MONiTOR HEATING SYSTEMS

Service Manual

MONITOR422 .
MONITOR 441
MONITOR 2 2 MONITOR 41
MONITOR 21, MONITOR 40
 MONITOR HEATING SYSTEMS
Section 2: Installation

I 1X. OD cobper Tubing

NOTE: Fuel tank musr be a minimum 3 feet away from flue pipe.
 MONITOR HEATING SYSTEMS
Section 3: Operation

3-1 INTRODUCTION - Circulation Fan Output : 388 cubic feet:min.

Monitor is an easy-t~operate vented kerosene - Fuel source : Remote, separate tank
heater. Routine operation features high BTU output. - Potential heating area : 900-3200 sq. feet
automatic adjustment of room temperature, low fuel
and power consumption, and choice of automatic or 'The energy from the combustion process IS
manual heater operation. released in the form of heat and vaporized water.
This section provides all information necessary to Normally. heating systems discharge water from
operate the Monitor Heating System. All operation combustion to the atmosphere without condensing
procedures specified should be performed in the it. This 93% efficiency rating means that. assuming
order in which they are described.
the water cannot be condensed, 93% of the heat
produced by the combustion process is recovered.
Assuming the water can be condensed, the effi-
3-2OPERATING SPECIFICATIONS
The following specifications apply to the operation ciency is 87%.
of the Monitor 441 and the Monitor 422.
NOTE: Actual effective heatirig area depends upon
Monitor 441 numerous factors such as type and severii
- Rated Efficiency (as applied to kerosene of climate, type of dwelling construction,
condition of dwelling, and thickness and
heaters): 93%'
- Rated Efficiency (as applied to central heating effectiveness of dwelling insulation.
systems): 87%
- Power Consumption : as follows Table 3 1 lists Monitor 641 performance specifica-
tions at various user-selected heat output settings.
HlGH MEDlUMHlGH MWUMLOW LOW
IGNITION BUR4 BURN BURN BUFIN
340watts 65watls matts 58- 58wam

Table 3-1 HEATER PERFORNlANCE SPEUFlCATlONS

Ssthng
Specification Medium Medium
Low Low High
High
I Rating I
I
16,200 I
I
ZI,MX) 1
I
33.900 I
I
43.cm I
Heater Output/hr. I 15.000 I, 19.W I 3.500 1 40.0OO
Fuel Consum~tion(~al/hr) 0.12 0.16 ,025 0.39
&hrs/day burntime (5-gal. tank) 52days 3.9days 25daP 2.WaYs

Bhrs/day burntime (55gal.tank) 57.3days 43days ( 27.5days 2Y.Mays

Continuous-use bumtime (55-gal.tank) l9.ldays , 14.3days Q2days 72days
Bhrs/day bumtirne (275-gal-tank) 2BS.5days 214.fflays 137.5days 107.8days
Continuous-use bumtime (275-~al.tank) 955days 71.6days 45.8days 35.9days
, MONITOR HEATING SYSTEMS
Section 3: Operation

Monitor 422 - Circulation Fan Output : 176 cubic feet/min

- Rated Efficiency (as applied t o kerosene - Fuel source : 1.32 U.S. gal., separate tank
-
heater): 93%'
Rated Efficiency (asapplied to central heating - optional
Potentional heating area : 600-2000 sq. feet
system):0?%
- Power Consumption : as follows Table 3 2 lists Monitor 422 pertormance specifica-
tions at various user-selected heat output set tin^.
HIGH MEDIUMHIGH MWUMLOW LOW
lGmm BURN BlJW BUFIN BURN
51- 50watts 50watts

TaMe 3-2HEATER PERFORMANCE SPECIFICATIONS

Setting
Specification Med~urn Med~um
Low Low High
High
Rating 9,600 11,700 17,400 22,000

Heater Output/hr. 8,900 10.900 16200 20,400

Fuel Consumption (gal/hr) 0.07 0.09 0.13 0.164

Bhw/day bumtime ti32-gal. tank) 2.4days 1.Bdays 1.3days 1.OdayS

Continuous-use burntime (1.32-gaI.tank) 18.9hrs. 14.7hrs. 102hrs. 8.0hrs.
Bhrs/day bmtime (55-gal.tank) 982days 76.4days 52.9days 41.9days

Continuous-use burntime (55-gal.tank) 32.7days 25.5days I7.6days 14.Ddays

NO= Capsule tank cannot be used in Conneeticut and Massachusetls.

 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 performance as follows:

Figure 3-1,INDICATORS

11 12 13 14 15

OPERATION

21 22 23 10 17 18 19 20

FIGURE AND lTEhtl NO CONTROL OR INDICATOR FUNCTlON

Figure 34,hem1 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
Figure 3-1, hem2 AUTO Indicator Light Lights when heater runs in automatic mode.
AUTO, RUN, and appropriate BURNER STA-
TUS Indicators are illuminated simuttaneously
if heater is burnina.
Figure 31, Item3 ECONOMY PLUS Lights when heater runs in Economy Plus
Indicator Light mode.
Figure 3-1, hem4 Empty Indicator Light In case af using the cartridge tank,when the
fuel is empty, EMPlY Indicator Light blinks.
This LigM is not provided with Monitor 441.
Figure 3-1. Item5 BURNER STATUS Light in accordance with heat output as fd-
indicator Lights lows:
H B a t w Light Pattern
High Bindicators-ON
Medium High 6indicato+ON
Medium Low 4indic.N
Low Zndicators-ON
MONITOR HEATING SYSTEMS
Section 3: Operation

FIGURE AND ITEM NO CONTROLOR INDICATOR

- - -
Figure 3-1, ttem6 TEMP-Indicator Light
Figure 3-1,Item7 AM Indicator Light
Figure 3-1. kern8 PM Indicator Light
Figure 3-1, hem9 Digital Display
Figure 3-2, Item10 TIMER SELECTOR
push-button switch
Figure 3-2. Item11 CLOCK SET
Indicator Light
FUNCTION
Lights when heater is running and ~ i ~ i & l
Window is showing the temperature.
Indicates SET and ROOM temperature when
heater is running, and indicates time when
heater is Off. .
Indicates time and temperature for automatlc
operation setting.
The automatic function allows the program-
ming of different temperatures for different
times of the day. Two, three or four settlngs
can be used.
Allows programming of current time when
illuminated.

NOTE: Prior to programming current time,

Digital Display shows 88:88.
IMPOKTAKT: Oncs c m t time has been
pmgrarnmed, press the SET
p t s h b b n switch within 60
#cond6.0themise do& db-
p b y will mvsnt to previously
progtammed time, If any.
Figure 3-2.Item72 1st Indicator LgM Allows programming of first automatic time
and temperature selection when illuminated.
When programmed, heater automatically oper-
ates at specified time and temperature 0.e. 6:
00 am., 70'F), if set for AUTO, providing that
heat81 has been .set for automatic mode of
operation.
TiME TEMP,HOWUP), MINEDOWN) and
SET push-button switches are used to prp
gram first operated time and temperature.
IMPORTAKI. Onca time and temperature
have bssn prograramsd, the
SET p u s M d b n mwttch must
be pres8ed with in %seeon&
Ohemisel time and tempera
ta will rWMt to pmviwsty
programmed time, Iany.
When this Light illuminates, 1st presently prct
grammed time and temperature displayed.

