Boiler - SupplyHouse.coms3.supplyhouse.com/product_files/Triangle Tube - CC-125S - Install... ·...

Warranty Registration Card must be filled out by the customer and mailed within thirty (30) days of installa-

tion in order to gain warranty coverage.

When receiving the CHALLENGER, any claims for damage or shortage in shipment must be filed immedi-

ately against the transportation company by the consignee.

Leave all documentation received with appliance with owner for future reference.

* I N S T A L L A T I O N A N D M A I N T E N A N C E * * I N S T A L L A T I O N A N D M A I N T E N A N C E *

M A N U A LM A N U A L

2011-38 Challenger Boiler Manual

If the information in this manual is not followed exactly, a fire or explosion may

result causing property damage, personal injury or death.

FOR YOUR SAFETY

• Do not store or use gasoline or other flammable vapors and liquids in the vicinity of

this or any other appliance.

• WHAT TO DO IF YOU SMELL GAS

- Do not try to light any appliance- Do not touch any electrical switch; do not use any phone in your building.- Immediately call your gas supplier from a neighbor’s phone. Follow the gas

supplier’s instructions.- If you cannot reach your gas supplier, call the fire department.

Installation and service must be performed by a qualified installer, service agency or thegas supplier.

Boiler

Date: 8/30/2011

WARNING

NOTICE

PRODUCT AND SAFETY INFORMATION

Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Product and Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

SECTION I - PRE-INSTALLATION ITEMS

Code Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Determining Product Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Boiler Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Residential Garage Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Boiler Freeze Protection Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SECTION II - COMBUSTION AIR AND VENTING

Combustion Air Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Ventilation Air Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Combustion Air and Vent Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Removal of an Existing Boiler from a Common Vent System . . . . . . . . . . 9

Commonwealth of Massachusetts Installation . . . . . . . . . . . . . . . . . . . . . . . 10

SECTION III - APPLIANCE PREPARATIONS

Shipping and Handling Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Wall Mounting Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Wall Mounting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Stud Walls - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Wall Bracket Installation - Solid Walls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Appliance Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Piping Support Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

SECTION IV - BOILER PIPING

General Piping Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Low Water Cut Off/CH Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Additional Limit Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Backflow Preventer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Boiler System Piping Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Expansion Tank and Makeup Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Diaphragm Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Closed-Type Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Circulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Table of Contents

i

Sizing Primary Piping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

System Piping - Zone Circulators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

System Piping - Zone Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Near Boiler Piping Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

System Piping - Radiant Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

System Piping - SMART Indirect Fired Water Heater (I.F.W.H). . . . . . . . . 19

System Piping - Special Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Central Heating (CH) System Piping Diagrams. . . . . . . . . . . . . . . . . . . . . . 20

SECTION V - INSTALLING VENT / COMBUSTION AIR & CONDENSATE DRAIN

Installing Vent and Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Installing Condensate Drain Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-22

SECTION VI - GAS PIPING

Gas Supply Piping Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Natural Gas

Pipe Sizing -Natural Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Natural Gas Supply Pressure Requirements. . . . . . . . . . . . . . . . . . . 24

Natural Gas Orifice Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Propane Gas

Pipe Sizing - Propane Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Propane Gas Supply Pressure Requirements . . . . . . . . . . . . . . . . . . 25

Propane Gas Orifice Requirements . . . . . . . . . . . . . . . . . . . . . . . . . 25

SECTION VII - INTERNAL WIRING

General Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

CHALLENGER Factory Wiring Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . 27

SECTION VIII - EXTERNAL WIRING

Installation Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Line Voltage Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Control Module Circulator AMP Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Low Voltage Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Thermostat Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

CH Circulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

System Circulator - Zone Valve Application . . . . . . . . . . . . . . . . . . . . . . . . 30

Outdoor Reset Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

External Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-32

Table of Contents

ii

SECTION IX - START-UP PREPARATION

Check Boiler System Water Chemistry

Water pH Level 6.5 to 8.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Water Total Hardness Less Than 7 Grains/Gallon . . . . . . . . . . . . . . 33

Chlorinated Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Flush Boiler System to Remove Sediment. . . . . . . . . . . . . . . . . . . . . . . . . . 33

Check and Test Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Use of Antifreeze in the Boiler System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Filling the Boiler System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Check Low Water Cut-Off/CH Pressure Sensor . . . . . . . . . . . . . . . . . . . . . 34

Check for Gas Leaks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Check Thermostat Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Inspection of Condensate Drain Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . 35

SECTION X - START-UP PROCEDURES

Final Checks Before Start-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

CHALLENGER Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

If CHALLENGER Does Not Start Correctly. . . . . . . . . . . . . . . . . . . . . . . . 36

Check the CHALLENGER and System. . . . . . . . . . . . . . . . . . . . . . . . . . . . 36-37

Operating Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Appliance ON/OFF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Set Boiler Maximum Central Heating (CH) Set Point Temperature . . . . . . 39

Operation Verification - Space Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39-40

Control Display

Appliance ON/OFF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Highfire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Lowfire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Setting the Appliance Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Error (Hard Lockout) Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Error (Hard Lockout) Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

SECTION XI - OUTDOOR RESET CONTROL

Mounting the Outdoor Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Wiring the Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Adjusting Outdoor Reset Curve

CH Maximum Boiler Operating Temperature. . . . . . . . . . . . . . . . . 48

CH Minimum Boiler Operating Temperature Setpoint (Parameter 5) . . . . . . . . 48

CH Reset Curve Coldest Day (Parameter 6) . . . . . . . . . . . . . . . . . . 48

Table of Contents

iii

CH Reset Curve Warmest Day (Parameter 7) . . . . . . . . . . . . . . . . . 48

Changing Outdoor Reset Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Outdoor Reset Curve Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

SECTION XII - CHECK-OUT PROCEDURES

Check-Out Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

SECTION XIII - INSTALLATION RECORD

Installation Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

SECTIONS XIV - MAINTENANCE SCHEDULE

Service Technician - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Owner Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

SECTION XV - MAINTENANCE PROCEDURES

Annual Maintenance Procedures

Reported Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Check Surrounding Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Inspect Burner Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Check System Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Clean Condensate Drain Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 54

Check Ventilation Air Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Inspect Vent and Combustion Air Piping . . . . . . . . . . . . . . . . . . . . . 54

Check Boiler System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Removing Internal Flue and Condensate Pan for Inspection. . . . . . 54-55

Check Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Check Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Inspection of Ignition Electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Check Ignition Wiring and Ground Wiring . . . . . . . . . . . . . . . . . . . 56-57

Check Control Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Check Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Perform Start-Up and Checkout Procedure . . . . . . . . . . . . . . . . . . . 58

Check Burner Flame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Check Combustion Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Clean Boiler Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Review with Owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Handling Previously Fired Combustion Chamber Insulation . . . . . 60

Table of Contents

iv

REPLACEMENT PARTS

Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61-67

PRODUCT SPECIFICATIONS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Specification Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69-72

Table of Contents

v

Indicates the presence of a hazardoussituation which, if ignored, will resultin death, serious injury or substantialproperty damage.

Indicates a potentially hazardous situ-ation which, if ignored, can result indeath, serious injury or substantialproperty damage.

Indicates a potentially hazardous situ-ation which, if ignored, may result inminor injury or property damage.

Indicates special instructions on instal-lation, operation or maintenance,which are important to equipment butnot related to personal injury hazards.

Indicates recommendations made byTriangle Tube for the installers whichwill help to ensure optimum operationand longevity of the equipment.

NOTICE

WARNING

CAUTION

BEST PRACTICE

DANGER

The following terms are used throughout this manual to bring attention to the presence ofpotential hazards or important information concerning the product.

Triangle Tube reserves the right to modify the technical specifications and components ofits products without prior notice.

NOTICE

Definitions

Product & Safety Information

1


Do not use this appliance if any parthas been under water. Immediately calla qualified service technician to inspectthe appliance and to replace any part ofthe control system which has beenunder water.

WHAT TO DO IF YOU SMELL GAS

- Do not try to light any appliance

- Do not touch any electrical switch; donot use any phone in your building.

- Immediately call your gas supplierfrom a neighbor’s phone. Follow thegas supplier’s instructions.

- If you cannot reach your gas suppli-er, call the fire department.

Installation and service must be per-formed by a qualified installer, serviceagency or the gas supplier.

Should overheating occur or the gassupply fails to shut off, turn OFF themanual gas control valve external tothe appliance.

DO NOT add cold make up water whenthe appliance is hot. Thermal shock cancause potential cracks in the heatexchanger.

When servicing the appliance:

- Avoid electrical shock by discon-necting the electrical supply prior toperforming maintenance.

WARNING

WARNING

WARNING

CAUTION

DANGER

Qualified Installer:

Prior to installing this product read allinstructions included in this manual and allaccompanying manuals/documents with thisappliance. Perform all installation stepsrequired in these manuals in the properorder given. Failure to adhere to the guide-lines within these manuals can result insevere personal injury, death or substantialproperty damage.

Homeowner:

- This product should be maintained /serviced and inspected annually by aqualified service technician.

- This manual is intended for use by aqualified Installer/Service Technician.

Please reference the appliance model num-ber and the serial number from the ratinglabel, on the right panel when inquiringabout service or troubleshooting.

Triangle Tube accepts no liability for anydamage resulting from incorrect instal-lation or from the use of components orfittings not specified by Triangle Tube.

NOTICE

NOTICE

WARNING

2

3


Protection must be taken againstexcessive pressure!

TO PROTECT AGAINST EXCES-SIVE TEMPERATURE AND PRES-SURE

• Check if the 30 psi [2 bar] pressurerelief valve supplied is installed inthe recommended location.

• To avoid injury, install the reliefdevices to comply with local coderequirements.

Parameter 1 (Installation Type) mustbe set to 3 (Heating Only) or 1(Heating + SMART I.F.W.H.) for allCHALLENGER Solo Boilers (HeatOnly, CC85s, CC105s, CC125s andCC150s), see page 44 for settingParameters.

DANGER

NOTICE

Pre-Installation Items

4

SECTION I - Pre-Installation Items

Code Compliance

The CHALLENGER is certified to the Boiler(ANSI Z21.13/CSA 4.9) standard.

This appliance must be installed in accordanceto the following:

- All applicable local, state, national andprovincial codes, ordinances, regula-tions and laws.

- For installations in Massachusetts, coderequires the appliance to be installed bya licensed plumber or gas fitter, and ifantifreeze is utilized, the installation ofa reduced pressure backflow preventerdevice is required in the boiler’s coldwater fill or make up water supply line.

- For installation in Massachusetts all directvented appliances must comply with theguidelines as outlined on page 10.

- Massachusetts Plumbing Board ProductApproval Code # is CI-0111-219 for theCHALLENGER.

- The National Fuel Gas Code NFPA54/ANSI Z223.1 - Latest edition.

- National Electric Code ANSI/NFPA 70.

- For installations in Canada -“InstallationCode for Gas Burning Equipment”CAN/CSA B149.1 Canadian ElectricalCode Part 1 CSA C22.1.

- Standards for Controls and SafetyDevices for Automatically Fired Boilers,ANSI/ASME CSD-1, when required.

The CHALLENGER gas manifold andgas controls meet the safe lighting andother performance requirements as speci-fied in ANSI Z21.13 standard.

Determining Product Location

Before locating the CHALLENGER check forconvenient locations to:

- Heating system piping- Venting - Gas supply piping- Electrical service

Ensure the appliance location allows the com-bustion air and vent piping to be routed directlythrough the building and terminate properly inthe same pressure zone outside with a minimumamount of length and bends.

Ensure the area chosen for the installation of theCHALLENGER is free of any combustiblematerials, gasoline and other flammable liquids.

Failure to remove or maintain the areafree of combustible materials, gasolineand other flammable liquids or vaporscan result in severe personal injury,death or substantial property damage.

Ensure the CHALLENGER and its controlsare protected from dripping or spraying waterduring normal operation or service.

The CHALLENGER should be installed in alocation so that any water leaking from theappliance, piping connections or relief valvewill not cause damage to the surrounding areaor any lower floors in the structure. When suchlocation cannot be avoided, it is recommendedthat a suitable drain pan, adequately drained, beinstalled under the appliance. The pan must notrestrict combustion air flow.

NOTICE

WARNING


Boiler Replacement

If the CHALLENGER is replacing an existingboiler, the following items should be checkedand corrected prior to installation:

- Boiler piping leaks and corrosion.

- Proper location and sizing of the expan-sion tank on the boiler heating loop.

- If applicable, amount and quality ofpropylene glycol.

- Vent condition

Clearances

The CHALLENGER is approved for follow-ing clearance to combustibles:

- Top panel - 12 inches [30.5 cm]

- Front - 0 inches

- Bottom panel - 12 inches [30.5 cm]

- Rear - 0 inches

- Right side - 4 inches [10.2 cm]

- Left side - 1.5 inches [3.8 cm]

- Boiler Piping - 0.25 inches [0.6 cm]

- Reference the appropriate vent supple-ment for venting clearance requirements.

