Monitor GF3800 Building instructions

MONITOR HEATINGSYSTEMS
Table of Contents
Section 1: Description
1-1 Specifications(GF3800)
1-2 SpecialFeatures(GF3800)
1-3 Safety Features(GF3800)
1-4 Specifications (GF1800)
1-5 SpecialFeatures (GF1800)
1-6 Safety Features (GF1800)
1-7 Manual Gas Valve
1-8 Automatic Gas Valve
1-9Gas ControlValve
1-10 Burner(GF3800)
1-11Orifice(GF3800)
1-12 Burner (GF1800)
1-13 Orifice (GF1800)
1-14 IgnitionPlugUnit(GF3800)
1-15 IgnitionTransformer(GF3800)
1-16 Ignition PlugUnit(GF1800)
1-17 IgnitionTransformer (GF1800)
1-18 FlameDetector
1-19CombustionBlower(GF3800)
Page 1~12
1-20HeatExchanger
1-21 Flue Pipe
1-22 Air Circulation Fan
1-23 Air PressureSwitch
1-24 OverheatProtectorSwitch(GF3800)
1-25ThermalFuse(GF3800)
1-26 Overcurrent Fuse
1-27 ElectricalSystem
1-28 Microprocessor
1-29 TemperatureSensor
1-30 SafetyMechanisms
1-31 ClothCoveredExhaustPipe
1-32 Air Circulation Fan Guard
1-33 CombustionBlower (GF1800)
1-34 OverheatProtectorSwitch (GF1800)
1-35 ThermalFuse (GF1800)
Elements of combustionsystem(GF3800)
Elements of combustionsystem (GF1800)
Section 2: Installation
2-1 NoticeBeforeInstallation
2-2 Heaterinstallation
ApplicableWallThickness of FluePipe
2-3 FluePipeClearances
2-4 Installing an Extension Kit
2-5 Gas Connection
2-6Gas Conversion
Gas ConversionProcedure(GF3800)
Page 13~30
2-7 HighAltitudeInstallation(GF3800)
2-8 ManifoldPressureReadings(GF3800)
Gas ConversionProcedure (GF1800)
2-9 HighAltitudeInstallation (GF1800)
2-10ManifoldPressureReadings (GF1800)
Instructions for Manifold PressureAdjustments
2-11Backguard(GF3800)
2-12 Back guard (GF1800)
Section 3: Operation - Page 31~39
3-1 Introduction
3-2 OperatingSpecifications(GF3800)
3-3 OperatingSpecifications (GF1800)
3-4 OperatingControls and Indicators
3-5 Pre-operationCheckList
3-6 Operation
3-7 ManualHeaterOperation
3-8 AutomaticHeaterOperation
3-9 Programming the weekly timer
for automaticheateroperation
3-10 Heat Sensor
3-11MonitorShutdown
3-12Recoveryfrom a PowerFailure
3-13 RecoveryfromOverheatCondition
3-14 RecoveryfromBlownFuse
3-15 OperationControlsystem
GF3800/GF1800 Operation timing chart

MONITOR HEATINGSYSTEMS
Table of Contents
Section 4: Maintenance/Servicing Page 40~41
4-1 Cleaning the Cabinet 4-5 ElectricMotorMaintenance
4-2 Checking the FluePipe 4-6 Checking the BurnerFlame
4-3 Cleaning the Interior 4-7 Cleaning the Burner
4-4 Cleaning the BlowerGuard
Section 5: Troubleshooting Page 42~57
ResistanceValues (GF3800)
Component VoltageReadings(GF3800)
Resistance Values (GF1800)
Component VoltageReadings (GF1800)
Test PointVoltage(GF3800)
TestPointVoltage (GF1800)
Troubleshooting Diagrams(Mechanical)
TroubleshootingDiagrams(Electrical)
Indication of Failure mode
Section 6: ElectricalSystem Page 59~61
Schematics
Printed Circuit Board Wiring Diagram(GF3800)
Printed Circuit Board Wiring Diagram (GF1800)
SERVICEPARTS LIST- , Page 62~69
GF3800Serviceparts list
Exploded views and PartsList(GF3800)
GF1800 Serviceparts list
Explodedviews and PartsList (GF1800)

