused by objects 29 that impede free air circulation Look for debris and other obstructions at front of heater at Circulation Fan at rear of the heater and at Flue Pipe tip outside dwelling STEP5 Remove Louver Assembly STEP6 Clean
54. mpera ture will revert to previously programmed time if any When selector switch is set to this position 1st presently programmed time and temperature are displayed Figure 3 2 Item12 2ND Position Programs second automatic heater operation as same as 1st position 24 MONITOR HEATING SYSTEMS Section 3 Operation FIGURE AND ITEM NO CONTROL OR INDICATOR FUNCTION Figure 3 2 Item13 3HD Position Programs third automatic heater operation as same as 1st position Figure 3 2 Item14 4TH Position Programs fourth automatic heater operation as same as 1st position Figure 3 2 Item15 Figure 3 2 Item16 Figure 3 2 Figure 3 2 Item18 Figure 3 2 Item19 Figure 3 2 Item20 TIME push button switch I TEMP push button switch HOUR UP MINUTE DOWN repetitive action push button switch _ SET push button switch CLEAR push button switch ON OFF push button switch 25 This switch is used to set time and change display over This switch is used set temperature and change display over Programs time or temperature NOTE Each time push button switch is pressed the digit advances in incre ments of one digit If push button is pressed and held the degits are advanced repetitively Sets time and or temperature this control is not pressed after time and or temperature have been programmed the time and or temperature programmed as indicated by displ
55. ntrolled by a microprocessor with four sets of Time Temperature programming per day PRE PURGE PRE HEAT IGNITION COMBUSTION HEATING SHUTDOWN nuc mi imer MONITOR HEATING SYSTEMS Section 1 Description mechanisms 1 5 SPILL TRAY The Spill Tray Protects the floor from damage resulting from fuel spillage Provides a secure tip resistant heater base Metal retainers 2 secure the heater to the Spill Tray The legs are positioned with in the circular indenta tions 1 6 HEATER CABINET A steel Cabinet holds and protects all internal components A number of primary parts are assembled to form this housing 1 7 COMBUSTION SYSTEM The Combustion System is responsible for the production of heat which is circulated into the room In the Combustion Systems a mixture of fuel and air is burned to produce heat Air is drawn from outside the dwelling to Combustion Chamber At the same time fuel is metered from a storage tank into this same Combustion Chamber Within the chamber the air fuel mixture is ignited to produce heat The Monitor combustion systems are safeguarded by a pair of overheat protector switches They will shut down the heater to protect it from damage in the event of excessive heat build up The overheat protector switches reset automatically after cooling down 1 8 COMBUSTION CHAMBER This tall cylinder is positioned on the Heater Base is secured to the base by phillips head screws
56. om entering into the reservoir Should a foreign substance 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 Care must be taken to prevent dust dirt or other debris from clogging or blocking the inlet valve CAUTION 1 24 SOLENOID PUMP The Solenoid Pump is mounted the Fuel Constant Level Valve controlled by a microprocessor and MONITOR HEATING SYSTEMS Section 1 Description four modes High Medium High Medium Low Low fuel flow is delivered to the Burner Pot 1 25 ELECTRICAL SYSTEM Electrical power is supplied to the Monitor to run the Microprocessor and the other electrically energized component Electrically 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 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 27 TEMPERATURE SENSOR The sensor which is capable of sensing room tem
57. ormance as follows RUN AUTO EMPTY BURNER STATUS et 1 5888888 LOW HIGH 1 2 3 4 6 f 8 Figure 3 1 INDICATORS 10 1 12 13 14 15 OPERATION TIMER SELECTOR TIME TEMP SET CLOCK CLOCK ON OFF AUTO TEMP SET 15 2nd 3rd Ath TIME HOUR MINUTE SET CLEAR 18 19 FIGURE AND ITEM NO CONTROL OR INDICATOR FUNCTION Figure 3 1 Item1 RUN Indicator Light Light to indicate that power has been apllied to heater Illuminates when operation ON OFF push button switch is pressed to position ON 20 21 Figure 3 2 CONTROLS 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 Item3 Empty Indicator Light In case of using the cartridge tank when the fuel is empty EMPTY Indicator Light blinks This Light is not provided with Monitor 40 Figure 3 1 Item4 BURNER STATUS Light in accordance with heat output as fol Indicator Lights lows Heat Output Light Pattern High Bindicators ON Medium High 6indicators ON Medium Low Aindicators ON Low 2indicators ON 23 MONITOR HEATING SYSTEMS Section 3 Operation FIGURE AND ITEM NO CONTROL OR INDICATOR FUNCTION Figure 3 1 Item5 TEMP Indicator Light Lights when heater is running and Digital Window is showing the temperature Figure 3 1 Item6 AM Indicator Light Figure 3 1 Item PM Ind