To provide serviceability to the appli-ance it is recommended that the follow-ing clearances be maintained:

Top panel - 24 inches [61 cm].

Front - 24 inches [61 cm].

Bottom panel - 24 inches [61 cm].

Rear - 0 inches

Sides - 6 inches [15.2 cm]

When maintaining the approved clear-ance or less than recommended serviceclearances, some product labeling maybecome hidden and unreadable.

If the enclosure in which the appliance isinstalled is less than 45 cubic feet [1.3m3], the space must be ventilated. Seepage 8 Ventilation Air Requirements forguidelines and requirements.

When installing the CHALLENGER in aconfined space, sufficient air must be pro-vided to allow, under normal operating con-ditions, proper air flow around the productto maintain ambient temperatures withinsafe limits to comply with the National FuelGas Code NFPA 54 - Standard.

Residential Garage Installations

When installing the CHALLENGER in a resi-dential garage, the following special precautionsper NFPA 54/ANSI Z223.1 must be taken:

- Mount the appliance a minimum 18 inch-es [458 mm] above the floor level of thegarage. Ensure the burner and ignitiondevices / controls are no less than 18inches [458 mm] above the floor level.

- Locate or protect the appliance in amanner so it cannot be damaged by amoving vehicle.

BEST PRACTICE

NOTICE

WARNING

WARNING

5

6


Boiler Freeze Protection Feature

The boiler control has a freeze protection fea-ture. This feature monitors the boiler supplywater temperature and responds as followswhen 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 isdisabled during a hard lockout, (burnerdoes not operate) however the CH circu-late or will operate.

The boiler freeze protection feature isdesigned to protect the boiler, installedin a primary/secondary piping arrange-ment. See Section IV for primary/sec-ondary piping examples. See Section IXfor antifreeze guidelines.

CAUTION

CAUTION

Combustion Air and Venting

7

SECTION II- Combustion Air andVenting

Combustion Air Contamination

If the CHALLENGER combustion airinlet is located in any area likely to causeor contain contamination, or if products,which could contaminate the air cannotbe removed, the combustion air must berepiped and terminated to another loca-tion. Contaminated combustion air willdamage the appliance and its burner sys-tem, resulting in possible severe personalinjury, death or substantial propertydamage.

Do not operate a CHALLENGER if thecombustion air inlet is located near alaundry room or pool facility. Theseareas will always contain hazardous con-taminants.

Pool, laundry products, common house-hold and hobby products often containfluorine or chlorine compounds. Whenthese chemicals pass through the burnerand vent system, they can form strongacids. These acids can create corrosionof the heat exchanger, burner compo-nents and vent system, causing seriousdamage and presenting a possible threatof flue gas spillage or water leakage intothe surrounding area.

Please read the information listed below.If contaminating chemicals are locatednear the area of the combustion air inlet,the installer should pipe the combustionair inlet to an area free of these chemi-cals per SECTION VI of this installationmanual.

Potential contaminating products

- Spray cans containing chloro/fluorocar-bons

- Permanent Wave Solutions

- Chlorinated wax

- Chlorine - based swimming pool chem-icals / cleaners

- Calcium Chloride used for thawing ice

- Sodium Chloride used for water soft-ening

- Refrigerant leaks

- Paint or varnish removers

- Hydrochloric acid / muriatic acid

- Cements and glues

- Antistatic fabric softeners used inclothes dryers

- Chlorine-type bleaches, detergents, andcleaning solvents found in householdlaundry rooms

- Adhesives used to fasten building prod-ucts and other similar products

Areas likely to contain these products

- Dry cleaning / laundry areas and estab-lishments

- Beauty salons

- Metal fabrication shops

- Swimming pools and health spas

- Refrigeration Repair shops

- Photo processing plants

- Auto body shops

- Plastic manufacturing plants

- Furniture refinishing areas and estab-lishments

- New building construction

- Remodeling areas

- Garages with workshops

WARNING

WARNING

8


Ventilation Air Requirements

For installations, involving only the CHAL-LENGER, in which the minimum serviceclearances are maintained as listed on page 5,no ventilation openings are required.

For installations with less than the minimumservice clearances involving only the CHAL-LENGER, the space / enclosure must providetwo openings for ventilation. The openingsmust be sized to provide 1 square inch [6square centimeters] of free area per 1,000BTUH [0.3 Kw] of appliance input. The open-ings shall be placed 12 inches [30.5 cm] fromthe top of the space and 12 inches [30.5 cm]from the floor of the space.

For installations in which the CHALLENGERshares the space with air movers (exhaust fan,clothes dryers, fireplaces, etc.) and other com-bustion equipment (gas or oil) the space mustbe provided with adequate air openings to pro-vide ventilation and combustion air to theequipment. To properly size the ventilation /combustion air openings, the installer mustcomply with the National Fuel Gas CodeNFPA 54, ANSI Z223.1 for installations in theU.S or CAN/CSA B149.1 for installations inCanada/

The space must be provided with venti-lation / combustion air openings proper-ly sized for all make-up air requirements(exhaust fans, clothes dryers, fireplaces,etc.) and the total input of all applianceslocated in the same space as the CHAL-LENGER. The input of a CHAL-LENGER which uses combustion airdirectly from the outside, is excludedthus additional free area for the open-ings is not required. Failure to provideor properly size the openings couldresult in severe personal injury, death orsubstantial property damage.

Combustion Air and Vent Piping

The CHALLENGER requires a Category IVventing system, which is designed for pressur-ized venting and condensate.

The CHALLENGER is certified as Direct Vent(sealed combustion) appliance. A Direct Ventappliance utilizes uncontaminated outdoor air(piped directly to the appliance) for combustion.

Install combustion air and vent pipe asdetailed in the CHALLENGER PVC,CPVC and SS Vent Supplement 2010-19included in the appliance installationenvelope. Refer to instructions for partslist and method of installation.

Contact Triangle Tube for other ventingoptions including PVC ConcentricVent/Air Termination Supplement 2008-04 or CHALLENGER ConcentricVent/Air System Supplement 2010-23.Refer to these instructions for parts listand method of installation.

Verify installed combustion air and ventpiping are sealed gas tight and meet allprovided instructions and applicablecodes, failure to comply will result insevere personal injury of death.

WARNING

NOTICE

DANGER

NOTICE

9


Removal of an Existing Boiler from aCommon Vent System

When an existing boiler is removed froma common venting system, the commonventing system is likely to be too large forproper venting of the remaining appli-ances. At the time of removal of an exist-ing boiler, the following steps shall be fol-lowed with each appliance remainingconnected to the common venting systemplaced in operation, while the other appli-ances remaining connected to the com-mon venting system are not in operation.

1. Seal any unused openings in the commonventing system.

2. Visually inspect the venting system forproper size and horizontal pitch and deter-mine there is no blockage or restriction,leakage, corrosion and other deficiencieswhich could cause an unsafe condition.

3. Insofar as is practical, close all buildingdoors and windows and all doors betweenthe space in which the appliances remain-ing connected to the common venting sys-tem are located and other spaces of thebuilding. Turn on clothes dryers and anyappliance not connected to the commonventing system. Turn on any exhaust fans,such as range hoods and bathroomexhausts, so they will operate at maximumspeed. Do not operate a summer exhaustfan. Close fireplace dampers.

4. Place in operation the appliance beinginspected. Follow the lighting instructions.Adjust thermostat so appliance will operatecontinuously.

5. Test for spillage at the draft hood reliefopening after 5 minutes of main burneroperation. Use the flame of a match or can-dle, or smoke from a cigarette, cigar or pipe.

6. After it has been determined that eachappliance remaining connected to the com-mon venting system properly vents whentested as outlined above, return doors, win-dows, exhaust fans, fireplace dampers, andany other gas-burning appliance to theirprevious condition of use.

7. Any improper operation of the commonventing system should be corrected so theinstallation conforms with the NationalFuel Gas Code, ANSI Z223.1/NFPA 54and/or CAN/CSA B149.1, Installationcodes. When resizing any portion of thecommon venting system, the commonventing system should be resized toapproach the minimum size as determinedusing the appropriate tables in Part II of theNational Fuel Gas Code ANSIZ223.1/NFPA 54 and/or CAN/CSAB149.1, Installation codes.

Do not install the CHALLENGER into acommon vent with other gas or oil appli-ances. This may cause flue gas spillage orappliance malfunction, resulting in possi-ble severe personal injury, death or sub-stantial property damage.

DANGER

BEST PRACTICE

10


For direct-vent appliances, mechanical-vent heating appliances or domestic hotwater equipment, where the bottom of thevent terminal and the air intake is installedbelow four feet above grade the followingrequirements must be satisfied:

1. If there is not one already present, oneach floor level where there are bed-room(s), a carbon monoxide detectorand alarm shall be placed in the livingarea outside the bedroom(s). The car-bon monoxide detector shall complywith NFPA 720 (2005 Edition).

2. A carbon monoxide detector shall alsobe located in the room that houses theappliance or equipment and shall:

a. Be powered by the same electricalcircuit as the appliance or equip-ment such that only one serviceswitch services both the applianceand the carbon monoxide detector;

b. Have battery back-up power;

c. Meet ANSI/UL 2034 Standards andcomply with NFPA 720 (2005Edition); and

d. Have been approved and listed bythe Nationally Recognized TestingLaboratory as recognized under 527CMR.

3. A Product-approved vent terminal mustbe used, and if applicable, a Product-approved air intake must be used.Installation shall be in strict compliancewith the manufacturer’s instructions. Acopy of the installation instructionsshall remain with the appliance orequipment at the completion of theinstallation.

4. A metal or plastic identification plateshall be mounted at the exterior of thebuilding, four feet directly above thelocation of vent terminal. The plateshall be of sufficient size to be easilyread from a distance of eight feet away,and read “Gas Vent Directly Below”.

Installer must provide tag identificationplate and ensure the lettering meets coderequirements.

For direct-vent appliances, mechanical-vent heating appliances or domestic hotwater equipment, where the bottom of thevent terminal and the air intake are installedabove four feet above grade the followingrequirements must be satisfied:

1. If there is not one already present, oneach floor level where there are bed-room(s), a carbon monoxide detectorand alarm shall be placed in the livingarea outside the bedroom(s). The car-bon monoxide detector shall complywith NFPA 720 (2005 Edition).

2. A carbon monoxide detector shall:

a. Be located in the room that housesthe appliances or equipment;

b. Be either hard wired or batterypowered or both; and

c. Shall comply with NFPA 720 (2005Edition)

3. A Product-approved vent terminal mustbe used, and if applicable, a Product-approved air intake must be used.Installation shall be in strict compliancewith the manufacturer’s instructions. Acopy of the installation instructionsshall remain with the appliance orequipment at the completion of theinstallation.

NOTICE

Commonwealth of Massachusetts Installations Only

11

Appliance Preparations

SECTION III - Appliance Preparations

Shipping and Handling Instructions

To avoid damage to gas fitting and piping atbottom of appliance, appliance must beshipped with rear or back of appliance(longest box length) laying down flat.

The CHALLENGER is generally easier tohandle and maneuver once removed from theshipping carton.

To remove the shipping carton:

Use care not to lift the appliance frompiping or damage can occur. Use carenot to drop or bump the appliance asdamage to the appliance may result.

1. Remove any shipping straps and the topshipping carton.

2. Carefully lift the appliance out of the carton.

3. Discard all packing materials.

Wall Mounting Installation

Prior to mounting appliance install pip-ing support bracket according toinstructions on page 13.

The CHALLENGER should be wall mountedusing the bracket provided with the applianceand is not designed for floor installation. Iffloor installation is required an optional floorstand part number PSSTND04 is availablethrough Triangle Tube. Appliance is not to beinstalled on carpeting.

The wall used for mounting the CHAL-LENGER must be vertically plumb andcapable of supporting a minimum 110pounds [50 kg]. Failure to comply withthese requirements could result in per-sonal injury, death or substantial prop-erty damage.

NOTICE

CAUTION

NOTICE

WARNING

Fig. 1: Optional Floor Stand Assembly,

Part Number: PSSTND04

12


Wall Mounting Guidelines

1. The wall-mounting bracket is designed forstud spacing of 12 inch [30.5 cm] or 16inch [40.6 cm] on centers. For unconven-tional stud spacing, a solid / secure mount-ing surface must be provided for installa-tion of the bracket.

2. For applications using wood studs, installthe bracket using the lag screws providedwith the appliance. Ensure both lag screwsare installed securely in the studs.