Figure 32,ttem73 2nd Indicator Light Allows programming of second automatic

time and temperature selection when illumi-
nated.
 MONITOR HEATING SYSTEMS
Section 3: Operation
- -~
FIGURE AND IEhA NO CONTROL OR INDICATOR
-- - - -
Figure 3-2, ttemi4 3rd Indicator Light
Figure 32,ttem15 4th Indicator Light
Figure 3-2,Item16 TIME push-button
switch
Figure 3-2,Item17 TEMP push-button
switch
figure 32,Item18 HOUR/UP,
MINUTE/DOWN . NOTE: Each time push-button switch is
repetitiveaction
push-button switch
Figure 3-2.Item19 SET push-button switch
figure 32,Item20 CLEAR push-button switch
ON/OFF push-button
Figure 3-2,kern21
switch
FUNCTION
-
Programs 3rd automatic heater operation as
same as 1st Indicator Light.
Programs 4th automatic heater operation as
same as 1st Indicator Light.
This switch is used to set time and change
display over.
This switch is used set temperature and
change display over, in 2 degree increments.
Programs time or temperature.
pressed, the digit advances in incre-
ments of one digit, If push-button is
pressed and held, the digits are
advanced repetitively.
'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 programmedtime and/
w tempemre.
Erases any programmed time and temperature.
When cleared, time and/or temperature previ-
ously pmgrammed and displayed disappear@)
frwn window.
IMPORTANT: Both current time and auto-
matically programmed
tims(s), tampamture(r) will
have to be reprogrammed tf
.kcblal operation is inter-
rupted by power failure or by
dbcocmecting heater plug
fmm wall outlst beyond 5
mkurbss nthh otarrs, the
h t o r will go brto MANUAL
mode of opemtion and main-
tahrr#wntwnpsmtureacwfd-
ing to ttm setting bmperature
you've #leded by using the
Jide sdector for the rseet
tempemmatthekwarrigtlt
hand Jde ot ths cabinet
ON position (push-button is 'in')applies power
to the unit. When this occurs, the RUN indica-
tor lights to indicate that heater operation has
begun.
OFF position (push-button is 'our) remove
power fmm the heater. All circubexwpt for
Clock and Air Row -are shut down.
MONITOR HEATfNG SYSTEMS
Section 3: Operation
RGURE AND IT34 NO CONTROL OR INDICATOR
Figure 3-2,Item22 AUTO push-button
switch
Figwe 3-2,item23 , ECONOMY P U S
push-button switch
3 4 PRE-OPERATIONCHECK UST
After heater installation. but prior to Monitor 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:
Check that the Monitor heater is plugged into
wall outlet
(I20 Vac, 60 Hz)
Verify that adequate supply of kerosene is
available in fuel tank
Confirm that fuel is free of water M Other
contaminants
Check fuel tank for good operating condition; it
must be free of rust, conosion, 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 dweliing, check area immediately
around Flue Pipe for combustibles or obstntc-
tions to.free air circulation
Inspect Air Line for cracks, loose connections
or blockage
Check Exhaust Line for cracks, toose ComaC-
tions or blockage
~t rear of hater, verifythat air flaw to tk Air
Circulation Fan is not blocked
FUNCTiON
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, AUfO indicator goes out
and then heater will operate in MANUAL
mode. During rrianual operation, the user turns
heater ON and OR, at will.
When AVTO is disengaged, the unit will
operate om .a manual.temperature determined
by the AUTO setting for that time of day.
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.
NOTE: Economy Plus mode is accepted only
in the MANUAL mode.
Inspect dwelling interior and confirm that imme-
diate area near heater is free of combustible
and obtects that might interfere with free air
flow.
.r Make certain that Heat Sensor is not exposed
to drafts, direct sunlight, nor direct heat from
the Monitor.
.I Confirm that heater is level
If 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.3-6through 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's performance.
 MONITOR HEATING' SYSTEMS
Section 3: Operation
3-6MANUAL HEATER OPERATION
Operation of the heater is under the direct control of
the user (heater will 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 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. If priming is unnecessary skip to
step 2.
m. Prime the Heater '
Gently press and release the Fuel Constant Level
Valve Reset Lever four or five times.
STEPZ: Select Manual Operation
If heater operation is in AUTO mode, press the
AUTO push-button switch and change Auto to
Manual made.
STEP3: Select Temperature Setting
Press the TEMP push-button switch and press
either the UP or DOWN push-button switch to set
me digital set room temperature indicator to the
desired temperature, and then press the SET push-
button switch.
IMPORTAW. In case no temperature is mat, tsm-
perature will automatically k n t at
the wtting temperature nlect.d by
using lhe slide selectot for the m8et
temperature.
-4: Turn Monitor On
Press me 0N:OFF push button switch to position
ON. The RUN indicator light illuminates to indicate
that power has been applied to the instrument and
tte heater is cycled for manual mode of operation.
IbSlRCTlONS FOR ECONOMY PUlS MODE
To engage the economy plus mode. simply press
down !he button labeled -nomy P'rrs's to
disengage press again.
NOTE: Operation switch must be 'OW end in
MANUAL mode.
This feature minimizes the 'ON ' and ' O f f cycling
of the unit by allowing it to overshoot the set
temperature by 12 degrees instead of the n m l
4 degrees.
The advantages of this feature are to increase the'
overall efficiency ofthe 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
control engaged (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
senlngs 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.
STEPI: Program Clock for C u m ! Time
A Press the nMER SELECTOR push-button
switch,at which time the CLOCK SET indicator
light will illuminate.
8. Press HOUR push-bunon switch to program
current hour on the Clock.
IMPORTANR Be wre to set clock tor AM or PM,
as appIopMld
NOTE Both hour and minute digits on Display
Window are advanced in in-mments of one
by pressing the a~pro~riate push-button
switch one time for each digit; digits can
also be advanced repetitively by pressing
and holdlng the appropriate push-button
swim.
C. Press MINUTE push-button switch to program
the cunent minutets) on .Clock
D. immediately after programming cunent time in
t e r n of hours and minutes, press the SET
push-button switch.
STEP2: Program the lst Time Temperature
A Pressing the TIMER SELECTOR push-button
switch will illuminate the 1st indicator light
8. n m pust-+bunon switct~.
MONITOR HEATING SYSTEMS
Section 3: Operation
C. Press HOUR and MINUTE push-button
switches to program 1st desired time.
IMPORTAKT: Be sure to set the dock AM or PM,
as appropriate.
Immediately after programming the 1st desired
D.
time. press the SET push-button switch. This
step must be completed within fifteen seconds
after programming the time.
E, Press TEMPpush-button switch.
F, Press UP and for DOWN push-button switch(es)
to program 1st desired temperature.
G, Immediately after programming the 1st desired
temperature. Pressthe 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 SELECSTOR push-button
switch again, the 2nd Indicator Light will illuminate,
at which time the 2nd setting can be programmed.
Press again to set 3rd and again to set 4th.
IMPORTAHT: The SET push-button swnch must be
pressed attar each setting b lock
into memory.
Should heater power be interruptad
by a power failure or by disconnsction
of h e power owd beyond 5 minutes,
heater roveris to MANUAL operation,
and all AVTO programming ts e d the Display Window.
STEP4: Salad Automatic Operation
Press AUTO push-button switch. The AUTO in-
dicator light will illuminate.
-5: Turn Monitor ON
Press ON/- push-button switch to position ON.
The RUN indicator light will illuminate to indicate
that power has been.applied to the heater.
F m this point, heater operation is as follow exam-
ple.
34 REPROGRAMMHG THE MONerOR HEATER
On occasion. it m y be ne-ry to rf3PrOgm the
Monitor.
Remagramming is pertwmed as specified belaw:
S m : Reprogramming Current Time
(ifnecessary)
A. .Press the TIMER SELECTOR push-button
switch to illuminate the CLOCK SET indicator
light
8, 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: If SET push-button switch is not
pressed, wrrent 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. (Ist,
2nd, 3rd, or 4th)
8. Press TIME push-button switch.
C. Press CLEAR push-button switch. Time dis-
played on window will disappear.
D, Using HOUR and MINUTE push-button
switches program new desired time by watch-
ing the Display Window.
E, Press SET push-button switch.
F, Press TEMP push-button switch.
G, Press CLEAR push-button switch. Set Temper-
ature displayed on Window will disappear.
H, Using UP and DOWN push-button switches
program new desired temperature by watching
I. Press SET pusbbutton switch.
3-9 HEAT SENSOR
Heat Sensor islocated on the rear of the cabinet. It
is recommended to leave the aensor in its original
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
w m air f m the heater. Loosen the screw and
release the sensor from the mar of the cabinet
Fasten the sensor to Zhe wall with the screw.
3-10 MONITOR SHVrOOWN
A simple one-step procedure Q utilized shutdown
the Monitor.
Press ON/OFF push-button switch to position OFF,
the RUN indicator will extinpuish.
-ANT: Orrcs h a t e r has shut down, It an-
not bs rsrtarted until poa-putge ey-
da has been canpletd. If ONIOFF
switch is k R in posttion ON, Monttor
ommtiar will automatically resbrt
m-pie- m-
p ur
g a.
 MONITOR HEATING' SYSTEMS
Section 3: Operation
3-TI ,OUT OF N E L , Install the tank with the arrow pointing forward, and
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).
m.Tum Heater OFF
Press ON/OR switch to O R .
STEP2: . Flll Fuel Tank
A, Close shut-off valve at outlet of ~ u eTank.
l
5. Drain Fuel Tank (from battom; 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!OFF switch to ON. Proceed 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 E M P N indicator light illuminates
and flashes, a buaer will sound for twenty
seconds. The burner mode is changed to 'Low"
automatically, and Men, the heater will shut off
after 30 minutes.
The remaining burning time is indicated at the
Display Window.
Refueling:
STEPk 1urn Heater OFF
Press ONfOFF switch and wait 15 minutes for the
heater to tool.
STEP2. Utt Out the Capsuk Fuel Tank
--
Open the tank carer and lift out the capsule fuel
tank
Turn the tank upside down. and remove the fuel
. -2:
Fill the Capsule Fod Tank
Fill the capsule fuel tank with fresh, c-1 clear
kerosene by using a siphon.
-4: M&I tht hpwk Fuel tank
Replace and tighten the fuel caD.To insure proper
fuel flaw, be sure the cap is secured
close the tank cover.
STEPS: Turn.Heater ON
Press ON O f f switch to ON. Proceed with normal
heater operation.
342 RECOVERY FROM A POWER FAILURE
For the power intemption of up to 5 minutes, the
set memory is- kept and will resume operation
automatically with the set memory.
For power intemptions beyond 5 minutes, heater
will resume operation (after a 3 minutes cool down
period) in the MANUAL mode and maintain room
temperature according to the setting temperature
selected by ustng 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 illuminate the CLOCK SET indicator light, the
Display Wlndow will show 88:88 indicating the
need to reset the clock and re-program the heater
for automatic aperation.
REMAM In wrkr to dispby mmt temperature,
It .hould be wt before tfie heater is
plugged h and energized.
New rewt tsmpemtaire selected after
plugged kn will take effect only after a
powsr-
3-13 RECOVERY FROM OVERHEAT
The Monitor is protected against damage resulting
from an ovetrtteat condition by two 110'C (Monitor
422).nsc (Monitor441) automatic reset tfmnostats.
h the event of an overneat the thennostats are
triggered to cut off the flow of kerosene to. the
B u m Pat. the flame is extinguished automatically,
a user is alerted to Fhe condition by
blinkin0 of the Bumer Status indicatws.
To recover from an overheat condition. as
diin@d below:
STEPI: Turn OFF Heater
Allow Monitor H d e r to cod
NOTE: Bewrettmtheaterbscodtotwch.
A period of 30 to 6minutes should be sufficient to
permit heater to cool completely.
unplug mbr
Disconnect heater power cad from wall outlet
Section 3: Operation