58. ose connectors Remarks Fuel lines must be secure and free of leaks Replace tubing when necessary All exhaust lines must be covered by a cloth insuation cover Fuel color should be crystal clear if fuel is contaminated see Cor rective Maintenance procedure paragraph 4 9 WARNING UNPLUG HEATER BEFORRE PRO CEEDING HEATER MUST ALSO BE COOL BEFORE STATING Clean heater Clean lint free cloth and a mild non abrasive household cleaning agent USE ONLY NON PETROLEUM DISTILLATE CLEANERS Wipe down exterior of heater cabi net Vacuum heater interior if necessary Clean Air Circulation Fan Monthly Vacuum blades fan cage Wipe Inspect air lines for leaks or loose connections Inspect rubber Air Hose at rear of heater Look for cracks wear or signs of deterioration replace if necessary Clean fuel constant level Valve filter Inspect fusible link Valve input fitting Clean only if necessary Varify that heater is level Clean Kerosene Refer to paragraph 4 5 Procedure is described in paragraph 4 6 Check Leveling Guide MONITOR HEATING SYSTEMS Section 4 Maintenance Activity Material Inspect Combustion Ring Flame Sensor Rod and Baffle Suggested frequency every 3 years Remarks Clean all carbon deposits Replace if excessively worn or cracked NOTE If any gaskets torn when Components are removed the gasket must be replaced
59. perfor mance of this procedure STEPI Disassembly A Using a phillips head screwdriver unscrew the screws holding the rounded diamond shaped cover plate at the bottom of the Fuel Constant Level Valve Remove the cover plate Strainer Cover T EIS ai A Strainer TT W Drain Guide Container M 40 T 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 Pull the filter straight out of the fuel reservoir B If the filter is dirty but undamaged rinse the filler 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 STEP3 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 plate C Wipe up any spilled fuel 4 6 CLEANING FUSIBLE LINK VALVE INTAKE FIT TING ON M 21 At periodic intervals the fitting on the Fusible Link Valve should be cleaned to prevent any accumula tion of foreign materials from clogging the inlet This is accomplished as follows 80
60. r jil MONITOR HEATING SVSTEMS Service Manual MONITOR 21 MONITOR 40 The information contained herein is proprietary to Monitor Products Inc shall not be disclosed duplicated nor otherwise copied in whole or part for any other purpose without express written permission of the Legal Department of Monitor Products Inc This data is issued to authorized Monitor Servicing Personnel for guidance in the installation and maintenance of the subject product and is intended for use by authorized Monitor service personnel only Further Monitor Products Inc reserves the right to make improvements and corrections and to alter apecifications of products described herein at any time without prior notice Monitor Products Inc TA amp Marlen Drive Robbinsville NJ 08691 MONITOR HEATING SYSTEMS Table of Contents EE A TOTES TI PPO STEER NEE CPS PS SES ET EL Section 1 Description ieee vein ns 1 7 1 1 Introduction 1 2 Physical Specifications 1 3 Functional Descrip tion 1 4 Description 1 5 Spill Tray 1 6 Heater Cabinet 1 7 Combus tion System 1 8 Combustion Chamber 1 9 Burner Pot 1 10 Combus tion Ring Assembly 1 11 Burner Cap 1 12 Flame Sensor 1 13 Igniter 1 14 Combustion Air System 1 15 Flue Pipe 1 16 Combustion Blower 1 17 Heat Exchanger 1 18 Air Circulation Fan 1 19 Air Pressure Switch 1 20 Fuel Delivery System 1 21 External Fuel Tank 1 22 Fusible Link Valve 1 2