3. For applications using metal studs, install thebracket to the studs using 3/16” [5 mm] tog-gle bolts and washers (provided by others)

4. DO NOT mount or attempt to mount thewall bracket to hollow sheet rock or lathwalls using anchors. Only install applianceto studs or equivalent wood structure.

5. For applications using solid walls (rock,concrete, brick, cinder block, etc.), installthe wall bracket using anchors (doubleexpansion shields) bolts and washers pro-vided with the appliance.

6. The appliance is too heavy and bulky for asingle person to lift and attempt to mount; aminimum of 2 people is required formounting the appliance.

Use extreme care not to drop the appli-ance or cause bodily injury while liftingor mounting the appliance onto thebracket. Once mounted verify that theappliance is securely attached to thebracket and wall. Failure to comply withthe above guidelines could result in prop-erty damage, personal injury or death.

Stud Walls -Installation

1. Locate the studs in the general area of theappliance placement.

2. Place the wall-mounting bracket on thewall centering the mounting slots with the

stud centers and ensuring the upper edge ofthe bracket is away from the wall.

3. Level the bracket, while maintaining it’s cen-tering with the studs and use a pencil to markthe location of the mounting slots/holes.

4. Remove the bracket from the wall and drill1/4” [6 mm] diameter hole by 3” [76 mm]deep positioned in the center of each mark.For applications using metal studs and3/16” [5 mm] toggle bolts, drill therequired clearance hole.

5. Reposition the bracket onto the wall andalign mounting slots/holes. Insert the twolag screws provided (or toggle bolts formetal studs) through the mountingslots/holes and loosely tighten.

6. Level bracket and tighten screws (bolts formetal studs) securely making sure not to over-tighten to avoid damaging drywall or plaster.

Wall Bracket Installation - Solid Walls

1. Locate the general area of the applianceplacement.

2. Place the wall-mounting bracket on thewall ensuring the upper edge of the bracketis away from the wall.

3. Level the bracket and use a pencil to markthe location of the mounting slots/holes onthe wall.

4. Remove the bracket from the wall and drilla 5/8” [16 mm] diameter hole by 1-3/8” [35mm] deep positioned in the center of eachmark.

5. Install the anchors (provided) flush orslightly recessed in the drilled holes withthreaded side facing down.

6. Reposition the bracket on the wall andalign mounting slots/holes. Insert the twobolts with washers (provided) through themounting slots/holes and loosely tighten.

7. Level bracket and tighten bolts securely.

NOTICE

13


Appliance Mounting

1. Obtain assistance in lifting the applianceonto the wall bracket.

2. Install the appliance making sure the appli-ance mounting lip located along the upperedge of the rear jacket panel engages thewall-mounting bracket. Ensure the appli-ance is seated properly and is secure.

Piping Support Bracket

Appliance must be installed using the sup-plied copper fittings and piping supportbracket. DO NOT braze directly to cop-per appliance pipes or damage may resultto internal parts (gaskets).

1. Pre-install the brass compression fittingsinto the piping support bracket as shown inFig. 4, page 15. Use retaining clips to holdfittings in place.

Apply pipe joint compound to the com-pression ferrule and compression nutthreads of all brass fittings before instal-lation. Install appliance pipes into the fit-tings until bottom of hex on gas pipe fit-ting rests against the top of the pipingsupport bracket before tightening anycompression nuts. Do not over tightencompression nuts. If fitting leaks loosencompression nut first and then retighten.

2. Prior to mounting the appliance on the walland with the rear or back of appliance lay-ing flat, slip the appliance piping into thefittings until bottom of hex on gas pipe fit-ting rests against the top of the piping sup-port bracket before tightening any com-pression nuts.

3. Tighten all fittings to appliance pipingconnections with two wrenches.

Use a two wrench method when tighten-ing piping near the appliance and its pip-ing connections. Use one wrench to pre-vent the appliance connections fromturning and the second to tighten adja-cent piping. Failure to support the appli-ance piping connections could damagepiping.

4. Once appliance is mounted according toAppliance Mounting instructions on thispage, secure piping support bracket to wallwith hardware supplied.

BEST PRACTICE

CAUTION

WARNING

Lag Screw(Stud Wall)Bolts with Washer(Solid Wall)

Wall Anchors (Solid Wall Only)

Optional Concentric Vent/Air Adapter

Fig. 2: Wall Mounting The CHALLENGER

14

Boiler Piping

SECTION IV - Boiler Piping

General Piping Requirements

- All plumbing must meet or exceed all local,state and national plumbing codes.

- Support all piping using hangers. DO NOTsupport piping by the appliance or its com-ponents.

- Use isolation valves to isolate system com-ponents.

- Install unions for easy removal of theCHALLENGER from the system piping.

Use a two wrench method when tighten-ing piping onto the appliance connec-tions. Use one wrench to prevent theappliance piping from turning / twisting.Failure to support the appliance pipingand connections in this manner couldcause damage to the appliance and itscomponents.

Pressure Relief Valve (PRV)

1. The CHALLENGER has a ASMEMaximum Allowable Working Pressure of43.5 PSI [3 bar]. The appliance is suppliedwith a 30 psi [2 bar] pressure relief valveand must be piped using the PRV connec-tion as shown in Fig. 3 page 15.

2. To avoid potential water damage to the sur-rounding area or potential scalding hazarddue to the operation of the relief valve, thedischarge piping:

- Must be connected to the discharge out-let of the relief valve and directed to asafe place of disposal.

- Length should be as short and direct aspossible. The size of the discharge lineshould not be reduced, maintain thesame size as the outlet of the relief valve.

- Should be directed downward towardsthe floor at all times. The piping shouldterminate at least 6 inches [153 mm]above any drain connection to allowclear visibility of the discharge.

- Should terminate with a plain end, notwith a threaded end. The material of thepiping should have a serviceable temper-ature rating of 250ºF [121ºC] or greater.

- Should not be subject to conditionswhere freezing could occur.

- Should not contain any shut-off valvesor obstructions. No shut-off valveshould be piped between the applianceand relief valve.

Failure to comply with the guidelines oninstalling the pressure relief valve and dis-charge piping can result in personal injury,death or substantial property damage.

Low Water Cut Off / CH Pressure Sensor

- The CHALLENGER is equipped with a fac-tory installed pressure sensor type LWCO.

- The minimum operating Central Heating(CH) system pressure is 7 psig [0.5 bar].

- If CH System pressure is below 7 psig [0.5bar] the main display will flash a soft lockoutof “LOP” followed by the pressure reading.Once CH system pressure is increased above7 psi [0.5 bar] normal boiler operation will berestored.

- Check local codes if a LWCO is required. Ifso, determine if this device meets theirrequirements.

WARNING

WARNING

15

Boiler Piping

Boiler Return Connection with Tee Fitting and Boiler Drain Valve

Boiler Supply Connection

with TeeFitting and

Temperature/Pressure Gauge

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

Fig. 3: Boiler Pressure Relief Valve and Drain Valve Installation

Drain Valve(by Others)1 inch

CompressionAssembly(supplied)

1 inchCompression

Assembly(supplied) 1 inch Tee (by Others)

1 inchTee

(supplied) Temperature Pressure Gauge (supplied)

Piping Bracket(supplied)

Retaining Clip(supplied)

CompressionFerrule

Compression Nut

Compression/NPT Adapater

ManualAir Vent

(supplied)

3/4” Tee(supplied)

3/4” Nipple(supplied)3/4” Street

Elbow (supplied)

Installer must providerelief valve drain pipingdirected to a suitable place of drainage

Pressure Relief Valve(supplied)

Note:

Fig. 4: Near Appliance Piping Assembly

16

Boiler Piping

Additional Limit Control

If a Low Water Cut Off (LWCO) is required bycertain local jurisdictions or when the boiler isinstalled above the system piping, the follow-ing guidelines must be followed:

- The LWCO must be designed for waterinstallations, electrode probe-type isrecommended.

- The LWCO must be installed in a teeconnection on the boiler supply pipingabove the appliance.

- Wiring of the LWCO to the CHAL-LENGER should be done in series withthe 120 VAC service to the appliance .

If the installation is to comply with ASMECSD-1 or Canadian requirements, an addition-al high temperature limit may be needed.Consult local code requirements to determinecompliance. The limit should be installed asfollows:

- Install the limit in the boiler supply pip-ing between the boiler and any isolationvalve.

- Maximum set point for the limit is200ºF [93ºC].

- Wiring of the limit device to the CHAL-LENGER should be done in series withthe 120 VAC service to the appliance.

Backflow Preventer

- Use a backflow preventer valve in themake-up water supply to the applianceas required by local codes.

Boiler System Piping Applications

It is required on all piping applicationsto utilize a primary/secondary pipingarrangement. Maintain the minimumboiler flow rate, see Graphs 5-10 onpages 69-71.

Expansion Tank and Makeup Water

Ensure the expansion tank is properly sized forthe boiler water volume (approximately 1 gal-lon [4 L]) and the system water volume andtemperature.

Undersized expansion tanks will causesystem water to be lost through the pres-sure relief valve and cause additionalmakeup water to be added to the system.Eventual boiler heat exchanger failurecan result due to this excessive makeupwater addition.

The expansion tank must be located as shownin Fig. 5 and Fig. 6 on page 18 when using aprimary/secondary piping arrangement or asper recognized design methods. Refer to theexpansion tank manufacturer instructions foradditional installation details.

Connect the expansion tank to an air separatoronly if the air separator is located on the suc-tion side (inlet) of the system circulator.Always locate and install the system fill con-nection at the same location as the expansiontank connection to the system.

Diaphragm Expansion Tank

Always install an automatic air vent on the topof the air separator to remove residual air fromthe system.

BEST PRACTICE

CAUTION

17

Boiler Piping

Closed-Type Expansion Tank

It is recommended to pitch any horizontal pip-ing upwards toward the expansion tank 1 inchper 5 feet [2.5cm / 1.5 M] of piping. Use 3/4”piping to the expansion tank to allow air with-in the system to rise.

DO NOT install automatic air vents on aclosed-type expansion tank system. Airmust remain in the system and bereturned to the expansion tank to pro-vide an air cushion. An automatic airvent would cause air to be vented fromthe system resulting in a water-loggedexpansion tank.

Circulator

The CHALLENGER must be supplied with aCentral Heating (CH) circulator. The circulatorwhen wired directly to the CHALLENGERwill provide circulation for the freeze protec-tion feature of the boiler control. See Graph 5-10 on page 69-71 for pressure drop and mini-mum flow rate through the boiler.

Sizing Primary Piping

See Fig. 7 and 8, page 20, for recommendedpiping arrangements based on various applica-tions. Size the piping and system componentsrequired in the space heating system, using rec-ognized design methods.

System Piping - Zone Circulators

Connect the CHALLENGER to the systempiping as shown in Fig. 7 page 20 when zoningwith zone circulators.

The installer must provide a separate circulatorfor each zone of space heating.

To ensure an adequate flow rate throughthe CHALLENGER, the boiler supplyand return piping size must be a mini-mum of 1 inch.

System Piping - Zone Valves

Connect the CHALLENGER to the system pip-ing as shown in Fig. 8 page 20 when zoning withzone valves. The primary / secondary pipingensures that the boiler loop has sufficient flow.


CAUTION

NOTICE

NOTICE

18

Boiler Piping

Max.12"

Boiler

Supply System

Return System

[30.5 cm]

Cold Water Fill

Boiler Supply Return

7

10

1

2

3

5 4 6

6 6

11

7 1

10

9

8 4

3

6

6 6

Cold Water Fill

Boiler Supply

Minimum 3/4" Piping

Boiler Return

Return System

Supply System

11

Max.12" [30.5 cm]

Fig. 6 : Near Boiler Piping - Closed Type Expansion Tank

Fig. 5: Near Boiler Piping - Diaphragm Expansion Tank

1. System circulator

2. Automatic air vent

3. Air separator

4. Automatic fill valve

5. Diaphragm expansion tank

6. Isolation valve

7. Drain/purge valve

8. Tank fitting

9. Closed type expansion tank

10. Primary/secondary connection

11. CH circulator with flow check

19

Boiler Piping

System Piping - Radiant Heating

The heat exchanger design of the CHAL-LENGER allows operation in a condensingmode. This feature requires no regulation ofthe return water temperature back to the boilerin radiant heating applications.

The maximum boiler water supply temperaturecan be maintained by the CHALLENGER,potentially eliminating the need for a mixingsystem to achieve the desired temperature if allzones of heat are at the same temperature setpoint.

Size the system piping and circulator to providethe flow needed for the radiant system.


System Piping - SMART Indirect FiredWater Heater (I.F.W.H.)

See Figs. 7 and 8, page 20 for recommended pip-ing for a Triangle Tube SMART I.F.W.H.. Thisapplication will provide higher domestic hotwater flow rates for a short period of time (dumpload). The SMART’s boiler piping should bepiped as a zone load in the system. TheCHALLENGER’s boiler piping should be con-nected to the system piping in a primary sec-ondary piping arrangement.