m P 4 : Cheek tor Cause of Overheating STER Turn Monitor OFF

NOTE: Overheating is usually caused by objects STEP2 Unplug h a t e r

that impede tree air circulation. STEP3: Remove louver assembly

-4: Remove front cover

Look for debris and other obstructions a t front of
heater, at Circulation Fan a t rear of the heater, and
at Flue Pipe tip ourside dwelling.
STEPS: Remove Louver h m M y
m. ~ l & n eater bierior
NOTE As the ~ k n Cover
t of the Monitor 441 is
connected-to the Printed Circuit Board by
Lead Wires, pljll the Front Cover to the front
side slightly and remove the Connector of
the Lead Wires from the Printed Circuit
Board, and then, remove the Front Cover.

STEP^ Locate and replace W s )

STEP6: Reattach front cover

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
(In case of the Monitor 49% be sure that
'
the connector is wnnactsd to the printed
circuit board)
STEP7: Reattad louver assarnbiy
STEPB: Plug heater power w r d into wall outlet

-
from exterior of cabinet, including exterior of Com-
bustion Chamber and Heat Exchanger. m.Tum M m b r ON
M ReplacsLouver Aswmbiy STEPlO: Reprogram heater

STEP& Reeonnee! Monitor Heater P w e r Plug to mmm

Aut#natic opemtion cycb
the Wail O'WL appliabi8)
STEP9 Turn Heater ON
S E P l 2 .SdectAutomatic operation (if appii
STEPIO: Reprogram Heater Microprochswr -1
m.Sdsct Mode of operation

C A m I atter the camplolion of maww

pmcmdura, tht heater overheats
again, something hi wrong !
Do not operate heater Mtil Plob-
km has been diagnosed and cor
rectsd

3-W RECOVERY RlOM BLOWN NSE

All elechical components of the Monitor heater are
protected against pawer overloads and electrical
matfundions by two 2-p fuses and a lGamp
fuse. Should fuse blow, the ~BCWW Drocedm is
outlined below:
 M-422 OPERATION TIMING CHART

OPERATION SW

SENSOR SW

I ( ROOM TEMP

SET TEMP .-
/

FLAME I
I

PHOTO TRIAC.
PHOTO COUPLER

L E D INDICATOR

I l l
i b ' I BUZZER -
 MONITOR HEATING SYSTEM:S
Section 4: Maintenance
,....._

4-1 INTRODUCTION cally in arder to sustain the efficiency of the Monit01

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 maltunction.
4-2 PERIODIC MAINTENANCE
The Maintenance Schedule provided in Table 4-1
describes the tasks that must be pertormed periodi·
Heating Systems.
At the time of the demonstration or installation,
heater maintenance should be discussed with the
user; emphastze that a clean heater and proper fuel
are the keys to opt1mum heater operation· and
performance.

Table 4-1 SUGGESTED MAINTENANCE ACnvrrtES

Activity Material Re marks

Check ail fuel pipes for leaks and
loose connections
lnspect exhaust piping tor leaks or
loose connections
Check fuel for water and/or ether
contamination.
If the capsule tank is used on the
Monitor 422 the capsule tank filter
should be checkecl, cleaned or
replaced, as weil as the constant
levet valve strainer.
lnspect Fuel Pipe for obstruction
lnspect electrical wiring for
cracks, signs of deterioration, bare
wires and;or loose connectors
Clean heater
Clean Air Circulation Fan (Monthly)
lnspect airpiping tor leaks or loose
connections.
lnspec:t rubber Air Hose at rear of
heater.
Clean fuel constant leve! Valve
filter. lnspect fusible link Valve
input fltting.
_,
Clean only if necessary. Verity that
heater is leve!.
lnspect flue _pipe for obstruction
or corrosion.
3/S" OD copper tubing
Clean, lint-free elath and a mild
non-abrasive household cleaning
agent. USE ONL Y NON-
PETROLEUM DISTILLAïE
CLEANERS.
Clean Kerosene
35
Fuel piping must be secure and
tree of leaks; Replace tubing
when necessary.
Ali exhaust pipes must be covered
by a elath insulation caver.
If cloth cover shows signs of
discoloration at joints, check
o-rings.
Fuel color should be crystal clear.
if fuel is contaminated, see Cor-
rective Maintenance procedure,
paragraph 4-9,
WA'RNING:
UNPLUG HEATER BEFORE PRO-
CEEOING. HEATER MUST ALSO
BE COOL BEFORE SiARTING.
Wipe down exterior of heater cabi-
net. Vacuum heater interior (if
necessary).
Vacuum fan cage. Wipe tan
blades.
Look for cracks, wear, or signs of
deterioration; replace if necessary.
Reter to paragraph 4-5. Procedure
is described in paragraph 4-6.
Check Leveling Guide.
tf blocked, clean and vacuum.
tf corroded badly, replace.
MONITOR HEATING SYSTEMS
Section 4: Maintenance

Activity Mate rial Re marks

lnspect Combustion Ring, Flame Clean ali carbon deposits. Replace

Sensor Red, Baffle, and Burner if excessively wom, warped, or
Cloth.(Suggested frequency every cracked.
3 years). NOTE: If any gaskets are tom
when Components are
removed, the gasket must
be replaced.
Clean Combustion Chamber (every Vacuum ali carbon deposits from
3 years) interior of chamber.

