Combination Boiler and/ or Water Heater * I N S TALLAT I O N AN D MAI N T E NAN C E * M A N U A L NOTICE Warranty Registration Card must be filled out by the customer and mailed within thirty (30) days of installation in order to gain warranty coverage. When receiving the CHALLENGER, any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee. Leave all documentation received with appliance with owner for future reference.
Table of Contents PRODUCT AND SAFETY INFORMATION Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Product and Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 SECTION I - PRE-INSTALLATION ITEMS Code Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Determining Product Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents Circulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Sizing Primary Piping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 System Piping - Zone Circulators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 System Piping - Zone Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Near Boiler Piping Diagrams . . . . . . . . . . . . . . . . . . .
Table of Contents SECTION VIII - INTERNAL WIRING General Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 CHALLENGER Factory Wiring Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . 34 SECTION IX - EXTERNAL WIRING Installation Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Line Voltage Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents Operation Verification - Domestic Hot Water . . . . . . . . . . . . . . . . . . . . . . . 47-48 Control Display Appliance ON/OFF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Additional DHW Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Highfire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents Check System Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Clean Condensate Drain Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 62 Check Ventilation Air Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Inspect Vent and Combustion Air Piping . . . . . . . . . . . . . . . . . . . . . 62 Check Boiler System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Product & Safety Information Definitions The following terms are used throughout this manual to bring attention to the presence of potential hazards or important information concerning the product. DANGER NOTICE Indicates the presence of a hazardous situation which, if ignored, will result in death, serious injury or substantial property damage. Indicates special instructions on installation, operation or maintenance, which are important to equipment but not related to personal injury hazards.
Product & Safety Information DANGER WARNING Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system which has been under water. Should overheating occur or the gas supply fails to shut off, turn OFF the manual gas control valve external to the appliance. WARNING WARNING DO NOT add cold make up water when the appliance is hot.
Product & Safety Information DANGER DANGER Bacteria can develop in the domestic water system if certain minimum water temperatures are not maintained.
Pre-Installation Items SECTION I - Pre-Installation Items - Code Compliance NOTICE The CHALLENGER is certified to both the Boiler (ANSI Z21.13/CSA 4.9) and Water Heater (ANSI Z21.10.3/CSA4.3) standards. The CHALLENGER gas manifold and gas controls meet the safe lighting and other performance requirements as specified in ANSI Z21.13 standard.
Pre-Installation Items Boiler or Water Heater Replacement NOTICE If the CHALLENGER is replacing an existing boiler and/or hot water heater system, the following items should be checked and corrected prior to installation: - Boiler and domestic piping leaks and corrosion. - Proper location and sizing of the expansion tank on the boiler heating loop. Proper location and sizing of the thermal expansion tank (if used) on the domestic supply line. - If applicable, amount and quality of propylene glycol.
Pre-Installation Items Boiler Freeze Protection Feature CAUTION The boiler control has a freeze protection feature. This feature monitors the boiler supply water temperature and responds as follows when no call for heat is present: - 42ºF [6ºC] Boiler circulator and burner are ON. - 50ºF [10ºC] Boiler circulator and burner are OFF. The boiler freeze protection feature is designed to protect the boiler, installed in a primary/secondary piping arrangement.
Combustion Air and Venting SECTION II- Combustion Air and Venting Potential contaminating products Combustion Air Contamination WARNING If the CHALLENGER combustion air inlet is located in any area likely to cause or contain contamination, or if products, which could contaminate the air cannot be removed, the combustion air must be repiped and terminated to another location.
Combustion Air and Venting Ventilation Air Requirements Combustion Air and Vent Piping For installations, involving only the CHALLENGER, in which the minimum service clearances are maintained as listed on page 5, no ventilation openings are required. The CHALLENGER requires a Category IV venting system, which is designed for pressurized venting and condensate. The CHALLENGER is certified as Direct Vent (sealed combustion) appliance.
Combustion Air and Venting Removal of an Existing Boiler and or Water Heater from a Common Vent System 5. Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle, or smoke from a cigarette, cigar or pipe. BEST PRACTICE 6.