The boiler system piping must be a“closed” system to avoid any oxygencontamination and potential failure ofthe outer tank of the SMART.

Refer to the installation manual provided withthe SMART for additional installation details.

See Parameter 1 and Note 3, page 44 for para-meter, wiring and operational details using theSMART I.F.W.H. with a CHALLENGER boil-er.

System Piping - Special Application

If the boiler is used in conjunction with achilled water/medium system, the boiler andchiller must be piped in parallel. Installflow/check valves to prevent the chilled medi-um from entering the boiler.

If the boiler is used to supply hot water to theheating coils of an air handler where they maybe exposed to chilled air circulation, installflow/check valves or other automatic devicesto prevent gravity circulation of the boilerwater during cooling cycles.

NOTICE

NOTICE

20

Boiler Piping

2

6

5

5

4

6 12

9

8

10 11

4

4

4

4

4 4

7

Additional

Max.[30.5 cm]12"

Zone Load

1

Zone Loador SMART I.F.W.H.

5

5

4

6

2

3

3

3

3

[30.5 cm]9

8

1011

4

4

4

4

44

Zone Loador SMART I.F.W.H.

Additional

7

6

Max.12"

Zone Load

1

Fig. 7: Central Heating (CH) System Piping - Zoningwith Zone Circulators

1. CHALLENGER boiler

2. Boiler circulator with flow check

3. Flow/check valve

4 Isolation valve

5. Zone circulator


7. Pressure relief valve

8. Air separator




Fig. 8: CH System Piping - Zoning with Zone Valves

1. CHALLENGER boiler

2. Boiler circulator with flow check

4 Isolation valve

5. Zone valve


7. Pressure relief valve

8. Air separator




12. System circulator

Installing Vent/Combustion Air & Condensate Drain

21

SECTION V - Installing Vent /Combustion Air & Condensate Drain

Installing Vent and Combustion Air

The CHALLENGER must be ventedand supplied with combustion air asshown in the CHALLENGER PVC,CPVC and SS Vent Supplement 2010-19, included in the installation envelope.Refer to instructions for parts list andmethod of installation. Once installationis completed, inspect the vent and com-bustion air system thoroughly to ensuresystems are airtight and comply with theinstructions given in the venting supple-ment and are within all requirements ofapplicable codes. Failure to comply withthe installation requirements on theventing and combustion air piping willcause severe personal injury or death.

Contact Triangle Tube for other ventingoptions including PVC ConcentricVent/Air Termination Supplement 2008-04 or CHALLENGER ConcentricVent/Air System Supplement 2010-23.Refer to these instructions for parts listand method of installation.

Installing Condensate Drain Assembly

1. Locate the condensate trap assembly andcut top with hacksaw or knife and install asshown in Fig. 13 page 22.

The installer must fill the condensatetrap with water prior to assembling onthe appliance. Do not operate appliancewithout factory supplied condensatetrap installed on appliance.

2. Remove front door and install trap. Ensurethe trap is completely seated and secure onthe appliance.

3. Connect 13/16” ID tubing to the drainbarbed fitting of the trap assembly.

The drain line materials must be anapproved material by the authority hav-ing jurisdiction. In absence of suchauthority, PVC and CPVC piping mustcomply with ASTM D1785 or D2845.The cement and primer used on the pip-ing must comply with ASME D2564 orF493. For installations in Canada, useULC certified PVC or CPVC pipe, fit-tings and cement/primer.

4. Continue the tubing from the trap assemblyto a floor drain or condensate pump.

When selecting and installing a conden-sate pump, ensure the pump is approvedfor use with condensing appliances. Thepump should be equipped with an over-flow switch to prevent property damagefrom potential condensate spillage.

5. The CHALLENGER will typically producea condensate that is considered slightlyacidic with a pH content below 4.0. Installa neutralizing filter if required.

The condensate drain must remainfilled, unobstructed and allow unre-stricted flow of condensate. The conden-sate should not be subject to conditionswhere freezing could occur. If the con-densate is subjected to freezing orbecomes obstructed , it can leak, result-ing in potential water damage to theappliance and surrounding area.

DANGER

NOTICE

NOTICE

NOTICE

NOTICE

CAUTION

22

Installing Vent/Combustion Air & Condensate Drain

Condensate Drain Trap Assembly* Carefully cut top of condensate drain trap assembly at location shown.

*

Fig. 13: Condensate Drain Trap Assembly

23

Gas Piping

SECTION VI - Gas Piping

Gas Supply Piping Connection

The gas supply piping must be installedin accordance to all applicable local,state and national codes and utilityrequirements.

1. Install a 1/2” NPT pipe union at the factorysupplied gas piping nipple, for ease of service.

2. Install the factory supplied manual shutoffvalve in the gas supply piping as shown inFig. 14. For installations in Canada theinstaller must tag and identify the mainshutoff valve.

3. Install a sediment trap (drip leg) on the gassupply line prior to connecting to the CHAL-LENGER gas train as shown in Fig. 14.

4. Support the gas piping using hangers. Donot support the piping by the appliance orits components.

5. Purge all air from the gas supply piping.

6. Before placing the CHALLENGER intooperation, check and test all piping connec-tions for leaks.

- Close the manual shutoff valve duringany pressure test with less than 13”w.c.[32 mbar].

- Disconnect the CHALLENGER and itsgas valve from the gas supply pipingduring any pressure test greater than13”w.c. [32 mbar].

Do not check for gas leaks with an openflame. Use a gas detection device or bub-ble test. Failure to check for gas leakscan cause severe personal injury, deathor substantial property damage.

7. Use pipe joint compound compatible withnatural and propane gases. Apply sparing-ly only to the male threads of pipe joints sothat pipe dope does not block gas flow.

Failure to apply pipe joint compound asdetailed above can result in severe per-sonal injury, death or substantial prop-erty damage.

Use a two-wrench method of tighteninggas piping near the appliance and its gaspiping connection. Use one wrench toprevent the appliance gas line connec-tion from turning and the second totighten adjacent piping. Failure to sup-port the appliance gas piping connectioncould damage the gas line components.

NOTICE WARNING

WARNING

WARNING

Position Bracket so Gas Pipe Hex Rests on Bracket

Tee Fitting (by Others)

Union Fitting (by Others)

Manual GasValve

(Supplied)

Cap Fitting(by Others)

Sediment TrapMin. Length of 3” [7.6 cm]

Fig. 14: Recommended Gas Supply Piping

Support gas piping

NOTICE

24

Gas Piping

NATURAL GAS

Pipe Sizing - Natural Gas

Refer to Table 1 for schedule 40 metallic pipelength and diameter requirements for naturalgas, based on rated CHALLENGER input(divide by 1,000 to obtain cubic feet per hour).

- Table 1 is based on Natural Gas with a spe-cific gravity of 0.60 and a pressure dropthrough the gas piping of 0.30”w.c. [0.75mbar].

- For additional gas piping sizing informa-tion, refer to ANSI Z223.1. For Canadianinstallations refer to B149.1.

Natural Gas Supply Pressure Requirements

1. Pressure required at the gas valve inletsupply pressure port:

- Maximum 13”w.c. [32 mbar] at flow orno flow conditions to the burner.

- Minimum 5”w.c. [13 mbar] during flowconditions to the burner. Must be veri-fied during start up and with all othergas appliances operating within the gaspiping service.

- Maximum gas inlet pressure must notbe exceeded and minimum gas inletpressure is for the purpose of inputadjustment.

2. Install 100% lockup gas pressure regulatorin the gas supply line if inlet pressure canexceed 13”w.c. [32 mbar] at any time.Adjust the lockup pressure regulator for13”w.c. [32 mbar] maximum.

DO NOT adjust or attempt to measuregas valve outlet pressure. The gas valveis factory-set for the correct outlet pres-sure. This setting is suitable for naturaland propane gas and requires no fieldadjustment. Attempts by the installer toadjust or measure the gas valve outletpressure could result in damage to thevalve, causing potential severe personalinjury, death or substantial propertydamage.

Table 2: Natural Gas Orifice Requirements

WARNING

Length of Pipe in

Feet

Capacity of Schedule 40 Metallic Pipe in Cubic Feet of Natural Gas Per

Hour (based on 0.60 specific gravity, 0.30" w.c. pressure drop)

SCH 40 1/2" 3/4" 1" 1-1/4" 1-1/2"

10 132 278 520 1050 1600

20 92 190 350 730 1100

30 73 152 285 590 890

40 63 130 245 500 760

50 56 115 215 440 670

75 45 93 175 360 545

100 38 79 150 305 460

150 31 64 120 250 380

Table 1: Gas Piping Sizing - Natural Gas

CHALLENGER

MODEL

Natural

Orifice Size

Orifice

Marking

CC85s 0.256” [6.50 mm] 650

CC105s 0.256” [6.50 mm] 650

CC125s &

CC150s0.285” [7.25 mm] 725

25

Gas Piping

PROPANE GAS

Pipe Sizing - Propane Gas

Contact the local propane gas supplier for rec-ommended sizing of piping, tanks and 100%lockup gas regulator.

Propane Gas Supply Pressure Requirements

1. Adjust the propane supply regulator pro-vided by the gas supplier for 13”w.c. [32mbar] maximum pressure

2. Pressure required at the gas valve inlet sup-ply pressure port:

- Maximum 13”w.c. [32 mbar] at flow orno flow conditions to the burner

- Minimum 5”w.c. [13 mbar] during flow con-ditions to the burner. Must be verified duringstart up and with all other gas appliancesoperating within the gas piping service.

- Maximum gas inlet pressure must not beexceeded and minimum gas inlet pressureis for the purpose of input adjustment.

DO NOT adjust or attempt to measure gasvalve outlet pressure. The gas valve is fac-tory-set for the correct outlet pressure.This setting is suitable for natural gas andpropane and requires no field adjustment.Attempts by the installer to adjust or mea-sure the gas valve outlet pressure couldresult in damage to the valve, causingpotential severe personal injury, death orsubstantial property damage.

Prior to start up, ensure the appliance isset to fire propane. Check the rating labelfor the type of fuel. Check the gas valvefor propane conversion label. If there is aconflict or doubt on the burner set up,remove the gas valve and check for thepropane orifice, see Fig. 15. Failure toensure proper burner setup could result insevere personal injury, death or substan-tial property damage.

Table 3: Propane Gas, Orifice Requirements:

WARNING

WARNING

Throttle Screw

Gas Supply Inlet Pressure Port

Flow direction

Gas Orifice

O-Ring Gasket

Fig. 15 : Gas Orifice Assembly

CHALLENGER

MODEL

Propane

Orifice Size

Orifice

Marking

CC85s 0.199” [5.05 mm] 505

CC105s 0.199” [5.05 mm] 505

CC125s &

CC150s0.220” [5.60 mm] - 580 -

26

Internal Wiring

SECTION VII - Internal Wiring

ELECTRICAL SHOCK HAZARD. Foryour safety, disconnect electrical powersupply to the appliance before servicingor making any electrical connections toavoid possible electric shock hazard.Failure to do so can cause severe person-al injury or death.

Prior to servicing, label all wires beforedisconnecting. Wiring errors can causeimproper and dangerous operation.Verify proper wiring and operation afterservicing.

General Requirements

- Wiring must be N.E.C Class 1.

- If original wiring as supplied with theappliance must be replaced, use only TypeT 194F [90ºC] wire or equivalent as a min-imum.

- The CHALLENGER must be electricallygrounded as required by NationalElectrical Code ANSI/NFPA 70 - latest edi-tion and / or the Canadian Electrical CodePart 1, CSA C22.1, Electrical Code.

WARNING

CAUTION

27

Internal Wiring

Boiler Circulator

Boiler Circulator

Aquastat

Aquastat

SMART I.F.W.H AquastatSMART I.F.W.H Aquastat

Fig. 16: CHALLENGER Factory Wiring Diagrams

Schematic Diagram

Ladder Diagram

- The wiring for 120V field connections to the appliance shall have a minimum size of 14 AWG and a tem-perature 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.

Note

28

External Wiring

SECTION VIII- External Wiring

Installation Compliance

All field wiring made during installation mustcomply with:

- National Electrical Code NFPA 70 andany other national, state, provincial orlocal codes or requirements.

- In Canada, CSA C22.1 CanadianElectrical Code Part 1, and any otherlocal codes.

ELECTRICAL SHOCK HAZARD.Before making any electrical connec-tions to the CHALLENGER, disconnectelectrical power supply at the servicepanel. Failure to comply can causesevere personal injury or death.