lnspect air holes in Sumer Pot
Clean lgniter
Check air piping that interconnect
Combustion Blower and Air Pres-
sure Switch.
Check for cartlon build up in fuel
inlet going into bum chamber (every
year)
4-3 INSPECT EXHAUST1AIR PIPING
Verity that ali exhaust and air pipes are free of leaks
and loose connections, as specified below:
STEPl: Remove Protective Cloth
Remove cloth insulation cover(s) from ali exhaust
pipes.
STEP2: Inspection of Exhaust/Air Piping
A. Visually inspect beth air and exhaust piping tor
obvious cracks, leaks, or .loose connections.
Black carbon deposits may be evidence of
these leaks, and' o-rings may need to be
replaced.
8. Be sure that ali pipes are installed tightly and 36
Use a smal!, stitf brush or a short
length of soft copper wire to clean
any blocked heles.
The M422 may need air holes
reamed with a torchtip cleaner if
partially black on a 5 tc 7 year
basis.
Scrape any carbon deposits from
igniter.·
Replace air piping that is wom.
broken or brittle.
Disconnect copper fuel piping from
bum chamber and clear fuel inlet
tine by reaming with a solid pieœ of
wire(such as copper,bailing wire,or
coat hanger) which should be able
to go in approximately 3" without
obstruction.
NOTE: Removing anti retightening
bumer fuel connection
must be done when the
burner cools down com-
pletely. If it is done when
the bumer is hot. the weld-
ing on the fuel joint may
break. Fixing targue for
nut;30-40kg • cm(26
-35lb•in)
securely, especially at joints.
C. Tum heater ON.
O. Carefully apply a small amount of soapy water
(with a paint brush) to the surface areas of the
air/exhaust piping.
Any leaks that may exist will be readily
identified by the appearance. of bubbtes.
STEP3: Retum to Operating Condition
A. Tum heater OFF.
B. Dry ali pipes with paper towels.
C. Repair any leaks that have been tound (if
necessary, replace the tubing).
0. Replace elath insulation covers.
 MONITOR HEATING SYSTEMS
Section 4: Maintenance

4-4 VERIFY JGNITER OPERATION

Visually inspect tgniter Operation WARNING

CLOSE FUSIBLE UNK VALVE ON M422 OR CLOSE

WARNING: SHLIT.OFF VALVE OF THE EXTERNAL FUEL TANK
ON M-441 TO AVOlD ORAINING ALL FUEL FROM
HEATER IS OPERATIONAL DURING THIS INSPEC· TANKS.
TION. AVOlD DIRECT CONTACT wtTH ANY
NOTE: Power should be OFF during the perfor·
HEATED OR ELECTRICAL COMPONENT.
mance l?f this procedure.
STEP1: Prepare· for Inspection
STEP1: Oisassembly
Remove Louver Assembly.
A. Using a phillips head screwdriver. unscrew the
STEP2: Visual Inspection screws holding the rounded diamond·shaped

s:
A Turn heater ON.
Look (downward) ttlrough window on the Corn~
bustionChamber. 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 tc diagnose the problem.
C. An altemate inspection is to fee! the igniter
caver atter the unit has been in the ignition
stage tor about 5 minutes. lt should be warm.
CAlJTION: If igniter is broken,do not operate the
·oN 10FF" switch button repeatedly.
STEP3: Reassembly of Heater
Tum the heater OFF and replace the Louver Assem·
bly.
4-5 CLEAN FUEL CONSTANT LEVEL VALVE FIL·
TER
Contaminants are trapped by the filter tc prevent
them from clogging the Fuel Constant Leve! Valve.
The filter, itself has a great number of small pores.
Whenever a filter is tom or disfigured ·(enlarged
pores), it should immediately be replaced.
lnspect and clean the filter as indicated by the
procedure below:
caver plate at the bottom of the Fuel Constant
Levet 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. Caretully remove the rubber gasket which is
located behind the covPr plate.
STEP2: Inspection and Cleaning
A. Pull the filter straight out of the fuel reservoir.
8, If the filter is dirty (but undamaged), rinse the
filter in fresh, clean kerosene tc remove ali
particles. Replace damaged filters.
C, To drain off upper portion of fuel constant leve!
valve, back out phillips head screw which is
located slightly above and tc the lett of filter
cover plate. (See Fig4-1)
O. If upper portion drain is dirty or containing
water. then remove pump and inspect and
clean its screen.
STEP3: Reassembly
A. Push the (new or cleaned) filter back into the
bottom of the fuel reservoir.
8. Replace both the. rubber gasket and the cover
plate. (Take . care to properly align the screw
heles in the gasket and cover plate).
C. Wipe up any spilled fuel.

