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MAINTENANCE
PART 8. MAINTENANCE
A. MAINTENANCE PROCEDURES
Periodic maintenance should be performed once a year by a qualified service technician to assure
that all the equipment is in safe efficient operation. The owner can make necessary arrangements
with a qualified heating contractor for periodic maintenance of the heater. Installer must also inform
the owner that the lack of proper care and maintenance of the heater may result in a hazardous con-
dition. The installer should discuss the contents of the User's Information Manual with the owner.
B. BEFORE EACH HEATING SEASON:
A trained and qualified service technician should perform the inspections listed below at least once
a year.
• Heater – check the heater for dust or foreign materials, which may have been drawn in from the
air intake of the heater. Simply blow out or wipe down with a dry rag.
• Vent Termination – check to remove any obstructions, such as leaves, bushes, or other
sources which may interfere with the units ability to draw fresh air on the air intake or exhaust
flue gas from the exhaust outlet.
• Vent Piping – make sure that all vent piping is in good condition. Check Joints for possible leaks.
• Condensate – check the Condensate trap by simply starting the unit and observing the flow of
Condensate which should not be restricted in any fashion. (See instructions below.)
• Heat Exchanger – in the unlikely event the heater flue passage is becoming blocked, service
must be performed only by an authorized Heat Transfer Products Representative or Certified
Installing Contractor. (See coil cleaning instructions Section D)
• Burner – check burner for deterioration. If deterioration is observed, replace burner.
• System Water / Pressure – check pressure regulator and system pressure. Check system for
air which will create noise. Open air vents or purge system to bleed air then close once air is fully
purged from the system.
• Water Piping – check for and repair any leaks.
• Gas Piping – check for and repair any leaks.
C. CONDENSATE CLEANING INSTRUCTIONS
1. Turn down the thermostat so the Munchkin will not cycle and then follow the steps below.
a. Close gas valve
b. Disconnect the poly hose from the combustion blower motor
c. Disconnect the condensate hose from the outside connection (not from the Munchkin) so
flow can be observed.
d. Block the air flow in the exhaust by temporarily plugging the exhaust from the outside vent.
e. Disconnect the white, red, blue, and black connection from the Molex on the combustion
blower. (Refer to Control Wiring Layout fig. 8-1 this section.) This will cause the fan to run at
100%, which will then blow out any sediment that has accumulated in the condensate line.
(This process should only take a few minutes.)
f. The unit should now be ready to re-start.
2. Before re
-starting the Munchkin follow the steps below:
a. Reconnect the Molex connection and un-block the vent (IMPORTANT: MAKE SURE
EXHAUST VENT IS NO LONGER BLOCKED!)
b. Open the gas valve and turn up the thermostats
c. Observe the boiler function to make sure you see a condensate flow.
d. If you do not observe a condensate flow, repeat the above procedure.
3. If the problem is not corrected at this point, it is possible you have a material deposit problem,
in which case, a qualified plumber will need to be contacted to follow the Combustion Chamber Coil
Cleaning Instructions (Section D) included in this section to dissolve deposit and clean condensate
line.