Line Voltage Connections

1. Connect a 120 VAC/15A service to the120V terminals L, N and G inside theCHALLENGER as shown in Fig. 16,page 27.

2. Route the incoming 120 VAC power wirethrough the provided openings in the bot-tom right side jacket panel.

3. The appliance must be provided with anexternal service switch, check local coderequirements for compliance.

The installer must provide and install afused disconnect or 15 amp (minimum)service switch. Check local electricalcode requirements for compliance.

The ON/OFF switch of the CHAL-LENGER only disables the function of theappliance. Electrical power remains at thecontrol module. To avoid a shock hazard,disconnect power at the external serviceswitch when servicing the appliance.

Control Module Circulator AMP Ratings

- AMP draw of the CH circulator must not

exceed 2.3 amps.

WARNING

NOTICE

WARNING

29

External Wiring

Low Voltage Connections

1. Open the display cover and unscrew both

screws to remove the front cover

2. Pull the control/display forward until it tips

downward to provide access.

3. Ensure field installed low voltage wiring is

not run parallel or next to telephone or

power cable.

4. Consult Table 4 for making low voltage

connections.

Table 4: Low Voltage Electrical

Thermostat Wiring

Isolate 120V wiring from low voltagewiring to prevent any potential electrical“noise”.

1. Connect room thermostat or the end switch(isolated contact only) to the low voltageterminal strip on the drop down controlpanel, as shown in Fig. 16, page 27 and Fig.17.

2. For proper operation install the room ther-mostat on an inside wall away from influ-ences of heat and cold, i.e. water pipes,areas of draft, lighting fixtures and fire-places.

3. Set the thermostat anticipator (if applica-ble) as follows:

- Set for 0.1 amps when wired directly tothe CHALLENGER.

- Set to match the total electrical powerrequirements of the connected deviceswhen wired to zone relays or otherdevices. Refer to the relay manufactur-ers’ specifications and the thermostatinstructions for additional informationon the anticipator setting.

When making low voltage connections tothe CHALLENGER, ensure no externalvoltage is present in the thermostat cir-cuits. If external voltage is present, pro-vide an isolated contact to prevent dam-age to the appliance control.

NOTICE

NOTICE

FuseControl/Display

Fig. 17: Accessing Low Voltage X4 Connections

Temperature control Connector X4 Notes Room thermostat 7 – 8 Voltage free Outside temperature sensor 9 – 10 -

SMART I.F.W.H 5 – 6 Voltage free Aquastat (Optional)

30

External Wiring

CH Circulator

1. Connect the CH primary circulator to theCHALLENGER 120 V terminals 1,2 and 3located inside the appliance as shown inFig. 16, page 27.

2. Maximum CH circulator continuous cur-rent draw is 2.3 A.

System Circulator - Zone Valve Application

To energize the system circulator shown asitem 12 in Fig. 8 page 20 reference Fig. 18.Installer to provide a Transformer / Relay suchas Honeywell R8285 or equivalent and ZoneValves with isolated end switch such asHoneywell V8043 or equivalent.

Outdoor Reset Control

The CHALLENGER may operate with a vari-able appliance operating temperature using theTriangle Tube outdoor sensor, see pages 47through 49 for installation and set-up.

If the installer opts for a fixed operatingtemperature for the boiler system, theoutdoor sensor is not required andshould not be installed.

NOTICE

24 V

Transformer

by Others

Honeywell V8043

Zone Valves

or Equivalent

Honeywell R8285B1038

Transformer / Relay

or Equivalent

Low Voltage Terminal Strip

System Circulator

24V Low Voltage Wiring

120V High Voltage Wiring

Room Thermostats

H N120V R C

G

1 3 4 6

7

8

To Challenger

Fig. 18: Secondary System Circulator Wiring

31

External Wiring

H N

High Voltage

120

V.A.C.

24

V.A.C.

Room

Thermostat

Room

Thermostat

Zone 1

Zone 2

Additional zones Additional zones maybe added as shown above

To Challenger


Transformer

(Power)

Zone

Valve

Zone Valve

7 8

To ChallengerLow Voltage Terminal Strip

H N High Voltage

120 V.A.C.

24 V.A.C.

Room Thermostat

Room Thermostat

Zone 1

Zone 2

Additional zones Additional zones may be added as shown above

Transformer (Power)

Zone Valve

Zone Valve

* Isolation relay 7

8

*Use isolation relay on 3-wire zone valve with non-isolated end switch. Control can burn out if isolation relay is not used.

NOTICE:

4 Wire Zone Valve

3 Wire Zone Valve

Fig. 19: Multiple Zone Field Wiring Using Zone Valves

32

External Wiring

T T

To Challenger


Circulator

Zone 1

Thermostat

zone 1Honeywell

R845A

Relay

120

H

VAC

N

Circulator

Zone 2

Thermostat

zone 2

Additional zones may be

added as shown above

7 8

62 1 4 3 5

62 1 4 3 5

T T

T T

Fig. 20: Field Wiring with Zone Circulators

Thermostat Zone 1

Zone 1 Circulator

120 VAC N

To ChallengerLow Voltage Terminal Strip Zone 2

Circulator Zone 3 Circulator

Thermostat Zone 2

Thermostat Zone 3

R C T1 T1 T2 T2 T3 T3

C3 C3 C2 C2 C1 C1 PR PR X2 X1 L1 L2 ZC

H 7

8

Fig. 21: Typical Zone Relay Panel Wiring

33

Start-Up Preparation

SECTION IX - Start-Up Preparation

Check Boiler System Water Chemistry

Do not use petroleum-base cleaning orsealing compounds in the boiler system.Damage to seals and gaskets in the sys-tem components could occur, resultingin substantial property damage.

System water including additives must bepractically non-toxic, having a toxicityrating or Class of 1, as listed in ClinicalToxicology of Commercial Products.

Water pH Level 6.5 to 8.5

Maintain the boiler water pH between 6.5 and8.5. Check using litmus paper or contact a watertreatment company for a chemical analysis.

If the pH does not meet this requirement, do notoperate the CHALLENGER or leave the appli-ance filled, until the condition is corrected.

Water Total Hardness Less Than 7Grains/Gallon

For areas with unusually hard water (totalhardness above 7 grains/gallon or 120ppm ormg/l) consult a water treatment company.

Chlorinated Water

Do not use the CHALLENGER to heat aswimming pool or spa directly.

Maintain the chlorine level of the water at lev-els considered safe for drinking.

Flush Boiler System to Remove Sediment

The installer must flush the boiler system toremove any sediment to allow proper operationof the CHALLENGER .

Flush the systems until the water runs cleanand is free of sediment.

For zoned systems, each zone should be flushedthrough a purge valve. Purge valves and isola-tion valves should be installed on each zone toallow proper flushing of the system.

Check and Test Antifreeze

For boiler systems containing antifreeze solu-tions, follow the antifreeze manufacturer’sinstructions in verifying the inhibitor level andto ensure the fluid characteristics are withinspecification requirements.

Due to the degradation of inhibitors over time,antifreeze fluids must be periodically replaced.Refer to the manufacturer of the antifreeze foradditional instructions.

System water including additives must bepractically non-toxic, having a toxicityrating or Class of 1, as listed in ClinicalToxicology of Commercial Products.

WARNING

NOTICE

NOTICE

34


Use of Antifreeze in the Boiler System

NEVER use automotive or ethylene gly-col antifreeze or undiluted antifreeze inthe boiler system as freeze protection.This can cause severe personal injury,death or substantial property damage ifignored.

Determine the antifreeze fluid quantity usingthe system water content volume and followingthe antifreeze manufacturer instructions.

The boiler water volume of the CHALLENGERCC85s is 0.37 gallons [1.4 l], CC105s is 0.42gallons [1.6 l] and CC125s and CC150s are 0.50gallons [1.9 l]. Remember to include this vol-ume in sizing of the expansion tank.

Check with local codes requirements for theinstallation of backflow preventers or actualdisconnection from the boiler’s cold water fillor make up water supply line.

Massachusetts Code requires the installa-tion of a backflow preventer if antifreezeis used.

Ensure the concentration of antifreeze to waterdoes not exceed a 50/50 ratio.

System water, including additives, mustbe practically non-toxic, having a toxicityrating or Class of 1, as listed in ClinicalToxicology of Commercial Products.

Filling the Boiler System

1. Close the boiler drain valve located on thebottom of the appliance and any manual orautomatic air vent in the system.

2. Open all system isolation valves.

3. Fill the boiler system to correct systempressure. Correct pressure will vary witheach application.

Typical residential system fill pressure is12 psi [0.8 bar]. System pressure willincrease when system temperatureincreases. Operating pressure of the sys-tem should never exceed 25 psi [1.7 bar].

4. Purge air and sediment from each zone ofthe hydronic system through the purgevalves. Open air vents to allow air to bevented from the zones.

5. Once the system is completely filled andpurged of all air and sediment, check thesystem pressure and check/repair any leaks.

Unrepaired system leaks will cause con-tinual makeup water to be added to theappliance. Continual makeup watercould cause mineral buildup within theheat exchanger, reducing the heat trans-fer, causing possible heat buildup andeventual heat exchanger failure.

Check Low Water Cut Off/CH PressureSensor

- The CHALLENGER is provided with afactory installed LWCO that senses boilerCH system pressure of more than 7 psig[0.5 bar].

- Compare CH system pressure gauge read-ing to CHALLENGER’s control pressuredisplay reading, which can only be viewedwhen control is ON and no CH call is pre-sent. Adjust pressure accordingly.

WARNING

NOTICE

NOTICE

NOTICE

WARNING

35


Check For Gas Leaks

Prior to start-up and during initial oper-ation, smell near the floor and aroundthe appliance for gas odorant or anyunusual odor. Do not proceed with thestart-up if there is any indication of a gasleak. Any leaks found must be repairedimmediately.

Propane installations only - The propanesupplier mixes an odorant with thepropane to make its presence detectable.In some cases the odorant can fade andthe gas may no longer have an odor.

Prior to start-up of the appliance andperiodically after start-up have thepropane supplier check and verify theodorant level.

Check Thermostat Circuit

- Disconnect the external thermostat wiresfrom the control terminal strip, located onthe drop down panel.

- Connect a voltmeter across the wire endsof the external thermostat wiring.

- Energize each thermostat, zone valve andrelay in the external circuit, individuallyand check the voltage reading across thewire ends.

- There should NEVER be voltage mea-sured at the wire ends.

- If voltage is measured at the panel under anycondition, check and correct the externalwiring.

In systems using 3-wire zone valves,backfeed of voltage to the appliance is acommon problem. Use an isolation relayto prevent voltage from the external cir-cuit entering the CHALLENGER con-trol panel.

- Reconnect the external thermostatwires to the control terminal strip.

Inspection of Condensate Drain Assembly

1. Inspect and ensure the Condensate DrainAssembly is properly installed as describedon page 21 and shown in Fig. 13 on page22.

2. Remove the Condensate Drain Assemblyand fill with fresh water.

The condensate drain assembly must beinstalled on the appliance and filled withwater when the CHALLENGER is inoperation. The condensate drain assem-bly prevents flue gas emissions fromentering the condensate line. Failure toensure trap is filled with water couldresult in severe personal injury or death.

3. Re-Install the condensate drain assembly.

WARNING

WARNING

NOTICE

NOTICE

36

Start-Up Procedures

SECTION X - Start-Up Procedures

Final Checks Before Start-Up

c Read page 39 through 49 regarding theoperation of the CHALLENGER control.

c Verify the CHALLENGER and the boilersystem are full of water and all systemcomponents are correctly set for operation,including the minimum flow rate throughthe boiler, see pages 69-71.

c Verify Start-up Preparation items outlined onpages 33 thru 35 have been completed.

c Verify all electrical connections are correctand securely fastened.

c Inspect vent and combustion air piping forsigns of deterioration from corrosion, physicaldamage or sagging. Verify combustion airand vent piping are intact and correctlyinstalled and supported. Reference the properCHALLENGER vent supplement.

c Verify burner configuration - gas orificesize.

- Check for proper labeling on the gasvalve (propane only) and the rating labelfor proper gas configuration.

- If there is doubt on the burner configura-tion, remove the gas valve and check forproper gas orifice size. See pages 24 and25 for orifice sizes.

c Ensure the vent Condensate DrainAssembly is filled with water.

CHALLENGER Start-Up

1. Turn ON the electrical supply/service to the

appliance. Press the ON-OFF button “ ”

located on the front control panel to the OFF

position.

2. Read and follow the Operating Instructionsoutlined on page 38.

If CHALLENGER Does Not Start Correctly

1. Verify CH system is turned ON (parameter1) is set to “3”. Read setting the appliance

parameters section of the manual startingon page 44 for more information.

2. Check for loose electrical connections,blown fuse (external or internal at theappliance control) or open service switch.