--:-?
==--d
StTainer ----.;~·d"• ....,
SIJainer
eo-r :___==~-~<· . Strainer
1
Stra•ner
Caver

~~~~J~
/ .. ._.

Drain: Guide ~lainer

Orain GuidecOntainer
M-441 M-422

Figure 4-1 CLEAN FUEL CONSTANT L..=YEL VALVE

37
MONITOR HEATING SYSTEMS
Section 4: Maintenance
4-6 CLEANING NSIBLE UNK VALVE INTAKE FIS-
TING ON M422
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:
UNPLUG THE HEATER. POWER TO THE HEATER
SHOULD BE OFF DURING THE PERFORMANCEOF
THIS PROCEDURE.
STEP(: Close off Fuel Supply
A. Shut off fuel at the Storage Tank or remove fuel
from the fuel sump tank with siphon and syrlnge
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 any spilled fuel.
STEP2: Clean Valve
A. Loosen hex nut on Fusible Link Valve inlet
fittlng at rear of me heater. Disconnect the
copper tub~ngwhich 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 tub~ngto the intake
fitting and tlghten the hex nut.
B. Turn ON fuel at Fusible Link Valve and at
storage tank or fuel sump tank.
C. Check for leaks.
4-7 CORRECTIVE MAINTENANCE
The two procedures below are remed~esfor very
generalized types of operating difficult~es.
4-8 REPLACEMEM OF N S E S
A short circuit or s~milarelectrical malfunction could
cause the fuse to blow. Troubleshoot the cause of
the blown fuse.
Replace the fuse as follows:
DO NOT REPUCE N S E WHILE POWER 8 ON.
STEP(: Removal of Fuse
A. Unplug heater. Remove LOWer Assembly and
Front Cover.
8. Remove the fuse from fuseholder on the Printed
Circuit Board.
I 38
STEPP: Installation of New Fuse
A, Install a new fuse into the fuseholder. The fuse
must be a 2WV, 2 amp or a 250-V, 10 amp type
as marked on the printed circuit board.
Do not use oversized fuses.
8. Reptace 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.
srammed when Dower 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
me 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:
BEFORE PROCEEDING FURTHER, UNPLUG THE
HEATER
STEPI: Remove Contarninetion
A, Shut O f f the fuel supply at the storage tank or
at the Fusible Link Valve.
B. Drain off the contaminants from the fuel storage
tank or the fuel sump tank(M-422). Fill with
fresh, clean fuel.
SIEP2: Clsan the
A. Clean fuel constant level valve filter and filter
compartment.
B. Remove the Louver Assembly and Solenold
Bump on the constant level valve. Clean the
Solenoid Pump filter.
SIEP3: Reinstall Cleaned Components
A. Rep1ace the cmmnts coKect'y and lnstall
new gasket.
B. Turn on the fuel at the storage tank and at the
fusible llnk valve, and apply power to the heater.
If problem still exists and contammated fuel IS
suspected it can be checked by
A. Shutting off the fuel supply at the storage tank
and at the fusible llnk valve.
B. Drain off fuel at constant level valve.
C. Dcconnect fuel ltne at back of heater and hook
up a 5 gallon qu~cktank w ~ t hwoven good fuel.
D. Test run heater to see if problem clears up wrth
use of new fuel.
-qQ+++
 MONITOR HEATING SYSTEMS
Section Servicing
5-1 INTRODUCTlON
Sewicing 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 UNES
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).
2. Ifusing separate tank on the Monitor 422 shut
of! fusible link valve. On the Monitor 441 shut
off valve of separate tank.
3. Bend a 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.
8, With strainer cover removed, inspect, clean
and/or replace strainer if damaged.
C. Remove drain port screw and drain.
D. Replace strainer, cover and screw.
E. Open fusible link valve or shut-off valve to
refill system with fresh crystal clear ker-
osene.
F, Repeat steps 1-3 until all COntami~tedfuel
is drained off.
4. Remove fuel feed pipe from bumer 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.
NOTE: Remwing and retightening bumer fuel
connection must be done when a bumer
cools down completely. If it is done when a
bumer is hot. the welding on the fuel joint
may break. Fixing Torque for nut30
.
-40kg crn(26-351b.in).
5 4 CLEANING THE BURN CHAMBER & BURNER
POT
Under normal running conditions, soot will not
deposit in great quantities inside the burner, and a
light covering of soot will not affect the performance
of the unit thus it.need not be cleaned. However, if
heavy soat built up does occur the unit should be
opened and cleaned.
The bumer is assembled using gaskets to maintain
its air tightness. If these gaskets leak. the extra alr
can cause a serious soot problem and or exhaust
gases to escape into the area being heated.
NOTE: If any gaskets are tom when commnents
are removed, replace. Disconnect power
supply to unit.
If cleaning is necessary, use the following method
1. On the Monitor 422
A. Remove lower assembly.
8. 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.
I. 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 bumer pot to
the bum chamber. Pull the bumer pot up and
out.
2. On the Monitor 441
A. Remove louver assembly.
8. Remove front cover and wire connecto~.
C. Remove top cover.
D. Remove heat shield that covers combustion
chamber.
E. Remwe service panel.
F. Remove Fbame detector rod.
For a more thorough cleaning, use the same
procedure as for the W22 above.
MONITOR HEATING SYSTEMS
Section 5: Servicing

3. Turn counter-clockwise to remove combustion

ring. If ring does not turn, pull 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. If tar is present on the bumer bottom, remove
the tar by using a flat-bladed screw driver or
wire brush.then clean the area by using a 1 Nozzle Collar )I
vacuum cleaner etc.
NOTE: Make sure all air inlet openings are clear.
6. When cleaning the inside of me bumer pot,
remove the igniter and change the burner cloth Figure 5-3 Rgure 5 4
by the following procebure. C. Apply glue at all 4 corners of Burner Cloth
as Shown in Figure 5-5.
7. On the Monitor 422 Awroa. 318
A. Apply glue(P/Na&lT) on the burner bottom
as shown in Figure5-1.

u
Figure 5-1
B. Put the burner cloth on the burner bottom,
afterwards press and straighten out the
burner cloth so that it is glued flat and even NOTE: The Burner Cloth is not symmetrical in

1 [jy-'m
on the burner bottom. shape, therefore make sure to place it in
8. On the Monitor 44l the correct position so that the wider side
A. Apply glue arround the burner cloth as of the cloth is at lett side of the lgniter
shown in Figure 5-2. Shield as shown in Figure 5 5 .

9. Combustion ring may deform and deteriorate

I
after several years we and should be cleaned