MONITORHEATINGSYSTEM
Section 1: Description I GFSSOO
1-1 SPECIFICATIONS
Model No.
Type of Appliance
InputRating
Output Rating
Electrical Rating
Power Consumption
Heated Air Delivery
'Flue PipeHole
Dimensions
Weight
Inlet Gas SupplyPressure
Manifold TestPressure
GF3800
Fan typedirect vent wallfurnace
High 38,OOOBTU/hour(Nat.), 34,500 BTU/hour(LP.)
Low 21.600BTU/hour(Nat.), 21,600 BTU/hour(LP.)
High 30,700BTU/hour(Nat.), 27,900 BTU/hour(LP.)
Low 17,500BTU/hour(Nat.), 17,500 BTU/hour(LP.)
120 V,60Hz, Less than 2 amperes
80 Watts
High 388 Cubic feet/minute
Low 300 Cubicfeet/minute
2.5 inchesdiameter
Height: 26.6inches(67.56cm)
Width: 28.7inches(72.90cm)
Depth:14.0inches(35.50cm)
82 pounds
Nat. Gas Max.10.5inchW.C.(267 mmHzO)
Min. 5.1 inchW.C.(130 mmHzO)
LP.Gas Max.13.0inchW.C.(330 mmH2O)
Min. 11.0 inchW.C.(279 mrnHsO)
Nat. Gas
LP.Gas
3.4 inchW.C.
3.15 inchW.C.
(86mmH2O)
(80mmH2O)
The minimum and maximum inlet gas supplypressure areforthe purpose of input adjustment.
1-2 SPECIAL FEATURES
AUTOMATIC IGNITION
MEMORY BACK UP:Set memory canbe kept in
case of powerfailure forupto30 minutes.
DUAL BLOWERS: Separatefans for combustion
and room air circulation.
THERMOSTATICALLY CONTROLLED:Adjusts to
the desiredroomtemperature.
BUILT-INTIMER:Heater will automatically
operate as programmed bythe user.
AUTOMATIC RESET AFTER POWER FAILURE:
Heater will automatically resume operation
after power is restored.
INDICATOR LIGHTS:Easy-to-seesignalsshow
when heater isin operation,whentimer is
activated, and when the burner is operating.
CLEAN OPERATION:Products of combustion are
vented outside.
CONSUMES NO ROOMAIR: Airfor combustion
is drawnfrom outside.
EASY INSTALLATION:Includes all partsrequired
for standard installation.
CHILD LOCK: Preventsaccidentaloperation and
prevents smallchildren from altering the controls.
1-3 SAFETYFEATURES
SAFE RE-LIGHTING:Heaterwill not restart until
its combustionchamber has cooled.
ELECTRICAL PROTECTION:Heaterautomatically
shuts offinthe unlikelyevent ofa malfunction in
the electricalcircuitry or disruption ofthe power
supply.
NO EXHAUST IN ROOM:Products of combustion
are dischargedoutdoors.
FLUE PIPE: Outside airis drawnthrough a pipe-
within-a-pipe ventingsystem.Thisprocess
preheats combustion airand regainsheatfrom
exhaust gases.
^CAUTION: ALTERNATEPOWERSOURCES
The MonitorGF3800 maynot operatewhen
powered by sourcessuch asan auxiliary
generator, UPS (Uninterrupted Power
Source), inverters, etc.
This unit maynot operate ona GFI (Ground
Fault Interrupter)power circuit.
Check withyourdealer for guidance on
specific applications.