3. Is the external limit control (if applicable)open? Ensure the external limit is reset tothe closed position.

4. Is the gas supply valve(s) open at the appli-ance and meter?

5. Is incoming gas supply pressure at theappliance more than 5”w.c. [13 mbar] andless than 13” w.c. [32 mbar] for natural orpropane with all gas appliances ON orOFF.

6. Are the heating thermostats set above roomtemperature?

If none of these conditions correct the problem,contact Triangle Tube Tech Service.

Check the CHALLENGER and System

c Check Piping.

Check piping and components forleaks. If found, shut down the appli-ance and repair immediately.

Purge any remaining air from the systempiping. Air in the system piping willinterfere with circulation creating heatdistribution problems and system noise.

c Check Vent Piping and Combustion AirPiping.

Check for gas-tight seal at every con-nection and seam of the venting andcombustion air piping.

Venting system must be sealed gas-tightto prevent flue gas spillage and potentialcarbon monoxide emissions, which willresult in severe personal injury or death.

WARNING

37

Start-Up Procedures

c Check Gas Piping

Check around the appliance for gasodor following the procedure outlinedin this manual on Page 35.

If any gas leaks are found or suspected,shut the appliance down immediately.Use a gas detection device or bubble testto locate the source of the gas leak andrepair at once. Do not operate the appli-ance until the leak is corrected. Failureto comply with this procedure couldresult in severe personal injury, death orsubstantial property damage.

c Verify Flame Pattern and Combustion

Check the flame pattern through theinspection port on the left side of theheat exchanger. The flame should beblue and stable and should be the lengthof the burner.

The combustion testing and adjustmentsmust be performed by a qualifiedinstaller, service agency or the gas suppli-er. All combustion measurements must beperformed with calibrated equipment toensure proper reading and accuracy.

Test for C02 or 02 and for CO duringhigh and low firing rate. To manuallyplace the appliance into high or low firemode, reference page 42. The combus-tion reading should be within the rangelisted in Table 5. The CO level shouldnot exceed 100 ppm when combustionis correct.

The combustion levels should be mea-sured at high and low firing rate, refer topage 42 of the CHALLENGER controlsection on how to set the firing rate. Ifthe combustion levels are not within therange given in Table 5 for the firing rate,shut the appliance down and contact

Triangle Tube Engineering Department.Failure to comply with this requirementcould result in severe personal injury,death or substantial property damage.

Table 5: Recommended Combustion Levels

c Measure Input - Natural Gas Only

1. Ensure the appliance is firing at maximumfiring rate. To manually place the applianceinto high fire mode, reference page 42.

2. Operate the appliance for approximately10 minutes.

3. Turn off all gas appliances on the gas ser-vice, except the CHALLENGER.

4. At the gas meter, record the time requiredto use one cubic foot of gas.

5. Calculate Natural gas input using the fol-lowing equation:

3600 x 1000 / number of second recordedfor one cubic foot of gas = BTU/H.

6. The BTU/H calculated should approximatethe input rating listed on the appliance.

WARNING

WARNING

WARNING

Natural Gas Propane Gas

High Fire

(h or H)

( and +)

DOOR OFF*

9% to 10.1% C02 10.5% to 11.1% C02

5% to 3.2% 02 5% to 4.1% 02

Low Fire

(L)

( and -)

0 to 0.4 lower

C02 than high fire

9.0 % min. C02

0 to 0.4 lower C02

than high fire

10.5 % min. C02

0 to 0.6 higher

02 than high fire

5.0% max. 02

0 to 0.6 higher

02 than high fire

5.0% max. 02

CO Max. 100 ppm 100 ppm

* Door on can raise the maximum allowable C02 by

0.4 or lower the minimum allowable 02 by 0.6.

38

Start-Up Procedures

WARNING

FOR YOUR SAFETY READ BEFORE LIGHTING

OPERATING INSTRUCTIONS

TO TURN OFF GAS TO APPLIANCE

1. STOP! Read the safety information above. This

appliance is equipped with an ignition device

which automatically lights the burner. DO NOT

try to light the burner by hand.

2. Set room thermostat(s) to lowest setting. Turn the

external manual gas valve handle clockwise

“CLOSE” (valve handle shall be per-

pendicular to gas piping).

3. Turn “OFF” all electrical power to the appliance.

4. Remove the front jacket panel on the appliance.

5. Turn the external manual gas valve handle

counter clockwise to “OPEN” gas sup-

ply (valve handle shall be parallel to gas piping).

6. Wait five (5) minutes to clear out any gas. If you

then smell gas in the jacket enclosure or around

the appliance, STOP! Follow “B” in the safety

information above. If you don’t smell gas, go to

the next step.

7. Turn “ON” all electric power to the appliance. Push

ON/OFF button on the CHALLENGER control

panel display until LED above button is lit.

8. Set room thermostat(s) to desired setting(s).

9. The CHALLENGER control panel display will

show a sequence of numbers (1,2,3,4) as the right

digit. Sequence digit 3 or 4 indicates the appliance

is firing. A blank display means there is no call for

heat (all external thermostats are satisfied).

10. If the appliance will not operate with a call for heat

and the system piping is not hot, follow the instruc-

tions “To Turn Off Gas to Appliance”, below and

call your service technician or gas supplier.

11. Replace the front jacket panel. Make sure the panel is

seated firmly in place and all mounting screws are

tightened.

If you do not follow these instructions exactly, a fire or explosion mayresult causing property damage, personal injury or loss of life.

1. Set the room thermostat to lowest setting.

2. Turn“OFF” all electric power to the appliance if

service is to be performed.

3. Turn the external manual gas valve handle clock-

wise to “CLOSE”, (valve handle shall be

perpendicular to gas piping).

A. This appliance does not have a pilot. It is

equipped with an ignition device which automat-

ically lights the burner. DO NOT try to light the

burner by hand.

B. BEFORE OPERATING, smell all around the

appliance area for gas. Be sure to smell next to

the floor because some gas is heavier than air and

will settle on the floor.

WHAT TO DO IF YOU SMELL GAS• Do not try to light any appliance.

• Do not touch any electric switch; do not use

any phone in your building

• Immediately call your gas supplier from a

neighbor’s phone. Follow the gas supplier’s

instructions.

• If you cannot reach your gas supplier, call the

fire department.

C. Use only your hand to turn the external manual gas

valve. Never use tools. If the valve will not turn by

hand, don’t try to repair it; call a qualified service

technician. Force or attempted repair may result in

a fire or explosion.

D. 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 and any gas control

which has been under water.

39

Start-Up Procedures

Appliance ON/OFF

1. The appliance operation is started using theON/OFF button.

2. When appliance is in operation, the greenLED above the ON/OFF will be lit.

3. When the appliance is not in operation, thegreen LED above the ON/OFF will notbe lit. The main display will show “OFF”and the operating display will show .

Set Boiler Maximum Central Heating (CH)Set Point Temperature

1. Press the CH/DHW/Parameter button “ ”at the display panel for approximately 2 to3 seconds until the radiator symbol “ ”(CH) LED, lights up and the main displaybegins to flash.

2. Press the or buttons to set the desiredmaximum temperature setting on the maindisplay.

3. Press the reset button to close the set-ting menu and store the changes.

If the reset button is not pressed with-in 30 seconds, the settings menu is auto-matically closed and the changes arestored.

If the ON/OFF button is pressed prior

to the reset button, the settings menu

is closed and the changes are NOT stored.

Operation Verification - Space Heating

Digits and characters shown in brackets

[0], in the following outline, represent

the control module operating display.

1. Set the room thermostat to the lowest setting.

2. Turn off power to the appliance, wait a fewseconds and turn on power to the appliance.

3. The following operating displays shouldoccur:

[A] Self check on power up

[ ] No call for heat

4. Initiate a call for heat by raising the setpoint of the room thermostat to the highestsetting. The following operating displayshould occur

[1] This is the prepurge cycle. The burnerblower and the boiler circulator becomeenergized. The blower has a 5 second pre-purge cycle.

[2] This is the ignition cycle. The controlmodule will energize and open the gasvalve and begin the spark for ignition.

- If the burner flame proves, the burnerwill begin to modulate.

- If the burner flame is not establishedthe control module will repeat the igni-tion sequence after approximately 15seconds . If the flame is not establishedafter four attempts the control willlockout. The main display willshow [4] and the fault LED above the

reset button will flash and [E] willflash in the operating display.

- To verify flame failure safety lockout,close the manual shut off valve on thegas supply piping to the appliance andrepeat ignition sequence. When verifica-tion is completed, ensure the manual shutoff valve is returned to the open position.

[3] This is the normal Central Heating(CH) operation cycle. The control modulewill begin to modulate the burner firingrate based on actual appliance outlet tem-perature and the set point temperature.The CH water temperature is displayed onthe main display.

5. Allow the appliance to operate and the boil-er outlet temperature to reach the set pointtemperature.

NOTICE

NOTICE

40

Start-Up Procedures

[1] The setpoint temperature has beenreached. Combustion will cease and the postpurge cycle of the blower begins. The controlmodule will de-energize the gas valve andthe blower will continue with the 10 secondpost purge cycle, before shutting down. TheCH circulator will continue to run until theroom thermostat is satisfied.

6. Lower the room thermostat set point belowthe room temperature to end the call forheat.

[1] This begins a post purge cycle. Whenthe room thermostat is satisfied, the appli-ance will shutdown.

[7] The CH circulator will continue to runfor a 1 minute post pump cycle.

The CH circulator automatically runsfor 10 seconds once every 24 hours toprevent seizing. Timing for this automat-ic switching starts after the last call forheat.

[ ] The appliance is in Standby MODEwaiting for a call for heat.

7. Verify the operation of the appliance byrepeating the operational sequence severaltimes.

8. Return the room thermostat to a desired set-ting.

NOTICE

41

Start-Up Procedures

Control Display

Appliance ON/OFF

1. The appliance operation is started using theON/OFF button.

2. When appliance is in operation, the greenLED above the ON/OFF will be lit.

3. When the appliance is not in operation, thegreen LED above the ON/OFF will notbe lit. The main display will show “OFF”and the operating display will show .

Units

Press Up or Down arrow button to change thedisplayed units from U.S. Customary (ºF or psi)to metric (ºC or bar). The ºF/psi LED will be litfor U.S. Customary units or ºC/bar LED will belit for metric units.

Units cannot be changed if the main dis-play (Parameter Mode) or operating dis-play (Error Mode) is flashing.

NOTICE

A. On/Off button B. Parameter buttonC. - buttonD. + buttonE. Units U.S. customary or metric F. Not applicableG. Service buttonH. Reset/store button

Read-Out Operation1. On/Off (Lit when on)2. CH operation or setting maximum CH temperature3. DHW operation with optional Triangle Tube SMART I.F.W.H4. Main display with temperature or water pressure or fault code5. Temperature ºF or pressure psi6. Temperature ºC or pressure bar7. Not applicable8. Not applicable9. Operating display10. Flashes to indicate fault

42

Start-Up Procedures

Test Mode Function

TO TEMPORARILY PLACE THE BURN-ER INTO HIGH FIRE TEST MODE: pressand hold both the “ ” and “+” button simul-taneously once until operating display shows“h” or twice until the operating display shows“H” for high fire.

While in the test mode:

- high limit will function

- appliance CH circulator will function

- the test mode will time out in approxi-mately 10 minutes

TO TEMPORARILY PLACE THE BURN-ER INTO LOW FIRE TEST MODE: pressand hold both the “ ” and “ ” button simul-taneously until operating display shows “L”.

TO DEACTIVATE THE HIGH OR LOW

FIRE TEST MODE: press and hold both the

“+” and “-” button simultaneously.

43

Start-Up Procedures

Function

Main Display Operating Display

OFF

XXPXXP

XXX

7

Press

No demand for heatControl self-test

Fan pre purge or post purge cycle

Space Heating (CH) post pump cycle

XXX

XXX

6

A

1

Ignition sequence

XXX

2

Burner ON for space heating (CH)

XXX

LOP*

3

Burner ON for domestic hot water (DHW)with optional Triangle Tube SMART I.F.W.H.

4

Raise CH pressure above 7 psig [0.5 bar]

Burner ON for freeze protection

The LED will be lit for CH (central heating call)

9

Burner OFF due to reaching temperaturesetpoint

button to turn appliance ONLED lite above button will be lit

The LED will be lit for DHW (domestic hot water call) with optional Triangle Tube SMART I.F.W.H.

NOTICE

when appliance is ON

“X” represents temperature or pressure readings. When temperature is displayed it will be followed by “ºF” or “ºC” in the main display and the appropriate LED will be lit. When pressure is displayed it will be followed by a “P” in the main display. Pres-sure can only be read when the operating display is blank or shows a “A”.