and inspected before reinstallation. If combus-

Oue
b
\
.--___..' tion ring is warped, has cracked or is detenorat-
ing excessively it should be replaced.
10. When reassembling the unit check that com-
*OePl 'Is- Ftgure 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
Burner Cloth narrow between the Nozzle s c r e w s ( ~ 2 2or
) pins(Ni-441) inside the bumer
Collar and the Igniter Shield, then push the Pot.
Bumer Cloth, using your fingers or a screw 11. Reassemble by reversing the procedure foll-
driver, so that it slips in under the Naule owed during disassembly.
Collar. Afrerwards press and straighten out
the Bumer cloth so that it is glued fiat and NOTE: Use of the economy plus feature can
even on the Burner battom. minimize service calls and extend corn-
ponent life.
NOTE: in some m e s , pulling out the Fuel Nozzle
and Collar may make this procedure easier.
An easy out can be inserted into nozzle to
hetp break loose and remove it.
40
 MONITOR HEATlNG SYSTEMS
Section 5: Servicing

NOTE: Make sure the position of flame detector rod is centered between combustion ring and bumer pot
before reassernbiing.(See Figure 5-6)

Flame Detector Rod

I
Combustion Ring Assy
\
Combustion
Chamber

Gap
M-441: 4mm (0.16) or more
M-422:3mm (0.12') or more
Burner II 11 '

Pot

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
When cleaning the combustion chamber and the
bumer pot, the fuel inlet nozzle should also be
cleaned. This can be done as follows:
1, Disconnect copper fuel line at bum chamber.
2, Push a piece of wire (about the same size as
the I.D. of fuel inlet pipe) into the fuel inlet
nozzle.
3, If obstruction is felt twist wire back and forth (to
brake up soot and carbon) so that wire ulti-
mately penetrates igniter shield.
On M422, also check air holes surrounding
fuel inlet for blockage and clear if necessary.
 MONITOR HEATING SYSTEMS
Section 6: Troubleshooting

Monitor 422/441 Resistance values

APPROX. OHMS
COMPONENT M-422 M a 1
Igniter (connector B/B) 16.8 12.7
Power Transformer - Primary (AC 120V) 125 125
-
Power Transformer Secondary (AC 12V) 1.6 1.6
-
Power Transformer Secondary (AC 120V) M7 647
Damper Solenoid (connector 1/1) 4.600 4.600
Resistor (connector G/G) 63 W
Circulation Fan (M-422:RD 8 BK, M41:WH 8 BK) 235 115
Circulation Fan (M-422:BK B Y L M-441:BK & EL) 247.5 258.5
Combustion Blower (M-422:BK 8 BK, M-M1:WH B GR) 22 78
Combustion Blower(M41:GR B OR) - 92
Thermistor (connector O/Q, at 7 7 F) 10,000 10.000
Fuse 2A (read with fuse out) 0.1 0.1
Fuse 10A (read with fuse out) 0.01 0.01
Solenoid Pump (coil) 565 565

MSCONNECT HEATER FROM POWER SOURCE

BEFORE MAKING ANY RESSTANCE VESTS.
 MONITOR HEATING SYSTEMS
Section 6: Troubleshooting

Monitor 22 41 Resistance values

APPROX. OHMS
COMPONENT M-22 M-41
Igniter (connector B B) 16.8 12.7
Power Transformer - Prirnav (connector H ti) 97 97
--
Power Tracsformer - Secondav (connector L L) 824 824

Power Transformer - Secondary (connector M M) 1.3 1.3

Damper Solenoid (connector I I) 4,600 3.600
Resistor [connector G G) 68 91
Circulation Fan (M-41:WH & BK, M-22:RD & BK) 310 120
- - -

Fan (M-41:WH & GR, M-22:RD 8 YL)

C~rculat~on 365 190

Fan (M-41:BL & BK. M-22:GR & BK)

C~rculat~on 270 ' 260

C~rculationFan (M-41:BL & GR. M-22:GR & YL) 210 200

- - - - -

Combustion Blower (M-41:WH S GR. M-22:BK & BKI 22 78

Combustion Blower (M-41:GR 8 OR) - 92

Thermistor (connector Q Q, at 77 Fj 10.000 10,000

Fuse 2A (read with fuss out) 0.1 0.1
- - -

Fuse I D A (read w ~ t hfuse out) 0 .O1 0.01

Solenoid Pump ( c o ~ l ) 688 695

DISCONNECT HEATER FROM POWER SOURCE

BEFORE MAKING ANY RESISTANCE TESTS.
MONITOR HEATING SYSTEMS
Section 6:Troubleshooting

Monitor 4221441 Component Voltage Readings

COMPONENT READING TAKEN AT AC DC
Thermistor Q on PCB Sensor disconnected 5
-- -

Thermistor Q on PCB Sensor connected 1.53.2

Air Pressure Switch,' Connector J 110
Overheat Protector Closed
Air Pressure Switch,' Connector J 0
Overheat Protector Open
Damper Solenold I on PCB 105
Solenoid Pump K on PCB pulse'
C~rculat~on
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
l
Igniter B on PCB 110
Power Transformer AC 120V 110
(primary side)
Power Transformer AC 120V 120
(secondary s~de) AC 12V 12
Combustion Blower F on PCB 110 I

High Speed
Combust~onBlower F on PCB 921M-422)
Low Speed (Ql is Off) ~~(~-441)
Res~stor G on PCB 1WM-422)
22(M41)
*Pulse can only be measured with a hlgh impedance d~gltalvolt meter.
MONITOR HEATING SYSTEMS
Section 6: Troubleshooting

Monitor 22 ,'41Component Voltage Readings

COMPONENT READING TAKEN AT AC DC
Thermistor 0 on PCB Sensor disconnec:ic 5
Thermistor 0 on PCB Sensor connect& 1 .E-2.3
Air Pressure Switch Connector J 110
Overheat Protector Closed
Air Pressure Switch Connector J 0
Overheat Prctector Ooen
Damper Solenoid l on PCB 105
- -

Solencld Pump K on PCB 105

C~rculationFan H ~ g hSpeed GFi to BK BK to RD lM-21) 110
BL to BK BK to WH (M-4C1 110
C~rculatlonFan Low Speed YL to RD GR to YL IM-21) 110
GR to WH BL to GR IM-40) 110
lgn~ter B on PCB 110
Power Transformer H on PCB 110
(primary side)
Power Transformer Connector L 120
(secondary side) Connector M 11
Combost~onBlower F on PCB 110
High Soeed
Comcust~onBlower F on PCB P2fFvl-221
Low Soeed (RL3 is OFF) 88(M-41)
Resistcr G on PCB 18tM-22)
221 M -311
 TEST POINT VOLTAGE

Pre-purge lgnillng Pre-burning 1 Prebumlng 2

Mode Preparallon (C.F.M:Low)
Pre-heal low med 2 mln. (C.F.M:W

TP 2 5 V i 10% 5V f 10% 5V f 10% 5 V f 10Yo 5V f 10%

TP 3 12V If:30% 12V f 30% 12V f 30% 12V f 30% 12V f 30%

TP 4 1.5-3 2V 1.5-3 2V 1.5-3.2V 1.5-3.2V 1.5-3.2v

TP 5 pulse pulse pulse pulse pulse

lnflnitly
TP 6 ov ov variable 1.2V mifl. 1.2V min.
pulse at 5v
TP 7 plugin 5V 5V 5W

Waillng unlil
~igh Medium-High Medium-Low Low OFF Posl-purge pragrammed Lime
comes on'
TP 2 5V f 10% 5V k 10% 5 V f 10% 5V f 10% 5 V f 10% 5W f 10% 5V f 1 0 1
TP 3 12V f 30% 12V f 30% 12V f 30% 12V f 30% 12V f 30% 12Vf 30°/o 12V f 30%
TP 4 1.5 -3.2V 1.5-3.2V 1.5-3.2V 1.5 - 3.2V 1.5-3.2V 1.5-3.2V 1.5- 3.2V
TP 5 pulse pulse pulse pulse pulse pulse pulse
lnfinitly
TP 6 1.2V min. 1.2V min. 1.2V min. 1.2V min. OV variable OW
TP 7 5V 5V 5V 5V 5V 5V 5V
 MONITOR HEATING SYSTEMS
Section 6: Troubleshooting

2
2
/
-0
0 -.
2 ,
-W +W +Q +Q +Q + Q + '
,
m - m m n o '

, Q
'
5n i5'i
/ (Pa

4
d
ul rd
U l c r . < <-
c
1 . g 2 a g .
? 5 --

d $
0 ; s n
L "b < ~
E , ._ < <
0 5
c I3 . I C q q f