MONITORHEATING SYSTEM
Section 1: Description IGFISOOI
1-4 SPECIFICATIONS
Model No.
Type of Appliance
Input Rating
OutputRating
Electrical Rating
Power Consumption
Heated Air Delivery
FluePipeHole
Dimensions
Weight
GF1800
Fan typedirectvent wall furnace
High 20,OOOBTU/hour(Nat.), 20,000 BTU/hour(LP.)
Low 12,600BTU/hour(Nat.)F 13,400 BTU/hour(LP.)
High 16,OOOBTU/hour(Nat.), 16,000 BTU/hour(LP.)
Low 10,200BTU/hour(Nat.), 10,900 BTU/hour(LP.)
120 V,60Hz, Less than 2 amperes
65 Watts
High 176 Cubicfeet /minute
Low 113 Cubicfeet/minute
2.5 inchesdiameter
Height:26.0inches(66.04cm)
Width: 20.9inches(53.09cm)
Depth:13.0inches(33.02cm)
55 pounds
Inlet Gas SupplyPressure
ManifoldTestPressure
Nat. Gas Max.10.5inchW.C.(267 mmHzO)
Min. 5.1 inchW.C. (130 mmHzO)
LP.Gas Max.13.0inchW.C.(330 mmH2O)
Min. 1 1 .0 inchW.C.(279 mmH2O)
Nat. Gas 3.15inchW.C. (80mmH2O)
LP.Gas 3.19 inch W.C. (SlmmHzO)
The minimum and maximuminlet gas supplypressure areforthe purpose of input adjustment.
1-5 SPECIAL FEATURES
AUTOMATIC IGNITION
MEMORY BACK UP:Set memory canbe kept in
case of powerfailure forupto30 minutes.
DUAL BLOWERS:Separate fans for combustion
and room air circulation.
THERMOSTATICALLY CONTROLLED:Adjusts to
the desiredroomtemperature.
BUILT-IN TIMER:Heater will automatically
operate as programmed bythe user.
AUTOMATIC RESET AFTER POWER FAILURE:
Heater will automaticallyresumeoperation
after power is restored.
INDICATOR LIGHTS:Easy-to-seesignalsshow
when heater isin operation, whentimer is
activated, and when the burner is operating.
CLEAN OPERATION:Products of combustion are
vented outside.
CONSUMES NO ROOMAIR: Airfor combustion
is drawnfromoutside.
EASY INSTALLATION:Includes all partsrequired
for standard installation.
CHILD LOCK: Preventsaccidentaloperation and
prevents smallchildren from altering the controls.
1-6 SAFETYFEATURES
SAFE RE-LIGHTING:Heaterwill not restartuntil
its combustionchamber has cooled.
ELECTRICAL PROTECTION:Heaterautomatically
shuts offinthe unlikelyevent ofa malfunction in
the electricalcircuitry or disruption ofthe power
supply.
NO EXHAUST IN ROOM: Products of combustion
are dischargedoutdoors.
FLUE PIPE:Outside airis drawnthrough a pipe-
within-a-pipeventingsystem.Thisprocess
preheats combustion airand regainsheat from
exhaust gases.
A CAUTION: ALTERNATE POWERSOURCES
The Monitor GF1800 maynot operatewhen
powered by sourcessuch asan auxiliary
generator, UPS (UninterruptedPower
Source), inverters,etc.
This unit maynot operate ona GFI (Ground
Fault Interrupter)power circuit.
Check withyourdealer for guidance on
specific applications.

MONITORHEATINGSYSTEM
Section 1: Description
1-7 MANUAL GAS VALVE
The Manual Gas Valve is includedwithHeater.
Connect the Manual Gas Valve togas inlet at rear
of the cabinet.
Connectionmust be checked for gas-tightness
by means of leakdetectorsolution,soap and
water, oran equivalentnonflammable solution, as
applicable.
Figure 1-1
1-8 AUTOMATIC GAS VALVE
The Automatic Gas Valve isa normallyclosed
two-stage,electro/mechanicaldevicewhich
eitherallows gasto flow tothe burner or prevents
it from doing so.
When the valve is energized, a spring-loaded
plunger is lifted to permit the flow of gas.
Removingpowerfrom the valve drops the
plungerdown into the inlet to prevent gas from
passing through.
Coil
Spring
Body
Valve
Figure 1-2
1-9GAS CONTROLVALVE
TheGas ControlValveprovidesconstant gas
pressure (volume) oftwo modes(High,Low) to
the burner.
Operation oftheGas Control Valve is controlled
by the Microprocessor.
The specifications oftheGas Control Valve are
as follows:
Type ofgas
Inlet Gas Supply
Pressure(in W.C.)
Manifold
Pressure(in W.C.)
Burn Mode
Natural
7.0
LP
11.0
GF3800
3.4 1.26 3.15 1.26
GF1800
3.15
High
1.34
Low
3.19
High
1.42
Low
Adjusting
Screw
Diaphragm -^
Body
Figure 1-3
Manifoldpressure canbe cheked by removing
brass fittingfrom endofGas Control Valve and
inserting a guagewith 1/8NPT fitting.