* If factory installed CH Low Water Cut Off (LWCO) is below 7 psig [0.5 bar] the main display will flash a soft lockout of LOP (burner and CH primary pump is blocked) followed by the pressure reading. Once CH system pressure is increased above 7 psig [0.5 bar] normal boiler operation will be restored. Check LWCO wiring if LOP flashes to 90 _P (PSI) or 6.0 _P (bar).

44

Start-Up Procedures

Setting the Appliance Parameters

1. Press the “ ” button at the display panelfor approximately 2 to 3 seconds until maindisplay begins to flash.

2. Press the “ ” button repeatedly to scrollthrough the list of parameters. The operatingdisplay will show the parameter numberand main display will show the parametersetting.

3. To modify a parameter press the orbuttons.

4. Press the “ ” button to scroll to the nextparameter to be changed.

5. After all parameters have been changed,press the reset button to close the settingmenu and store the changes. The main dis-play will go blank and a P will be displayedin the operating display to let you know thecontrol was programmed.

If the reset button is not pressed within30 seconds, the settings menu is automati-cally closed and the changes are stored.

If the ON/OFF button is pressed prior

to the reset button, the settings menu

is closed and the changes are NOT stored.

NOTICE

AdjustmentsDescriptionParameters(Flashing)

Factory SettingsLED(Flashing)

Installation type 0

186ºF [86Cº]120ºF [49Cº]

0=Combi (Heat and DHW)

2=DHW only (no heating system required) 3=Heating only

CH pump continuous 0 0=Intermittent pump on for heat and post purge1=Pump continously active except during DHW call or if outside temperature is above parameter 7 with the outdoor sensor installed - Warm Weather Shut Down.

1=Heating + SMART I.F.W.H.

Min. supply temperature of the heat curve 86ºF [30Cº] Adjustment range 60°F to 140°F [16ºC to 60ºC] Min. outside temperature of the heat curve 0ºF [-18Cº] Adjustment range -22°F to 50°F [-30ºC to 10ºC] Max. outside temperature of the heat curve 64 ºF [18Cº] Adjustment range 60°F to 78°F [16ºC to 26ºC] CH pump post purge period 1 Adjustment range 0 to 15 minutes Not applicable 0 Adjustment range 0 to 15 minutes

Anti-cycling period during CH operation

The anti-cycling time starts when burner shuts down during a CH call due to boiler water reaching the boiler set point temperature plus a 6ºF [3ºC] differential. The CH circulator will continue to operate while the burner is blocked.

0 Minimal switch-off time in CH operation Adjustable from 0 to 15 minutes

1

2

5678

o

P

Main DisplayOperating

Display

Boiler set point temperatureNot applicable

Adjustment range 86ºF to 194ºF [30ºC to 90ºC]Adjustment range 104ºF to 149ºF [40ºC to 65ºC]

1

1

For installations with a Triangle Tube SMART Indirect Fired Water Heater (I.F.W.H.) piped in with the space heating zone loads, similar to figures 7 and 8 on page 20, parameter 1 should be set to 1. The SMART’s aquastat should be wired to the T-T contacts of the priority zone of a zone panel control to prioritize the domestic call for heat. The pump output of the priority zone should be wired to a 120V Double Pole Double Throw (D.P.D.T) coil relay, similar to Honeywell’s R4222D1013 relay. One of the normally open contacts should switch line voltage to the domestic I.F.W.H. pump, the other normally open contacts should be wired to the CHALLENGER’s Low voltage X4-5 and X4-6 electrical connectors, see Figure 17, page 29. During a domestic call for heat terminals X4-5 and X4-6, the primary boiler pump will operate and the boiler’s target supply water temperataure will shift to 186ºF [86ºC].

2

2

45

Start-Up Procedures

Error (Hard Lockout) Mode

If a system fault occurs, the system enters ahard lockout condition which requires a manu-al reset by pressing the RESET button . Ahard lock is indicated by a flashing [E] on theoperating display as well as a flashing LEDlight above the reset button. The error codeis located on the main display. The error mustbe corrected before the control will reset.

The appliance freeze protection featureis disabled during a Hard Lockout, how-ever the CH circulator will operate.

During a hard lockout or low water con-dition the appliance will not re-startwithout service. If the heating system isleft unattended in cold weather appro-priate safeguards or alarms should beinstalled to prevent property damage.

CAUTION

CAUTIONTable 6: 12 K Ohm NTC Sensor Resistance

46

Start-Up Procedures

10, 11, 12,

1, 28

4

0

2

29,30

5

6

8

13, 14 sensor fault S1 - CH supply

• 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

• Replace S2• E 20 Open sensor• E 21 Shorted sensor• E22 Decreased too quickly• E23 Increased too quickly• E24 Stuck

20, 21, 22, 23, 24

- CH return sensor fault S2

• Check wiring for break • Check for proper flow direction

- Sensor fault after self check • Replace S1 and/or S2

- Temperature too high • Air in installation • Pump not running • Insufficient flow in installation, shut off valves closed, pump setting too low • CHeck for wiring

- CH supply sensor S1 and CH return sensor S2 interchanged

• Check for proper flow direction• Replace S1 or S2

- No flame signal

• Manual gas shut off valve closed • Remove air from gas pipe • Gas supply pressure too low or failing • Gas valve or ignition unit not powered• Incorrect ignition gap• Check adjustment of gas valve

- Poor flame signal • Condensate drain blocked • Check adjustment of gas valve

- Flame detection fault • Replace ignition cable + spark plug cap • Replace ignition unit at gas valve• Replace boiler controller

- Incorrect fan speed • Fan catching on casing • Wiring between fan and casing • Check wiring for poor wire contact • Replace fan

- Gas valve relay fault • Replace boiler controller

OperatingDisplay

(Flashing)Main Display Possible SolutionError Description

E

18, 19 fault- Flue sensor • E18 open sensor

• E19 Shorted sensor• Check/Replace sensor

E

50F - Improper frequency • Verify ground• Frequency should be between 45 and 65 Hz

E

E

E

E

E

E

E

E

E

Error (Hard Lockout) Codes*

NOTICEIf outdoor sensor is shorted the boiler will not enter into a hard lockout butwill maintain the minimum supply temperature of the heat curve.

* Red LED above button will flash, correct condition, and press button.

47


SECTION XI - Outdoor Reset Control

The appliance setpoint for a heating call can befixed or vary with the outdoor temperature. Ifthe application requires a constant supply tem-perature from the boiler, the outdoor temperaturesensor should not be connected to the appliance.If an outdoor temperature sensor is connected tothe appliance, the outdoor reset function is auto-matically enabled and will vary the CH setpointwith the change in outdoor temperature.

Mounting the Outdoor Sensor

1. Remove the front cover and mountingscrews / anchors from the sensor enclosure.

2. When mounting the enclosure, the exteriorwall selected should represent the coldestoutdoor temperature. Typically a northernor northeastern wall will suit most build-ings. A southern facing wall may suit build-ings that have large glass walls or windowson the southern face.

3. Ensure the sensor enclosure is shieldedfrom direct sunlight or the effects of heat orcold from other sources (exhaust fans,appliance vents...) to prevent false temper-ature sensing.

4. Mount the sensor enclosure at an elevationon the exterior wall to prevent accidentaldamage or tampering.

5. Avoid mounting the enclosure in areas sub-jected to excessive moisture.

6. Once an area on the exterior wall has beendetermined, to affix the enclosure use theenclosure as a template to mark the locationof the mounting screws.

7. Using a 3/16” [5 mm] drill bit, drill 2 pilotholes on the marked locations.

8. Tap the enclosed plastic anchors into thepilot holes. Use care not to damage theanchors.

9. Mount the sensor enclosure using thescrews provided.

Wiring the Sensor

1. Route two 18 gauge wires through the sealgasket. Connect the wires to the sensor ter-minals 1 and 2.

2. Route the sensor wire back to the CHAL-LENGER, ensuring the wires are not runparallel to telephone or power cables.

If the sensor wires are located in an areawith sources of potential electromagneticinterference (close to 120 V wiring) thesensor wires should be shielded or thewires should be routed in a groundedmetal conduit. If using shielded cable,the shielding should be connected to thecommon ground of the appliance.

3. Connect the sensor wires to the outdoor sen-sor terminals 9 and 10 on the low voltage X4connector terminal strip located at the con-trol on the swing out panel (see appliancewiring diagram, Fig. 16 page 27).

NOTICE

Sensor EnclosurePlastic Anchors (2)

Seal Gasket

Front Cover

MountingScrews

(2)

Fig. 22: Sensor Enclosure and Components

48


Adjusting Outdoor Reset Curve

The appliance CH set point along withParameters 5, 6 & 7 define the settings of theoutdoor reset curve. See Graph 1 and Table 7,page 49 for an example of modifying the out-door reset curve.

CH Maximum Boiler OperatingTemperature

If an outdoor temperature sensor is not con-nected to the appliance, the appliance setpointfor a heating call will be set to the CHMaximum Boiler Operating TemperatureSetpoint. If an outdoor temperature sensor isconnected, the CH Maximum Boiler OperatingTemperature Setpoint becomes the appliancesetpoint on the CH Reset Curve Coldest Day.

CH Minimum Boiler Operating TemperatureSetpoint(Parameter 5)

This parameter is not applicable if an outdoorsensor is not connected to the appliance. Whenan outdoor temperature sensor is connected, theCH Minimum Boiler Operating TemperatureSetpoint becomes the appliance setpoint on theCH Reset Curve Warmest Day.

CH Reset Curve Coldest Day(Parameter 6)

This parameter is not applicable if an outdoorsensor is not connected to the appliance. When

an outdoor temperature sensor is connected,the CH Reset Curve Coldest Day is the coldestdesign temperature of the heating system.

CH Reset Curve Warmest Day(Parameter 7)

This parameter is not applicable if an outdoorsensor is not connected to the appliance. Whenan outdoor temperature sensor is connected,the CH Reset Curve Warmest Day is thewarmest design temperature of the heating sys-tem.

Changing Outdoor Reset Parameters

1. Press the “ ” button at the display panelfor approximately 2 to 3 seconds until maindisplay begins to flash.

2. Press the “ ” button repeatedly to scrollthrough the list of parameters. The operatingdisplay will show the parameter numberand main display will show the parametersetting.

3. To modify a parameter press the orbuttons.

4. Press the button to close the settingmenu and store the changes.

The appliance control module has now been

reprogrammed with the desired parameter values.

Pressing the ON/OFF button will exit

the parameter setting mode without

storing the parameter changes.

NOTICE

Factory SettingMinimum

Setting

Maximum

Setting

186ºF

[86ºC]

86ºF

[30ºC]

194ºF

[90ºC]


Setting

Maximum

Setting

64ºF

[18ºC]

59ºF

[16ºC]

77ºF

[26ºC]


Setting

Maximum

Setting

00ºF

[- 18ºC]

-22ºF

[-30ºC]

50ºF

[10ºC]


Setting

Maximum

Setting

86ºF

[30ºC]

59ºF

[16ºC]

140ºF

[60ºC]

49


90

20

60

80

100

140

70 64

50 30 10 0 -10

77

Boile

r Tem

pera

ture

( F)

Outdoor Air Temperature ( F)

Boiler CH Set Point

Parameter 5 Set Point

Para

met

er 7

Set

ting

Para

met

er 6

Set

ting

Graph 1: Outdoor Air Temperature Reset Curve (Example)

Table 7: Outdoor Air Temperature Reset (Example)

Outdoor

Temperature

Appliance target Temp.

Based on Outdoor Temp.

10ºF or Lower 140ºF

30ºF 117ºF

50ºF 93ºF

64ºF or Higher 77ºF

Graph 1 illustrates Appliance CH Setpoint adjusted to 140ºF target temperature at10ºF outdoor air temperature

Note: Factory setting of CH set point is 186ºF

50

Check-Out Procedures

SECTION XII- Check-Out Procedures

Perform the following check-out proce-dures as outlined and check off items ascompleted. When procedures are com-pleted, the installer should complete theinstallation record on page 51.

Check-Out Procedures

c Boiler system water chemistry checked andverified as outlined on page 33.

c Any automatic air vents caps placed withinthe system are open one full turn.

c Air is purged from the heating zones andappliance system piping.

c Confirm the appliance has proper gas ori-fice as noted on pages 24 and 25.

c Thermostat circuit wiring checked and ver-ified that no voltage is present to the lowvoltage terminals as outlined on page 35.

c Operating Instructions on page 38 were fol-lowed during start-up.

c Combustion levels and flame pattern veri-fied as outlined on page 37.

c Measured the rate of input on Natural Gasas outlined on page 37.

c Checked the incoming gas pressure to theCHALLENGER to ensure a minimumpressure of 5”w.c [13 mbar] during flowconditions to all gas appliances and a max-imum pressure of 13”w.c [32 mbar] duringnon-flow conditions for Natural andPropane gas.

c Adjusted balancing valves and system limitcontrols to provide design temperatures tothe primary space heating system.

c In multiple zone applications, adjusted forcorrect flow of appliance water to eachzone.