Combustion Air and Venting Commonwealth of Massachusetts Installations Only For direct-vent appliances, mechanicalvent heating appliances or domestic hot water equipment, where the bottom of the vent terminal and the air intake is installed below four feet above grade the following requirements must be satisfied: 4. A metal or plastic identification plate shall be mounted at the exterior of the building, four feet directly above the location of vent terminal.
Appliance Preparations SECTION III - Appliance Preparations Wall Mounting Installation Shipping and Handling Instructions NOTICE Prior to mounting appliance install piping support bracket according to instructions on page 13. WARNING To avoid damage to gas fitting and piping at bottom of appliance, appliance must be shipped with rear or back of appliance (longest box length) laying down flat.
Appliance Preparations Wall Mounting Guidelines stud centers and ensuring the upper edge of the bracket is away from the wall. 1. The wall-mounting bracket is designed for stud spacing of 12 inch [30.5 cm] or 16 inch [40.6 cm] on centers. For unconventional stud spacing, a solid / secure mounting surface must be provided for installation of the bracket. 3. Level the bracket, while maintaining it’s centering with the studs and use a pencil to mark the location of the mounting slots/holes. 4.
Appliance Preparations Wall Anchors (Solid Wall Only) BEST PRACTICE Apply pipe joint compound suitable for potable water systems to the compression ferrule and compression nut threads of all brass fittings before installation. Install appliance pipes into the fittings until bottom of hex on gas pipe fitting rests against the top of the piping support bracket before tightening any compression nuts. Do not over tighten compression nuts. If fitting leaks loosen compression nut first and then retighten.
Boiler Piping SECTION IV - Boiler Piping above any drain connection to allow clear visibility of the discharge. General Piping Requirements - Support all piping using hangers. DO NOT support piping by the appliance or its components. Should terminate with a plain end, not with a threaded end. The material of the piping should have a serviceable temperature rating of 250ºF [121ºC] or greater. - Should not be subject to conditions where freezing could occur.
Boiler Piping Pressure Relief Valve (Supplied with Boiler) 3/4" Street Elbow Manual Air Vent (Supplied with Boiler) Drain Piping Directed to a Suitable Place of Drainage Boiler Supply Connection with Tee Fitting and Temperature/ Pressure Gauge Boiler Return Connection with Tee Fitting and Boiler Drain Valve Fig.
Boiler Piping Additional Limit Control Boiler System Piping Applications If a Low Water Cut Off (LWCO) is required by certain local jurisdictions or when the boiler is installed above the system piping, the following guidelines must be followed: - The LWCO must be designed for water installations, electrode probe-type is recommended. - The LWCO must be installed in a tee connection on the boiler supply piping above the appliance.
Boiler Piping Closed-Type Expansion Tank System Piping - Zone Circulators It is recommended to pitch any horizontal piping upwards toward the expansion tank 1 inch per 5 feet [2.5cm / 1.5 M] of piping. Use 3/4” piping to the expansion tank to allow air within the system to rise. Connect the CHALLENGER to the system piping as shown in Fig. 7 page 20 when zoning with zone circulators. The installer must provide a separate circulator for each zone of space heating.
Boiler Piping System Return System Supply 2 12" Max. [30.5 cm] 6 1 3 Cold Water Fill 6 4 6 7 10 11 5 Boiler Supply Boiler Return Fig. 5: Near Boiler Piping - Diaphragm Expansion Tank 9 System Supply 8 4 6 Minimum 3/4" Piping 1 Cold Water Fill 6 System Return 12" Max. [30.5 cm] 6 10 3 11 Boiler Supply Boiler Return Fig. 6 : Near Boiler Piping - Closed Type Expansion Tank 1. 2. 3. 4. 5. 6.
Boiler Piping System Piping - Radiant Heating NOTICE The heat exchanger design of the CHALLENGER allows operation in a condensing mode. This feature requires no regulation of the return water temperature back to the boiler in radiant heating applications. The boiler system piping must be a “closed” system to avoid any oxygen contamination and potential failure of the outer tank of the SMART. The CHALLENGER’s domestic piping should not be utilized.