5 -- ce,
J

d - 5
2 2 E
w d

c 93 . 1 c -a q- ,L
-
. 5P
 MONITOR HEATING SYSTEMS
Section 6: Troubleshooting

lNDlCATlON OF FAILURE MODE

- ----- - - - -
Digital Display The Reason of Indication Trouble Point

/ / / / At pre-purge, Flame rod is sensing flame Flame senslng clrcult grounded

C L/ / when there should be none. flame rod or p~nchedwlre

After power on, power supply to the micro- Timer clock circuit bad or power
1 1 1
7 r/ processer timing circuit is incorrect. source to unlt above or below
L L/ - .
acceptable levels.

At starting of operation; the circuit to drive Solenoid Pump control circuit

- I/ /- Relay RL6 of Solenoid Pump is mal- has a malfunction.

functioning.

: r
- I
1 When unit is shut off either manually or Driving circuit of RL6 or excess

:
I-
,'-
'- 1
' I-
I
'-
j automatically, flame rod does not detect fuel in burner pot.
I
' flame out within 300 seconds.
NOSW3t.i
cpalarrol pue passer 1aro1 l a s anten p r o 1 l u e l s u q l a n j c e ~
.uwo arler rue1 .yuet UI Ian1 s(
cPaddols ue j uotceInan9 sen
'ES BB srror(s moputr*
l e l d s # a ~(uolldnnalul
dallno llev ul pauasul
ramod a ~ getaql
e u Bnld o dsl
r a ~ re"
 REASON
1 I CORRECTIVE MEASURE

able 10 change

mrpln(lC121.

Failw 01 TR anay
llcM

ctmmct lmn ,*sir

la a1 O pins. and
Ma. ul t s m r r l u r a
llDn Lar Io Hbh.
R e o l ~ Sdolsrmd
s punD
I
1s circulal~anIan
malot able to
change w e d 7

I
Failua 01 citmlalfim
Ian mla
W a c s cidahon
Isr mta.
I

Fdlua a( phrro mac

Fail- PI biec

-
-
Failw ol mnbrnlim
blm:
- I
Max crrrhaum
blaa I
Fsilus d resirta la
9 -1irn~m-a.

- Failua 01 darpa
sdemid.
M a c a daroer
Jdemid I

Failua ol camcitr,
Icill. I
Failua ol mi-
 REASON

I t mas nK.9
than t 3Vdc .I
rPs 7
R e ~ l a c nIranrlmma,
I

F a lalN puporn 6 fh-FUME ROO B Y P A S ClRCUll

&l.cla md b w u ckcuil
~ can k mods
w
02Yh u lau
.I OT.

Failme ol diode
lDIW
1
M. caairtinp d 2 hwblsd 8lip.m clip¶. 2-0- ~ i n c 04 ~ sinaubled
S
- I-114- wm ua w t ~d i d . and 1-114- wan ~ m OHM k rssbla.
fhacrmp~mnbmm(ob.~dlopm~hreguenc*u.homh

-
d'wmb o k Iml* crmponM S U I ud ~ po)uWl.
(lum h a m ctcuil b mn& Ih. unit ij
bmsd 4 h m d i t d y nnm )Ir p.prg. p . h s a ~w l s ; *hen mod. liiht
q Ihd 0 D tl Hma dimowclod OH Ih. PCB and rspbced
with Um c b m Th mil lhould I h n cmlinw tunclkminp u

n- --
Failua ol * i t i t q l
a
d(pard.
Cored win-
I
Cored imQIbMn
1
 I REASON
1 CORRECTIVE MEASURE

Is window
curlain loo
Curlain or other obslruclion
covers clrculalion air Inlel.
- Cleen guard.

close to Ihe
rear of unil?
I
I Keep curtain ltom unit.
C

Is Circulelion . Obalecfe covers clrculelln~ Remove obstacle.

Fan Guard air oullet.
dusly7 properly7 h

Failure ol P.C.6 Replace or check P.C B

Circulalion Ian leilad. - Replace Fan Molor.

Repair or replace wiring.

 CONNECTION OF LEAD WIRES
TIMEfEMP SET
nrlI3
OPERATION TIMER SELECTOR
OODOO
n
TIMED
TEMP D
Panel Printed Wiring board

ECmDMY BURNER STANS fEMP Sm R O N

RUN AUTO PLUS
D i n

Lamp Pr~ntedWiring Board

Main Printed
Wiring Board

Pressure
Switch Semor (Thermistor)

Over lieat
Thermostat

Slide Switch
Solenoid Valve

+ Ground

Power
Blower for ma
Combustion
Blower for Fan
Resistor Clrculat~on Juncl~onBox
Thermostat

figure 7-1 MonitorU

MONITOR HEATiNG SYSTEMS
Section 7:Electrical System
Printed Circuit Wiring Diagram

CONNECTION OF LEAD WIRES

r1, , ,,,-h ,
OPERATION TIMER SELECTOR
=ODD,
D
TIMED
TEMP0
Panel Printed Wiring Board
TIMWtMP SEl
11

RUN A ECONOMY
D EMPTY BURNER STATUS TEMP SET
~ PLUS
m 0"

Lamp Rlnted Wong Board

Main Printed
Wiring Board Empty ~ a G pSwttch
(Float Sw~tch)

Pressure
Swrtch Sensor (Thermistor)

Over Heat
Thennostat I

TI4 Sllde Switch

Solenold Valve

+
'
F J
Ground

Power
Blower for Cord
Combustlon
Blarver for F=,
Resistor ~ l ~ u l a t l ~ n Thermostat Junctton fiox

figure 7-2 Monitw422

LoLo Med 1.5 - 2.0 mmM2o Fan La Speed Damper C

Med Hi 3.2 - 3.6 mmM2o Fan Lo Speed Damper 0

Hi 3.8 - 4.2 m d H 2 0 Fan Hi Speed Damper 0

LoLo Med 2.5 - 3.4 mmA32.o Fan Lo Speed Damper C

Med Hi 5.8 - 6.4 mmM2o Fan Lo Speed Damper 0

Hi 6.8 - 7.4 d o F a n = Speed Damper 0

Note: These Readings a r e to be taken after the heater has fully warmed up.
(Approximately 5 xni-~~u&s orrHkfi~e.)The damper adjustment can only be
done on Low or Low-Med Ranges.
 MONITOR 441
SERVICE PARTS LIST

MONITOR 441 SERVICE PARTS LISP

E M PART
NO. NO. DESCRIPTION ITEM
NO. PART
NO. OESCRlPnON
1 W 0 SPILL TRAY 55 6204 PHOTO COUPLER IC12
LEG POWER TRANSFORMER
AIR SUPPLY HOSE (A) AIR LINE
AIR SUPPLY HOSE (3) AIR PRESSURE SWITCH
CONSTANT LEVEL VALVE RUBBER BUSH
C.LV. STRAINER OVER HEAT THERMOSTAT
STRAlNNER GASKET FAN THERMOSTAT
FUEL PlPE CORD CONNECTOR
SOLENOID PUMP JUNCTION BOX COVER
GASKET fl) POWER SUPPLY CORD
BURNER CORD BUSHING
BURNER CLOTH LEVEL GUIDE
ROPE GASKET CARRYING HANDLE
HEATER SENSOR A S Y
GASKET (3) SUDE SWITCH ASSY
IGNITER BRACKET SUDE SWITCH COVER
HEATER COVER PACKING SLIDE SWITCH PANEL
IGNITER COVER SLIDE SWITCH KNOB
FLAME DETECTIVE PLUG JOINT PlPE
PLUG PACKING AIR DAMPER (E) '
FL PLUG BRACKET AIR DAMPER (S)
GASKET (4) AIR SUPPLY HOSE ASSY
HEAT EXCHANGER ASSY EXHAUST OUTLET CAP
GASKET (6) AIR PORT 0 RING
EXHAUST DUCT PlPE HOLDER
M l N G (P39) HOSE BAND
OIL SUMP PlPE AIR OUTLET CAP
JOINT SEAL PACKING FLUE PlPE A S Y
FUEL NOZZLE SLEEVE FLANGE SET
RIEL NOZZLE COVER FAN
BASE TRAY RETAINER CIRCULATION MOTOR
WINDOW GASKET BLOWER GUARD
WINDOW FRAME GASKET WRING GUARD
WINDOW GLASS UNDER COVER
WINDOW BASE GASKET LOWER
CHAMBER GASKET CONTROL COVER
COMBUSTION CHAMBER mom COVER
COMBUSTION RING ASSY LAMP PANEL
CHAMBER CAP SWITCH & LAMP ASSY
CONDENSEA (2.5 MFD) TOP COVER
BLOWER ASSY RESISTOR
DAMPER SOLENOID ASSY CABINET ASSY
SUCTION CASE A ASSY WALL CLAMPS
SEAL WCKING SCREW SET FOR FLUE PlPE
MOTER FOR COMBUSTION CARTON BOX
PWB ASSY CUSHION SET
PWB SPACER CLIP (A) OWNERS GUIDE
PWB SPACER CUP (B) TOUCH-UP PAINT (WHITE)
M~CROPROCESSOR GLUE
BUZZER TOUCH-UP WINT (GREY)
FUSE (250V 10A)
FUSE (250V 2A)
CAWCITOR (7.5 cl FD)
TR ARRAY (M54563P)IC4
 MONITOR 422
SERVICE PARTS LIST

MONITOR 422 SERVICE PARTS LfST

ITEM PART ITEM PAKT
NO. NO. DESCRIPTION NO. NO. DESCRIPTION
1 6200 SPILL TRAY 6273 OVER HEAT THERMOSTAT
2 5019 LEG FAN THERMOSTAT
3 61 01 AIR SUPPLY HOSE (A) AIR PACKING SET
4 6102 AIR SUPPLY HOSE (8) POWER SUPPLY CORD
5 6103 FUEL PIPE CORD BUSHING
6 6104 FUSIBLE VALVE LEVEL GUIDE
7 6105 CONSTANT LEVEL VALVE CARRYING HANDLE
8 6106 C.L.V. STRAINER SENSOR ASSY