MONITORHEATINGSYSTEM
Section 1: Description IGFSSOOI
1-10BURNER
This burner isa Bunsentypewith a specially
structuredflameportsection,whichshapes and
positions the flame, soitcanbe wrapped bythe
secondary air flow, and burncompletely.
Secondary Air
Flame Port Section
Primary AirandGas
Mixture Burner Port assy
Flame Holder
BurnerChamber
Burner Assy
Secondary Air
Mixing Plate Orifice
1-4
1-11 ORIFICE NOTE:
The orifice is made of brass,inserted into theFor altitude applications over2,000feetrefer to
gas passage ofthe mixer, and fixed bythegas page 21.
pipe.
yfV WARNING:
Use of incorrect orifice will create a fire hazard
and damage unit.
Gas Type
Shape,Stamp
Orifice size
Natural
0
Dia 3.50mm
pi
[}
IP
D
Dia 2.64mm
r\
J
Figure 1-5

mum lun nnMi IIMVJ OTOI cm
Section 1: DescriptionlGFisoo
1-12BURNER
Thisburner isa Bunsentypewith a specially
structured flameport section, whichshapes and
positions the flame, soitcanbe wrapped bythe
secondary air flow, and burncompletely.
Secondary Air
Flame Port Section
Primary AirandGas
Mixture
Burner Port Assy
Burner Assy
MixingPlate
Burner Chamber
Secondary Air
OrificeFigure
1 -6
1-13 ORIFICE NOTE:
The orifice is made of brass,inserted into theFor altitude applications over2,000feetrefer to
gas passage ofthe mixer, and fixed bythegas page 22.
pipe.
/^WARNING:
Use of incorrect orifice will create a firehazard
and damage unit.
Gas Type
Shape, Stamp
Orifice size
Natural
h
IIS
V
Dia 2.38mm
LP
Dia 1.87mmFigure
1-7

MONITOR HEATING SYSTEM
Section 1: Description IGFSSOO
1-14 IGNITIONPLUGUNIT
The Electrode is appliedhighvoltage, and
discharges tothe Grounding Rodto ignite the
burner. The discharge gap between the Electrode
andthe Grounding Rodis 1/8"±1/32" (3.5mm±0.
8mm).
Flame Detector Rod
Electrode
Grounding Rod
1/8"±1/32"
(3.5mm ±0.8mm)
Figure 1-8
1-15IGNITIONTRANSFORMER
The Ignition transformergenerateshighvoltage
using 120VAC power,discharged bythe Ignition
plug to ignite the burner.
120VAC
Power
Terminal
*
*
r
IN
HighTensionCord
-
GroundingTerminal
Figure 1-9
/!\ WARNING:
Oo not touchwhen functioning. Highvoltage of
15 kV is generated.
6

MONITORHEATINGSYSTEM
Section 1: Description IGFISOOI
1-16IGNITIONPLUGUNIT
The Electrode is applied high voltage, and
discharges tothe Grounding Rodto ignite the
burner. The discharge gap between the Electrode
and the Grounding Rodis 1/8"±1/32" (3.5mm±0.
8mm).
Flame Detector Rod
1/8"±1/32"
(3.5mm ±0.8mm)
Electrode
Grounding Rod
1-17 IGNITION TRANSFORMER
The Ignition transformergenerates high voltage
using 120VAC power,discharged bythe Ignition
plug to ignite the burner.
Power
Terminal
i
/!\ WARNING:
Do not touch when functioning. Highvoltage of
15 kVis generated.
Figure 1-10
m
:*
i*
if*
HighTensionCord
GroundingTerminal
Figure 1-11