Boiler Piping 4 3 5 4 3 5 3 Additional Zone Load 3 Zone Load or SMART I.F.W.H. 9 4 4 12" Max. [30.5 cm] 4 4 6 7 8 4 1 11 10 2 6 Fig. 7: Central Heating (CH) System Piping - Zoning with Zone Circulators 1. 2. 3. 4 5. 6. CHALLENGER boiler Boiler circulator with flow check Flow/check valve Isolation valve Zone circulator Drain/purge valve 7. Pressure relief valve 8. Air separator 9. Automatic air vent 10. Diaphragm expansion tank 11.
Domestic Piping SECTION V - Domestic Piping WARNING HOT WATER CAN SCALD! • Water temperatures over 125ºF [52ºC] can cause severe burns instantly, or death from scalds. • Feel water before bathing or showering. • Consumer Product Safety Commission and some states recommend temperatures settings of 130ºF [54ºC] or less. Setting thermostat higher than 130ºF [54ºC] will increase risk of scald injury and cause severe personal injury or death.
Domestic Piping • Maximum domestic working pressure is 150 psig [10 bar]. • Water quality limitations (based on E.P.A National Secondary Drinking Water Regulations): - Chloride, less than 150 ppm or mg/l - pH value min. 6.5, max. 8.5 - Total hardness 3 - 7 grains/gallon or 50120 ppm or mg/l. - Total Dissolved Solids (TDS), less than 120 ppm or mg/l. - Iron less than 0.3 ppm or mg/l. - Aluminum, less than 0.2 ppm or mg/l. - Copper, less than 1 ppm or mg/l. - Manganese, less than 0.
Domestic Piping Temperature & Pressure (T&P) Relief ValveStorage Tank or SMART Installations - plugged, reduced or restricted - subject to freezing CAUTION WARNING To reduce risk of excessive pressures and temperatures in a storage tank or Triangle Tube SMART I.F.W.H.
Domestic Piping The domestic water volume of the CHALLENGER is approximately 0.26 gallons [ 1 l]. Remember to include this volume when sizing the expansion tank. Water Hammer Dishwashers, clothes washers and fast-closing positive shut-off valves incorporated in the system all contribute to creating water shock. Install a water hammer arrester to prevent damage to pipes and appliances. See device manufacturer’s instructions for application and installation.
Domestic Piping Storage Tank Installations For applications requiring high domestic hot water flow rates for a short period of time (dump load), the installer may install a storage type tank (see Fig. 12 page 27) in the domestic piping. The installer must: BEST PRACTICE Additional thermostatic/anti-scald valves should be installed at each hot water faucet, bath and shower outlet. For applications with a domestic recirculation loop, the recirculation pump should be controlled by an aquastat.
Domestic Piping 1/2” compression x 3/4” NPT Adapter Fittings for DHW Fig. 10 : Installation of Domestic Compression Adapter Assemblies 1 5 8 6 2 9 M H 7 c 10 DHW Cold Recirculating Loop (optional) 2 To Dish Washer or High Temperature Application 6 3 2 Water Inlet 4 Fig. 11 : Domestic Piping - Standard Installations 1. 2. 3. 4. 5. 6.
Domestic Piping 1 Recirculating Loop (optional) 8 6 For service only see warning on page 23 9 2 10 6 2 M C H Remove any check valve 7 5 11 3 2 DHW Cold Water Inlet 4 Storage Tank 6 2 12 9 Note: Domestic cold water inlet through a storage tank will yield a lower domestic pressure drop in addition to greater domestic performance. Domestic set point temperature should be set to 149ºF [65ºC] see page 52. DHW function button ( ) should be set to ON ( ) at the display panel, see page 49.
Installation Vent/Combustion Air & Condensate Drain SECTION VI - Installing Vent / Combustion Air & Condensate Drain 2. Remove front door and install trap. Ensure the trap is completely seated and secure on the appliance. Installing Vent and Combustion Air 3. Connect 13/16” ID tubing to the drain barbed fitting of the trap assembly.
Installation Vent/Combustion Air & Condensate Drain * Condensate Drain Trap Assembly * Carefully cut top of condensate drain trap assembly at location shown. Fig.