61. r 4 6 Cleaning Fusible Link Valve Intake Fitting on M 21 4 7 Corrective Maintenance 4 8 Replacement of Fuses 4 9 Fuel Contamination MONITOR HEATING SYSTEMS Table of Contents Section 5 Servicing M RT sees nspas pasakun yusa 223 4545 Page 37 38 5 1 Introduction 5 2 Measurerment of Fuel Flow rate 5 3 Removal of Water Deposits and Contaminants from Fuel Constant Level Valve and Fuel Lines 5 4 Cleaning the Burn Chamber 5 5 Cleaning the Fuel Inlet Section 6 Troubleshooting CR era OE BER CAE GUE ORE GIGA IU wa ca ww SOR ocean 39 51 Resistance Values component Voltage Readings Test Point Voltage Troubleshooting Diagrams Mecanical Troubleshooting Diagrams Electrical Section 7 Electrical System Vs wi sw WA 52 54 Monitor 40 Printed Circuit Board Wiring Diagram Monitor 21 Printed Circuit Board Wiring Diagram Schematic MONITOR HEATING SYSTEMS Section 1 Description 1 1 INTRODUCTION The Monitor Heating System represents state of the art technology and although the heater is sophisticated it is simple to operate takes little time to maintain and requires minimum servicing The Monitor is a totally integrated heater consisting of a housing cabinet a combustion system air circulation system a fuel delivery system and micro computer system Redundant safety devices are included in the heater s design to protect the us
62. r iepnlaca covet Supplies only amall amount of fuel Instruct customer about titer and dua to dust or bubbles in Fuel reset jener we Switch Set temperatura Flame extends to High and Low 5 8 times Flame does not extend Failure of solenoid pump delivery parts Replace solenoid pump Nat specified Corect spacified 9 Is window Yes 1 Curtain or other obstruction covers circulati ir inlet curtain too ers circulation air inlet close to the rear of unit The Overheat Clean guard Thermostat is activated Keep curtain from unit Yes s Obstacle covers circulating air outlet Replace Fan Motor Does circula tion fan operate properly 15 Circulation Fan Guard Remove obstacle dusty Circulation fan failed Repair or replace wiring Incorrect wiring 1 sera sese Plug in AC cord if problem is found to be in PCB do not attempt to repair replace and send PCB thru your distrib utor to MPI for repair M 21 Presa the operation button switch ta position thare 5 al Yaa At plug in cord empty LED On M zT Remove the connector of operation oir cuit board from
63. r 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 osene F Repeat steps 1 3 until all contaminated fuel is drained off 4 Remove fuel feed pipe from burner pot and solenoid pump and drain fuel into pan 5 Once lines are clear reconnect fuel feed pipe turn operation switch ON and start a test run 5 4 CLEANING THE BURN CHAMBER Under normal running conditions soot will not deposit in great quantities in side the burner and a light covering of soot will not affect the performance 37 n L SEE 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 When cleaning the burner it is recommend ed to replace the gaskets cleaning is necessary use the following method 1 On the Monitor 21 A Remove louver assembly B Remove front cover Remove top cover and lead wire con nectors Remove front bracket and top bracket to cover combustion chamber Remove combustion chamber cap Remove service panel G Remove baffle from within combustion chamber H Remove
64. s 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 a Window Kit is installed in a double hung window The Window Kit can also be in stalled in a vertical sliding tylpe window Install the Window Kit in the manner outlined below STEP 1 Install Flue Pipe in Window Kit A Push the rubber seal into the Flue 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 Flue Pipe pointing UP align the screw holes on the Flue Pipe with those on the Spacer Secure with three 3 phillips head screws MONITOR HEATING SYSTEMS Section 2 Installation STEP 2 Install Window Kit in the Window IMPORTANT Prior to installation clean the win dow frame of all dust dirt and debris A Raise the lower window B 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 Slightly lift window kit frame Slide the L Adapter under the frame and position it at the 182 p point
65. stallation 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 cluding 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 addition to the space taken up by the heater interior space must also be reserved for free air circulation Remove all combustibles from the heat ing area Unless building or fire codes dictate otherwise the Monitor system can be placed on any floor surface including carpeting or other combustible material and provide safe operation 2 3 DRILLING REQUIREMENTS Through the wall Flue Pipe installation requires that a2 65mm hole be drilled through the dwelling wall 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 RECOMMEN