9 6 1 89 STRAINER GASKET SLIDE SWITCH ASSY
10 6108 SOLENOID PUMP PACKING SLIDE SWITCH COVER
11 6250 SOLENOID PUMP SLIDE SWITCH PANEL
12 61 10 OIL SUMP PIPE SLIDE SWITCH KNOB
13 6164 JOINT SEAL PACKING BLOWER ASSY
14 61 11 FUEL SUMP BLOWER MOUTH PACKING
15 6 1 12 GASKET (1) DAMPER SOLENOID ASSY
16 6182 BURNER SUCTION CASE
17 6 1 13 BURNER CLOTH SEAL PACKING
18 6114 GASKET(2) BLOWER GUARD
19 6 1 15 GASKET (3) ClRCULATiON MOTOR
20 6277 HEATER FAN BLADE
21 6195 IGNITER BRACKET WIRING GUARD '
22 61 17 HEATER COVER PACKING WIRING HARNESS FOR FAN MOTER
23 6 19 1 I G N E R COVER JOINT PlPE
24 6 1 18 FLAME DETECTlVE PLUG AIR DAMPER (S)
25 , 6 1 19 PLUG PACKING AIR SUPPLY HOSE ASSY
26 6196 FL PLUG BRACKET EXHAUST OUTLET CAP
27 6120 GASKET (4) AIR PORT 0 RING
28 6 12 1 HEAT EXCHANGER ASSY PlPE HOLDER
29 6 122 GASKET (6) HOSE BAND
30 6 123 EXHAUST DUCT AIR OUTLET CAP
31 6 176 O-RING (P39) FLUE PlPE ASSY
32 6124 WINDOW GASKET SLEEVE FLANGE SET
33 6125 WINDOW FRAME GASKET UNDER COVER
34 6068 WINDOW PLATE L O W
35 6069 WINDOW GLASS FRONT COVER
36 6 126 WINDOW BASE GASKET SWITCH & LAMP ASSY
37 6127 COMBUSTION CHAMBER ASSY TOP COVER
38 6 181 COMBUSTION RING ASSY LAMP PANEL
39 6 128 BURNER CAP FUEL TANK COVER
40 6 129 BAFFLE ASSY FUEL TANK ASSY
41 61 90 CHAMBER GASKET FUEL TANK CAP
42 6131 CHAMBER CAP FLOAT SWITCH
43 6251 POWER TRANSFORMER FLOAT SWITCH PACKING
4d 6252 PWB ASSY OIL FILTER
45 61 34 PWB SPACER CLlP (A) RESISTOR
46 6 135 PWB SPACER CLlP (8) CABINET ASSY
47 6253 MICROPROCESSOR UNION NUT
48 6203 BUZZER WALL CLAMPS
49 6172 FUSE (250V 10A) BASE TRAY RETAINER
50 6 173 FUSE (250V 2A) SCREW SET FOR FLUE PlPE
51 6256 CAPACITOR (1 cr FD) CARTON BOX
52 6 187 TR ARRAY (M54563P) IC4 CUSHION SET
53 6204 PHOTO COUPLER IC12 OWNERS GLllDE
54 6 137 CORD CONNECTOR TOUCH-UP PAINT (WHITE)
55 6 1 07 AIR LINE GLUE
56 61 84 AIR PRESSURE M C H TOUCH-UP PAINT (GRP()
n 6 1 36 RUBBER BUSH FUEL NOZZLE
 MONITOR 41
SERVICE PARTS LlST

MONITOR 41 SERVICE PARTS LlST

ITEM PART ITEM PART
NO. NO.
DESCRIPTION NO. NO.
DESCRIPTION
1 6400 SPILL TRAY 55 6340 CAPACITOR (1.8 pFD)
5019 LEG 6187 TR ARRAY (M54563P)IC3
6301 AIR SUPPLY HOSE (A) 6204 PHOTO COUPLER(IC9--11)
6302 AIR SUPPLY HOSE (B) 6132 POWER TRANSFOPMER
6303 CONSTANT LEVEL VALVE 6326 AIR LINE
6304 C.L.V.STRAINER 6343 AIR PRESSURE SW
6344 STRAINER GASKET 6136 RUBBER BUSH
6305 FUEL PlPE 6327 OVER HEAT THERMOSTAT
6306 SOLENOID PUMP 6152 FAN THERMOSTAT
6357 GASKET (1) 6137 CORD CONNECTOR
6401 BURNER 6032 JUNCTION BOX COVER
6363 BURNER CLOTH 6139 POWER SUPPLY CORD
6358 ROPE GASKET 4833 CORD BUSHING
631 1 HEATER 6037 LEVEL GUIDE
61 1 5 GASKET (3) 6138 CARRYING HANDLE
6402 IGNITER BRACKET 6186 SENSOR ASSY
6354 HEATER COVER PACKING 6205 SLIDE SWITCH ASSY
6403 IGNITER COVER 6206 SLIDE SWITCH COVER
6355 FLAME DETECTIVE PLUG 6207 SLIDE SWITCH PANEL
61 19 PLUG PACKING 6208 SLIDE SWlTCH KNOB
6196 FL PLUG BRACKET 4004 JOINT PlPE
6313 GASKET (4) 6407 AIR DAMPER (E)
6314 HEAT EXCHANGER ASSY 6408 AIR DAMPER (S)
6122 GASKET (6) 6145 AIR SUPPLY HOSE ASSY
6123 EXHAUST DUCT 4014 EXHAUST OUTLET CAP
6176 O-RING (P39) 4016 AIR PORT 0 RING
6315 OIL SUMP PlPE 4006 PlPE HOLDER
6164 JOINT SEAL PACKING 4008 HOSE BAND
6352 FUEL NOZZLE 4805 AIR OUTLET CAP
6353 FUEL NOZZLE COVER 6147 FLUE PlPE ASSY
6404 BASE TRAY RETAINER 6148 SLEEVE FLANGE SET
6124 WINDOW GASKET 6075 FAN
6125 WINDOW FRAME GASKET 6330 CIRCULATION MOTOR
6405 WINDOW GLASS 6331 BLOWER GUARD
6350 WINDOW BASE GASKET 6347 WIRING GUARD
6317 CHAMBER GASKET 6332 UNDER COVER
6349 COMBUSTION CHAMBER 6409 LOUVER
6356 COMBUSTION RlNG ASSY 6410 CONTROL COVER
6321 CHAMBER GAP 6411 FRONT COVER
6322 CONDENSER (2.5 pFD) 6412 LAMP PANEL
6323 BLOWER ASSY 6154 SWITCH ASSY
6406 DAMPER SOLENOID ASSY 6155 LAMP ASSY
6324 SUCTION CASE A ASSY 6337 TOP COVER
6144 SEAL PACKING 6338 RESISTOR
6348 MOTOR FOR COMBUSTION 6413 CABINET ASSY
6362 PWB ASSY 6345 UNION NUT
6134 PWB SPACER CLIP (A) 6194 WALL CLAMPS
6135 PWB SPACER CLIP (B) 6197 SCREW SET FOR FLUE PlPE
6202 MICROPROCESSOR 6414 CARTON BOX
6168 RELAY (A) 6342 CUSHION SET
6169 RELAY (B) 1148 OWNERS GUIDE
6203 BUZZER 8216 TOUCH-UP PAINT(WH1TE)
6172 FUSE (250V 10A) 8217 GLUE
6173 FUSE (250V 2A) 8279 TOUCH-UP PAINT(GREY)
 MONITOR 22
SERVICE PARTS LlST

MONITOR 22 SERVICE PARTS LlST

ITEM PART ITEM PART
NO. NO. DESCRIPTION NO. NO. DESCRIPTION
1 6200 SPILL TRAY 59 6136 RUBBER BUSH
2 LEG 6151 OVER HEAT THERMOSTAT
3 AIR SUPPLY HOSE (A) 6152 FAN THERMOSTAT
4 AIR SUPPLY HOSE (8) 6163 AIR PACKING SET
5 FUEL PlPE 6139 POWER SUPPLY CORD
6 FUSIBLE VALVE 4833 CORD BUSHING
7 CONSTANT LEVEL VALVE 6037 LEVEL GUIDE
8 C.LV.STRAINER 6138 CARRYING HANDLE
9 STRAINER GASKET 6186 SENSOR ASSY
10 SOLENOID PUMP PACKING 6205 SLIDE SWITCH ASSY
11 SOLENOID PUMP 6206 SLIDE SWITCH COVER
12 OIL SUMP PlPE 6207 SLIDE SWITCH PANEL
13 JOINT SEAL PACKING 6208 SLIDE SWITCH KNOB
14 FUEL SUMP 6140 BLOWER ASSY
15 GASKET (1) 6141 BLOWER MOUTH PACKING
16 BURNER 6142 DAMPER SOLENOID ASSY
17 BURNERCLOTH 6143 SUCTION CASE
18 GASKET (2) 6144 SEAL PACKING
19 GASKET (3) 6160 BLOWER GUARD
20 HEATER 6161 ClRCLlLATlON MOTOR
21 IGNITER BRACKET 6180 FAN BLADE
22 HEATER COVER PACKING 6192 WIRING GUARD
23 IGNITER COVER 6193 WIRING HARNESS(FAN MOTOR)
24 FLAME DETECTIVE PLUG 4004 JOINT PlPE
25 PLUG PACKING 6209 AIR DAMPER (S)
26 FL PLUG BRACKET 6145 AIR SUPPLY HOSE ASSY
27 GASKET (4) 4014 EXHAUST OUTLET CAP
28 HEAT EXCHANGER ASSY 4016 AIR PORT 0 RlNG
GASKET (6) 4006 PlPE HOLDER
EXHAUST DUCT 4008 HOSE BAND
O-RING (P39) 4805 AIR OUTLET CAP
WINDOW GASKET 6147 FLUE PlPE ASSY
WINDOW FRAME GASKET 6148 SLEEVE FLANGE SET
WINDOW PLATE 6149 UNDER COVER
WINDOW GLASS 6210 LOUVER
WINDOW BASE GASKET 6211 FRONT COVER
COMBUSTION CHAMBER 6154 SWITCH ASSY
COMBUSTION RING ASSY 6155 LAMP ASSY
BURNER CAP 6156 TOP COVER
BAFFLE ASSY 6212 LAMP PANEL
CHAMBER GASKET 6158 FUEL TANK COVER
CHAMBER CAP . 6159 FUEL TANK ASSY
POWER TRANSFORMER 6179 FUEL TANK CAP
PWB ASSY 6165 FLOAT SWITCH
PWB SPACER CLlP (A) 6178 FLOAT SWITCH PACKING
PWB SPACER CLlP (B) 6177 OIL FILTER
MICROPROCESSOR 6162 RESISTOR
RELAY (A) 6213 CABINET ASSY
RELAY (B) 6345 UNION NUT
BUZZER 6194 WALL CLAMPS
FUSE (250V 10A) 6214 BASE TRAY RETAINER
FUSE (250V 2A) 6197 SCREW SET FOR FLUE PlPE
CAPACITOR (1.5,~FD) 6215 CARTON BOX
TR ARRAY (M54563P)IC3 6175 CUSHION SET
PHOTO COUPLER(IC9--11) 1148 OWNERS GUIDE
CORD CONNERCTOR 8216 TOUCH-UP PAINT(WHITE)
AIR LINE 8217 GLUE
AIR PRESSURE SWITCH 8219 TOUCH-UP PAINT(GREY)