Gas Piping SECTION VII - Gas Piping - Gas Supply Piping Connection Disconnect the CHALLENGER and its gas valve from the gas supply piping during any pressure test greater than 13”w.c. [32 mbar]. WARNING NOTICE The gas supply piping must be installed in accordance to all applicable local, state and national codes and utility requirements. Do not check for gas leaks with an open flame. Use a gas detection device or bubble test.
Gas Piping NATURAL GAS 2. Install 100% lockup gas pressure regulator in the gas supply line if inlet pressure can exceed 13”w.c. [32 mbar] at any time. Adjust the lockup pressure regulator for 13”w.c. [32 mbar] maximum. Pipe Sizing - Natural Gas Refer to Table 1 for schedule 40 metallic pipe length and diameter requirements for natural gas, based on rated CHALLENGER input (divide by 1,000 to obtain cubic feet per hour). - Table 1 is based on Natural Gas with a specific gravity of 0.
Gas Piping PROPANE GAS Table 3: Propane Gas, Orifice Requirements: Pipe Sizing - Propane Gas Contact the local propane gas supplier for recommended sizing of piping, tanks and 100% lockup gas regulator. CHALLENGER MODEL Propane Orifice Size Orifice Marking CC85 0.199” [5.05 mm] 505 CC105 0.199” [5.05 mm] 505 CC125 0.220” [5.60 mm] - 580 - Propane Gas Supply Pressure Requirements 1. Adjust the propane supply regulator provided by the gas supplier for 13”w.c. [32 mbar] maximum pressure 2.
Internal Wiring SECTION VIII - Internal Wiring General Requirements WARNING ELECTRICAL SHOCK HAZARD. For your safety, disconnect electrical power supply to the appliance before servicing or making any electrical connections to avoid possible electric shock hazard. Failure to do so can cause severe personal injury or death. CAUTION Prior to servicing, label all wires before disconnecting. Wiring errors can cause improper and dangerous operation. Verify proper wiring and operation after servicing.
Internal Wiring Ladder Diagram Boiler Circulator Aquastat SMART I.F.W.H Aquastat SMART I.F.W.H Aquastat Note - The wiring for 120V field connections to the appliance shall have a minimum size of 14 AWG and a temperature rating of at least 194ºF (90º). - If any of the original wire as supplied with the appliance must be replaced with T wire or it’s equivalent. Schematic Diagram Boiler Circulator Aquastat Fig.
External Wiring SECTION IX- External Wiring WARNING Installation Compliance The ON/OFF switch of the CHALLENGER only disables the function of the appliance. Electrical power remains at the control module. To avoid a shock hazard, disconnect power at the external service switch when servicing the appliance. All field wiring made during installation must comply with: - National Electrical Code NFPA 70 and any other national, state, provincial or local codes or requirements. - In Canada, CSA C22.
External Wiring Low Voltage Connections Thermostat Wiring 1. Open the display cover and unscrew both screws to remove the front cover NOTICE 2. Pull the control/display forward until it tips downward to provide access. Isolate 120V wiring from low voltage wiring to prevent any potential electrical “noise”. 3. Ensure field installed low voltage wiring is not run parallel or next to telephone or power cable. 1.
External Wiring CH Circulator Outdoor Reset Control 1. Connect the CH primary circulator to the CHALLENGER 120 V terminals 1,2 and 3 located inside the appliance as shown in Fig. 16, page 34. The CHALLENGER may operate with a variable appliance operating temperature using the Triangle Tube outdoor sensor, see pages 55 through 57 for installation and set-up. 2. Maximum CH circulator continuous current draw is 2.3 A.
External Wiring 4 Wire Zone Valve H 120 N V.A.C. High Voltage Transformer (Power) 24 V.A.C. Room Thermostat Zone Valve Zone 1 Room Thermostat Zone 2 Zone Valve Additional zones Additional zones may be added as shown above 8 7 To Challenger Low Voltage Terminal Strip 3 Wire Zone Valve Transformer (Power) Zone 1 Zone 2 H 120 N V.A.C. High Voltage Room Thermostat 24 V.A.C. Zone Valve NOTICE: Room Thermostat *Use isolation relay on 3-wire zone valve with non-isolated end switch.