66. ta Replace trartnhommer Repat fuse Replace capacitar Replace resistor Replace comparator Replace Hinde Replace capacitor Replace aia Conect wiring Comect instalistion SYMPTOM RESULT cares Failure af IC CB 10 11 Change of burn High Low ia FAT 52 53 54 55 Fallura of aolanaid pump Connect rasis tor at ping and then sat temperature from Low to High Yas Failure af relay circulation fan i23 matar anie t change speed of HOS Failure of circulation Fam motor of relay 17253 38 Fedure of 5 Failure of combustion Failure of camper Failure of resistor pay a AZ dioda 221 of capacitor C10 c38 Failure of resistor Failure of capacitor Im ca Fallure of micro processes Yen of resistor MEASURE Replaces restetor Replace solenold pump Replace relay Replace circulation fan motor i B Replace relay Replace OS Replace combustion Replaca dampar salariale Replace resistor Zener diode capacitor Raplace resistor Replace capacitar Replace microproca MONITOR HEATING SYSTEM
67. tute the long stop Adjust to proper position and secure with screws and washers previously removed Before securing the stop to the window remove the protective backing and firmly stick the stop packing onto the underside of the stop NOTE Windows with deep sills may require the use of an extra intake and exhaust elbow to provide clearance for flue pipe hook up A piece of the air intake line can be cut to join the two intake elbows together Deep Window Sill One Exhaust Elbow Figure 2 5 15 Two Intake Elbows MONITOR HEATING SYSTEMS Section 2 Installation 2 11 INSTALLING AN EXTENSION KIT IMPORTANT The PVC air line is longer than the Installing an Extension Kit requires the construction exhaust line and may need to be cut of an air line and the exhaust line The air line is to size Be sure however to thor connected between the Air Supply Elbow at the rear oughly deburr all rough edges of the heater and the air inlet port on the Fiue Pipe Similarly the exhaust line is connected between the joint pipe at the rear of the heater and the exhaust port on the Flue Pipe Figure 2 6 COMPONENTS OF EXTENSION KIT ITEM DESCRIPTION ITEM DESCRIPTION w PIPE Air supply 6 PIPE CLAMP Bottom 2 JOINT Air line 7 SCREW Legs mounting 3 ELBOW 90 Air line 8 SCREW Pipe Clamp 4 LEG Wall standoff 9 BOND Adhesive 5 PIPE CLAMP Top 16 MONITOR HEATING SYSTEMS Section 2 Installation 2
68. ulimately penetrates to approx 1 38 MONITOR HEATING SYSTEMS Section 6 Troubleshooting 39 MONITOR HEATING SYSTEMS Section 6 Troubleshooting Monitor 21 40 Resistance values APPROX OHM COMPONENT M 21 40 igniter connector B B 8 127 Power Transformer Primary connector H H i 97 97 Power Transformer Secondary connector L L 824 824 Power Transformer Secondary connector M M 1 3 1 3 Damper Solenoid connector 1 1 4 600 4 600 Resistor connector G G 68 91 Circulation Fan M 40 WH 8 BK M 21 RD 8 BK 810 120 Circulation Fan M 40 WH amp GR M 21 RD amp YL mum i 365 190 Circulation Fan M 40 BL 8 BK M 21 GR amp BK mE 270 260 Circulation Fan M 40 BL amp GR M 21 GR amp YL 210 200 Combustion Blower M 40 WH amp GR M 21 BK 8 22 78 Combustion Blower M 40 GR amp OR 92 Thermistor connector Q Q at 77 F l 10 000 10 000 Fuse 2 read with fuse out 0 1 0 1 Fuse 10A read with fuse out m Solenoid Pump coil l 688 695 WARNING DISCONNECT HEATER FROM POWER SOURCE BEFORE MAKING ANY RESISTANCE TESTS 40 MONITOR HEATING SYSTEMS Section 6 Troubleshooting Monitor 21 40 Component Voltage Readings COMPONENT READING TAKEN AT l AC DC Thermistor Q on PCB Sensor disconnected 5 Thermistor Q on PCB Sensor connected 1 6 3 3 Air Pressure Switch Connector J 110 Overheat Protector Closed
69. 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 Hemove the protective backing and firmly mount it onto the underside of the outer win dow Figure 2 4 14 MONITOR HEATING SYSTEMS Section 2 Installation STEP 3 Install Window Lock A special window lock replaces the usual clam shell lock To install the window lock proceed as follows A Turn locking lever to left and disengage lock from lock bracket B Attach lock bracket to left hand side of upper window frame Use the two wood screws provided NOTE If the lock bracket prevents the lower window from sliding upward notch the bracket into the upper window frame C Slip lock into lock bracket IMPORTANT Window can be locked by turning locking lever to right to open turn locking lever to left and remove lock from bracket Two adjustable position stops are supplied to accommodate various window sash thicknes ses If short stop is too small remove two retaining screws and brackets which hold the short stop to the underside of the lock Remove the short stop and substi

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