External Wiring Thermostat zone 1 Honeywell R845A Relay Fig. 20: Field Wiring with Zone Circulators T T T 2 1 120 VAC H N 4 3 5 6 Circulator Zone 1 Thermostat zone 2 T T 2 1 4 3 5 6 Circulator Zone 2 Additional zones may be added as shown above 7 8 To Challenger Low Voltage Terminal Strip Thermostat Zone 1 Fig.
Start-Up Preparation SECTION X - Start-Up Preparation Flush Boiler and Domestic System to Remove Sediment Check Boiler System Water Chemistry The installer must flush the boiler system to remove any sediment to allow proper operation of the CHALLENGER . WARNING Flush the systems until the water runs clean and is free of sediment. Do not use petroleum-base cleaning or sealing compounds in the boiler system.
Start-Up Preparation Use of Antifreeze in the Boiler System Filling the Boiler System 1. Close the boiler drain valve located on the bottom of the appliance and any manual or automatic air vent in the system. WARNING NEVER use automotive or ethylene glycol antifreeze or undiluted antifreeze in the boiler system as freeze protection. This can cause severe personal injury, death or substantial property damage if ignored. 2. Open all system isolation valves. 3.
Start-Up Preparation Check For Gas Leaks NOTICE WARNING In systems using 3-wire zone valves, backfeed of voltage to the appliance is a common problem. Use an isolation relay to prevent voltage from the external circuit entering the CHALLENGER control panel. Prior to start-up and during initial operation, smell near the floor and around the appliance for gas odorant or any unusual odor. Do not proceed with the start-up if there is any indication of a gas leak.
Start-Up Procedures SECTION XI - Start-Up Procedures manual starting on page 52 for more information. Final Checks Before Start-Up c Read page 46 through 57 regarding the operation of the CHALLENGER control. c Verify the CHALLENGER and the boiler system are full of water and all system components are correctly set for operation, including the minimum flow rate through the boiler, see pages 80-82. c 3.
Start-Up Procedures c Check Gas Piping Triangle Tube Engineering Department. Failure to comply with this requirement could result in severe personal injury, death or substantial property damage. Check around the appliance for gas odor following the procedure outlined in this manual on Page 42. Table 5: Recommended Combustion Levels WARNING Natural Gas If any gas leaks are found or suspected, shut the appliance down immediately.
Start-Up Procedures FOR YOUR SAFETY READ BEFORE LIGHTING WARNING If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A. This appliance does not have a pilot. It is • If you cannot reach your gas supplier, call the fire department. equipped with an ignition device which automatically lights the burner. DO NOT try to light the burner by hand. C. Use only your hand to turn the external manual gas valve. Never use tools.
Start-Up Procedures Appliance ON/OFF 2. Turn off power to the appliance, wait a few seconds and turn on power to the appliance. 1. The appliance operation is started using the ON/OFF button. 3. The following operating displays should occur: 2. When appliance is in operation, the green LED above the ON/OFF will be lit. [A] Self check on power up [ ] No call for heat 3. When the appliance is not in operation, the green LED above the ON/OFF will not be lit.
Start-Up Procedures [1] The setpoint temperature has been reached. Combustion will cease and the post purge cycle of the blower begins. The control module will de-energize the gas valve and the blower will continue with the 10 second post purge cycle, before shutting down. The CH circulator will continue to run until the room thermostat is satisfied. 3. Press the reset button to close the setting menu and store the changes.
Start-Up Procedures - - If the burner flame is not established the control module will repeat the ignition sequence after approximately 15 seconds . If the flame is not established after four attempts the control will lockout and the main display will show [4]and the fault LED above the reset button will flash and [E] will flash in the operating display. [4] This is the normal DHW operation cycle. The control module will begin to modulate the burner firing rate based on actual DHW set point temperature.
Start-Up Procedures Control Display Operation Read-Out A. On/Off button B. CH /DHW/parameter button C. - button D. + button E. Units U.S. customary or metric F. DHW function off/eco/on G. Service button H. Reset/store button 1. On/Off (Lit when on) 2. CH operation or setting maximum CH temperature 3. DHW operation or setting DHW temperature 4. Main display with temperature of CH or DHW or CH water pressure or fault code 5. Temperature ºF or pressure psi 6. Temperature ºC or pressure bar 7.
Start-Up Procedures TO TEMPORARILY PLACE THE BURNER INTO LOW FIRE TEST MODE: press ” and “ ” button simuland hold both the “ taneously until operating display shows “L”. Test Mode Function TO TEMPORARILY PLACE THE BURNER INTO HIGH FIRE TEST MODE: press ” and “+” button simuland hold both the “ taneously once until operating display shows “h” for CH high fire or twice until the operating display shows “H” for DHW high fire.
Start-Up Procedures Function Main Display Operating Display Press button to turn appliance ON LED lite above button will be lit when appliance is ON OFF XXP No demand for heat XXP A Control self-test XXX 1 Fan pre purge or post purge cycle XXX 2 Ignition sequence XXX 3 Burner ON for space heating (CH) XXX 4 Burner ON for domestic hot water (DHW) XXX 6 Burner OFF due to reaching temperature setpoint 7 Space Heating (CH) post pump cycle 8 Burner ON for DHW pre-heating 9 Burner ON f
Start-Up Procedures Setting the Appliance Parameters 5. After all parameters have been changed, press the reset button to close the setting menu and store the changes. The main display will go blank and a P will be displayed in the operating display to let you know the control was programmed. 1. Press the “ ” button at the display panel for approximately 2 to 3 seconds until main display begins to flash. 2. Press the “ ” button repeatedly to scroll through the list of parameters.
Start-Up Procedures Error (Hard Lockout) Mode If a system fault occurs, the system enters a hard lockout condition which requires a manual reset by pressing the RESET button . A hard lock is indicated by a flashing [E] on the operating display as well as a flashing LED light above the reset button. The error code is located on the main display. The error must be corrected before the control will reset.
Start-Up Procedures Error (Hard Lockout) Codes* Main Display Operating Display (Flashing) Possible Solution Error Description • Check wiring for break • Check for proper flow direction • Replace S1 • E10 Open sensor • E 11 Shorted sensor • E12 Decreased too quickly • E13 Increased too quickly • E14 Stuck E - CH supply sensor fault S1 20, 21, 22, 23, 24 E - CH return sensor fault S2 0 E - Sensor fault after self check 1, 28 E - Temperature too high 2 E - CH supply sensor S1 and CH return s
Outdoor Reset Control SECTION XII - Outdoor Reset Control 4. Mount the sensor enclosure at an elevation on the exterior wall to prevent accidental damage or tampering. The appliance setpoint for a heating call can be fixed or vary with the outdoor temperature. If the application requires a constant supply temperature from the boiler, the outdoor temperature sensor should not be connected to the appliance.
Outdoor Reset Control Adjusting Outdoor Reset Curve an outdoor temperature sensor is connected, the CH Reset Curve Coldest Day is the coldest design temperature of the heating system. The appliance CH set point along with Parameters 5, 6 & 7 define the settings of the outdoor reset curve. See Graph 1 and Table 7, page 57 for an example of modifying the outdoor reset curve.
Outdoor Reset Control Boiler CH Set Point 100 77 Parameter 5 Set Point Parameter 6 Setting 80 Parameter 7 Setting Boiler Temperature ( F) 140 60 20 90 70 64 50 10 30 0 -10 Outdoor Air Temperature ( F) Graph 1: Outdoor Air Temperature Reset Curve (Example) Table 7: Outdoor Air Temperature Reset (Example) Outdoor Temperature Appliance target Temp. Based on Outdoor Temp.
Check-Out Procedures SECTION XIII- Check-Out Procedures c Checked and verified room thermostat(s) function properly and the thermostat(s) heat anticipator (if used) was properly set. c Observed several operating cycles for proper operation of the CHALLENGER and the system. c Set the room thermostat(s) to the desired room temperature. c Boiler system water chemistry checked and verified as outlined on page 40.
Installation Record SECTION XIV - Installation Record CHALLENGER Model Number: Serial Number: Date of Installation: Fuel: Natural Gas Propane Measured Rate of Input: Btu/hr Combustion Readings: CO2 % O2 % CO ppm The following items were completed during installation: Installation instructions have been followed and completed Check-out procedures have been followed and completed Information regarding the unit and installation received and left with owner / maintenance personnel.
Maintenance Schedule SECTION XV - Maintenance Schedule Owner Maintenance Service Technician Periodic: At least on an annual basis the following maintenance should be performed by a qualified service technician: - Check the area around the appliance. - Check and remove any blockage from the combustion air inlet and ventilation openings. Check the temperature and pressure gauges. General - Attend to any reported problems.
Maintenance Procedures SECTION XVI - Maintenance Procedures Verify that combustion air inlet area is free of any contaminates. Refer to the materials listed on page 7 of this manual. If any of these products are in the area from which the appliance takes its combustion air, they must be removed immediately or the combustion air intake must be relocated to another area.
Maintenance Procedures Clean Condensate Drain Assembly Check Boiler System 1. Remove the condensate assembly from the appliance. Verify all system components are correctly installed and operating properly. 2. Empty any water from the trap and drain assembly. Flush with fresh water as necessary to clean. Check the cold fill pressure for the system, typical cold water fill pressure is 12 psig [0.8 bar]. 3. Check the drain piping from the condensate drain assembly to the drain.
Maintenance Procedures 1 3 2 Fig. 23: Loosening of Flue Pipe Retaining Ring Fig. 24: Removal of Flue Pipe 3 2 1 Fig.
Maintenance Procedures WARNING WARNING Before manually operating the relief valve(s), ensure the discharge piping is directed to a suitable place of disposal to avoid a potential scald hazard. The discharge piping must be full size without restriction and installed to permit complete drainage of both the valve and line. When re-assembling the condensate pan and flue pipe ensure all gaskets are in place and correctly installed. Ensure all associated joints are complete, tight and secure.
Maintenance Procedures º) (45 0.43” [11 mm] 1.06” -1.12” [27 mm - 29 mm] 0.12” [3 mm] 1.18” [30 mm] 1.75” [44 mm] 0.12” [ 3 mm] Spark gap app. 0.18” [5 mm] Fig.
Maintenance Procedures Check Control Wiring electrical connector to the gas valve inside the appliance. Inspect all control wiring. Ensure wiring is in good condition and properly connected. Disconnect the wiring harness connectors from the blower. Check Control Settings Remove the mounting bolts and washers securing the front of the heat exchanger and set bolts and washers aside. 1. Check the control CH/DHW/parameter settings by pressing the thermometer button “ ” on control display.
Maintenance Procedures page 42 and repair if necessary. Place the appliance back into service. 11. Close isolation valves at the appliance boiler piping to isolate the appliance from the heating system. Check Combustion Levels 12. Attach a hose to the boiler drain valve and flush the boiler thoroughly with fresh water by using the purge valves to allow water to enter through the make-up water line to the boiler. Refer to page 44 of this manual for measuring combustion levels and burner adjustments.
Maintenance Procedures 15. Rinse the domestic heat exchanger for 5 minutes by opening both the domestic hot water outlet drain/flush valve and the isolation (shut) off valve on the domestic cold water inlet. WARNING To avoid risk of electrocution ensure all power is off to the appliance before servicing. Use G.F.C.I. protected power supply to pump. Additionally before powering up the circulating pump ensure all hose connections and fittings are leak free and no water is on the floor. 16.
Replacement Parts S T Condensate pan Control/Display Pressure relief and air vent assembly CH Return sensor S2 Blower DHW flow switch DHW sensor S3 Condensate drain trap assembly CH supply sensor S1 Low voltage/terminal strip X4 Ignition electrode High voltage terminal strip Fig. 27: CHALLENGER Internal Components Use only genuine Triangle Tube replacement parts to ensure warranty coverage and to avoid damage to appliance and improper operation of appliance.
Replacement Parts 3 Fig.
Replacement Parts 1 2 2 3 3 2 3 4 3 Fig.
Replacement Parts 2 Fig.
Replacement Parts 4 1 2 3 Fig.
Replacement Parts 1 Fig.
Replacement Parts 4 1 2 3 Fig.
Specifications 9.45” [24 cm] 6.10” [15.5 cm] 17.72” [45 cm] 4.63” [11.8 cm] (3” Air) Z F A CH Supply CH Return C [8 cm] 3.15” [6.5 cm] 2.56” [6.5 cm] 2.56” E [6.5 cm] 2.56” [5 cm] 1.97” [6.5 cm] 2.56” H 13.58” [34.5 cm] (80/125 Concentric Vent/Air or 3” Vent) D B 1” NPT 1” NPT 1/2” NPT DHW Cold 3/4” NPT DHW Hot 3/4” NPT Condensate Drain Flexible 33.07” [84 cm] Challenger CC 125 Challenger CC 105 30.71” [78 cm] 28.
Specifications - Water Heater NOTICE The following efficiency performance is achieved when the CHALLENGER is operated as a Water Heater according to DOE 10CFR, Part 430, subpart B, Appendix E, test procedure. Continuous Domestic Flow 77ºF Rise Water Heater Energy Factor Shipping Weight Lbs [Kg] Model Fuel Modulation Input BTUH [KW] CC 85 Natural or Propane 23,000 [6.7] to 84,000 [24.6] 1.8 gpm [6.8 lpm] 110,000 .87 66 [30] Natural or Propane 29,000 [8.5] to 106,000 [31] 2.3 gpm [8.7 lpm] .
78 If actual flow rate exceeds the value listed in Graph 2 the domestic outlet temperature will be reduced.
Specifications - Water Heater Domestic Pressure Drop Graph 3 : Pressure Loss Through Domestic CCSTRA01 Optional Strainer Pressure Drop Curve Graph 4 : Pressure Loss Through Optional Domestic Strainer 79
Specifications - Boiler CC85 Primary Loop Pumps - Grundfos Graph 5 : Pressure Loss Through Boiler - Grundfos Circulators CC85 Primary Loop Pumps - Taco Graph 6 : Pressure Loss Through Boiler - Taco Circulators NOTICE Minimum allowable boiler flow rate at full input: 4 gpm [15 lpm] CHALLENGER CC85 Pump curves and system curves do NOT include any allowance for near boiler piping.
Specifications - Boiler CC105 Primary Loop Circulators - Grundfos Graph 7 : Pressure Loss Through Boiler - Grundfos Circulators CC105 Primary Loop Circulators - Taco Graph 8 : Pressure Loss Through Boiler - Taco Circulators NOTICE Minimum allowable boiler flow rate at full input: 5 gpm [19 lpm] CHALLENGER CC105 Pump curves and system curves do NOT include any allowance for near boiler piping.
Specifications - Boiler CC125 Primary Loop Circulators - Grundfos Graph 9 : Pressure Loss Through Boiler - Grundfos Circulators CC125 Primary Loop Circulators - Taco Graph 10 : Pressure Loss Through Boiler - Taco Circulators NOTICE Minimum allowable boiler flow rate at full input: 6 gpm [23 lpm] CHALLENGER CC125 Pump curves and system curves do NOT include any allowance for near boiler piping.
Specifications - Boiler NOTICE The following efficiency performance is achieved when the CHALLENGER is operated as a Boiler according to ASHRAE 103 test procedure Model CC 85 Fuel Natural or Propane Modulation DOE Net Boiler Input Heating Capacity IBR Rating DOE Seasonal BTUH [KW] BTUH [KW] BTUH [KW] Efficiency AFUE Note 4 Note 1 & 4 Note 2 Note 3 23,000 [6.7] to 84,000 [24.6] Shipping Weight Lbs [Kg] 75,000 [22.3] 110,000 65,000 [19.3] 95% 66 [30] CC 105 Natural 29,000 [8.
Notes
Notes
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