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 forproper operation of the CHALLENGERand the system.

c Set the room thermostat(s) to the desiredroom temperature.

c Reviewed all instructions shipped with theCHALLENGER with the homeowner ormaintenance personnel.

c Completed the Installation Record on page51.

c Ensure all manuals and other documentsare returned to the Installation envelopeand given to the owner for safekeeping.

NOTICE

51

Installation Record

SECTION XIII - Installation Record

CHALLENGER Model Number:

Serial Number:

Date of Installation:

Fuel: Natural Gas Propane

Measured Rate of Input:

Combustion Readings:

CO2

O2

CO

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.

Installer Information

(Company)

(Address)

(Address)

(Phone Number)

Btu/hr

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

_________________________________________________________________

%

%

ppm

52

Maintenance Schedule

SECTION XIV - Maintenance Schedule

Service Technician

At least on an annual basis the following main-tenance should be performed by a qualified ser-vice technician:

General

- Attend to any reported problems.

- Inspect the interior of the appliance jacketarea; clean and vacuum if necessary.

- Clean the condensate drain assembly andfill with fresh water.

- Check for leaks: water, gas, flue and con-densate.

- Verify flue vent piping and air inlet pipingare in good condition, sealed tight andproperly supported.

- Check appliance water pressure, piping andexpansion tank.

- Check control settings.

- Check ignition electrode (sand off anywhite oxide; clean and reposition).

- Check ignition wiring and ground wiring.

- Check all control wiring and connections.

- Check burner flame pattern (stable and uni-form).

Additional items if combustion or performanceis poor:

- Clean heat exchanger and flue ways.

- Remove burner assembly and clean insideof burner head using compressed air only.

Once the maintenance items are completed,review the service with the owner.

Owner Maintenance

Periodic:

- Check the area around the appliance.

- Check and remove any blockage from thecombustion air inlet and ventilation open-ings.

- Check the temperature and pressure gauge.

Monthly:

- Check vent piping.

- Check combustion air inlet piping.

- Check the pressure relief valve.

- Check the condensate drain assembly.

Every 6 months:

- Check appliance piping and gas supply pipingfor corrosion or potential signs of leakage.

- Operate the pressure relief valve.

Follow the maintenance proceduresgiven throughout this manual. Failureto perform the service and maintenanceor follow the directions in this manualcould result in damage to the CHAL-LENGER or in system components,resulting in severe personal injury, deathor substantial property damage.

WARNING

53

Maintenance Procedures

SECTION XV - MaintenanceProcedures

Annual Maintenance Procedures

The CHALLENGER should be inspect-ed and serviced annually, preferably atthe start of the heating season, by a qual-ified service technician. In addition, themaintenance and care of the applianceas outlined on page 52 and furtherexplained on pages 53 through 59 shouldbe performed to assure maximum effi-ciency and reliability of the appliance.Failure to service and maintain theCHALLENGER and the system compo-nents could result in equipment failure,causing possible severe personal injury,death or substantial property damage.

The following information providesdetailed instruction for completing themaintenance items outlined in the main-tenance schedule on page 52. In additionto this maintenance, the CHAL-LENGER should be serviced at thebeginning of the heating season by aqualified service technician.

Reported Problems

Any problems reported by the owner should bechecked, verified and corrected before pro-ceeding with any maintenance procedures.

Check Surrounding Area

Verify that the area surrounding the CHAL-LENGER is free of combustible / flammablematerials or flammable vapors or liquids.Remove immediately if found.

Verify that combustion air inlet area is free ofany contaminates. Refer to the materials listedon page 7 of this manual. If any of these prod-ucts are in the area from which the appliancetakes its combustion air, they must be removedimmediately or the combustion air intake mustbe relocated to another area.

Inspect Burner Area

Remove the appliance front jacket panel.

Vacuum any dirt or debris from the blowercomponent.

Re-install front jacket panel when completed.

Do not use solvents to clean any of thecomponents. The components could bedamaged, resulting in unreliable orunsafe operation.

Check System Piping

Inspect all piping (water and gas) for leaks andverify that the piping is leak free and properlysupported.

Inspect the fittings and components on theappliance and verify they are leak free.

Eliminate all boiler leaks. Continual freshmake-up water will reduce the heatexchanger life causing appliance failure.Leaking water may also cause severeproperty damage to the surrounding area.Inspect the gas supply piping using theprocedure outlined on Page 35.

NOTICE

WARNING

WARNING

WARNING

54


Clean Condensate Drain Assembly

1. Remove the condensate assembly from theappliance.

2. Empty any water from the trap and drainassembly. Flush with fresh water as neces-sary to clean.

3. Check the drain piping from the condensatedrain assembly to the drain. Flush to cleanas necessary.

4. Fill the condensate drain assembly with water.

5. Reassemble the condensate drain assemblyonto the appliance.

When re-assembling the condensate drainassembly ensure all gaskets are in place andcorrectly installed. Ensure all associatedinternal joints are complete, tight and secure.Failure to comply can result in flue gas leak-age resulting in severe personal injury, deathor substantial property damage.

Check Ventilation Air Openings

Verify that all ventilation openings to themechanical room or building are open andunobstructed. Check the operation and wiringof any automatic ventilation dampers.

Check and verify the vent discharge and thecombustion air intake are free of debris andobstructions.

Inspect Vent and Combustion Air Piping

Visually inspect the venting system and com-bustion air piping for blockage, deteriorationor leakage. Repair any deficiencies.

Verify that the combustion air inlet piping isconnected, sealed and properly supported.

Failure to inspect the vent system andcombustion air inlet piping and to haveany conditions repaired, can result insevere personal injury or death.

Check Boiler System

Verify all system components are correctlyinstalled and operating properly.

Check the cold fill pressure for the system, typ-ical cold water fill pressure is 12 psig [0.8 bar].

Verify the system pressure, as the applianceoperates at high temperature, to ensure the pres-sure does not exceed 25 psig [1.7 bar].Excessive pressure reading may indicate expan-sion tank sizing is incorrect or system perfor-mance problems.

Inspect air vent and air separators in the sys-tem. Remove the caps on automatic air ventsand briefly depress the valve stem if present toflush vent. Replace the cap when completed.Ensure vents do not leak. Replace any leakingvents.

Removing Internal Flue and CondensatePan For Inspection

1. Loosen the flue pipe retaining ring asshown in Fig. 23, page 55.

2. Pull up on the flue pipe to disengage fromthe condensate pan as show in Fig. 24.

3. Pull the flue pipe down and out to disengagefrom the vent adapter as shown in Fig. 24,page 55.

4. Lift up the condensate pan to disengagefrom trap.

5. Once the condensate pan is clear of the bot-tom jacket, rotate it towards the front of theappliance and push down on the rear to dis-engage from the heat exchanger as shownin Fig. 25, page 55.

- Inspect the flue pipe and condensatepan for cracks, damage or distortion.Check all gaskets for tears, discol-oration or other damage, replace as nec-essary.

- Once inspection is completed re-assem-ble the condensate pan and flue pipe inreverse order.

WARNING

WARNING

55


12

3

1

2

3

Fig. 23: Loosening of Flue PipeRetaining Ring

Fig. 25: Removal of Condensate Pan

Fig. 24: Removal of Flue Pipe

56


When re-assembling the condensate panand flue pipe ensure all gaskets are in placeand correctly installed. Ensure all associat-ed joints are complete, tight and secure.Failure to comply can result in flue gasleakage resulting in severe personal injury,death or substantial property damage.

Check Expansion Tank

Refer to Section IV - Boiler Piping for rec-ommended location of the expansion tankand air eliminators.

Closed -Type Tank:

- Ensure tank is partially filled withwater leaving an air gap as a cushion.Refer to the manufacturer’s instructionfor proper fill level.

- Ensure the tank is fitted with a device thatreduces gravity circulation of air-saturatedtank water back into the system. This deviceprevents air from bubbling up through thewater as it returns from the system.

- Ensure no automatic air vents are usedin the system. This will allow air toescape from the system instead ofreturning to the tank.

Diaphragm Tank:

- Ensure the system contains a minimum ofone automatic air vent. Recommendedlocation of the air vent should be atop anair eliminator.

- Remove the tank from the system andcheck the charge pressure. For residentialapplications the charge pressure is typical-ly 12 psig [0.8 bar]. If tank does not holda charge pressure, then the membrane isdamaged and the tank should be replaced.

Check Relief Valve

Inspect the relief valve and lift the lever to ver-ify flow at least annually or as recommendedon the warning tag of the valve.

Before manually operating the reliefvalve, ensure the discharge piping isdirected to a suitable place of disposal toavoid a potential scald hazard. The dis-charge piping must be full size withoutrestriction and installed to permit com-plete drainage of both the valve and line.

If after closing the valve, the valve fails to seatproperly or continually weeps, replace therelief valve. Ensure the cause of the reliefvalve to weep is the valve itself, not due to sys-tem over-pressurization caused by an expan-sion tank that is waterlogged or undersized.

Inspection of Ignition Electrode

Remove the ignition electrode using a 3 mm orT-15 hex key inserted through the two top panelholes located above the igniter. If necessary sep-arate the top panel from the right side by insert-ing a straight screw driver in two slots on rightside of top panel and bending metal tab in slotsaway from the side. Lift top panel .

Remove any white oxides accumulated on theelectrode using fine grit sandpaper or steel wool.If the electrode does not clean to a satisfactorycondition. Replace the ignitor .

When replacing the ignition electrode, ensurethe gasket is in good condition and correctlypositioned replace gasket if necessary.

Check igniter to Fig. 26, page 57.

Check Ignition Wiring and Ground Wiring

Inspect the ignition wiring from the burner con-trol module to the ground at heat exchanger.

Ensure wiring is in good condition and secure-ly connected.

Check ground continuity of the wiring to theappliance heat exchanger or piping using acontinuity meter.

Replace and correct ground wire if ground con-tinuity is not completed and satisfactory.

WARNINGWARNING

57


0.12” [ 3 mm]

0.12”

[3 m

m]

0.43” [11 mm]

Spark gap app. 0.18”

1.06”

-1.12

” [2

7 mm

- 29 m

m]

[5 mm]

1.75”

[44 m

m]

1.18”

[30 m

m]

(45º)

Fig. 26: Igniter Dimensions

58


Check Control Wiring

Inspect all control wiring. Ensure wiring is ingood condition and properly connected.

Check Control Settings

1. Check the control CH parameter settings

by pressing the thermometer button “ ” on

control display. When the LED is lit for

“ ” this is the CH setting. Adjust settings

with “ ” or “ ” buttons as necessary.

2. Press the reset button to close the set-ting menu and store the changes.

3. Check any external limit control settings (ifused). Adjust settings as necessary.

Perform Start-up and Checkout Procedures

Start the appliance and perform the start-upprocedure as listed in this manual.

Verify the cold water fill pressure is correct andthe operating pressure of the boiler is withinnormal operating range.

Complete the checkout procedures as refer-enced in this manual.

Check Burner Flame

Inspect the burner flame through the observa-tion port on left side off the heat exchanger.

Verify flame pattern is blue and covers the entireburner surface during high fire. Ensure combus-tion at both high and lowfire meet the require-ments listed in Table 5, page 37. If combustion isOK and flame pattern is not fully blue & coversthe entire burner surface during highfire, shut theappliance down and allow it to cool thoroughlybefore disassembly.

Close the external manual gas valve on the gassupply line and disconnect the gas piping andelectrical connector to the gas valve inside theappliance.

Disconnect the wiring harness connectors fromthe blower.

Remove the mounting bolts and washers secur-ing the front of the heat exchanger and set boltsand washers aside.

Carefully remove the front plate of the heatexchanger. Ensure combustion chamber insula-tion is not damaged during removal. SeeWARNING on page 60.

Remove the burner head mounting screws andremove the burner head. Inspect the burner headfor deterioration. Use compressed air or a vac-uum to clean the burner head. Replace burnerhead if necessary. Replace burner head gasket.

Re-assemble the burner head and burner headgasket. Ensure mounting screws are tight.

Remove the blower.

Use a vacuum cleaner or compressed air toclean the interior of the blower and venturiassembly. Inspect the blower blades to ensurethey are clean and not damaged.

Re-assemble the blower and venturi onto frontplate of the heat exchanger . Ensure all gas-kets are in good condition, and positioned cor-rectly. Replace gaskets if necessary.

Re-assemble the front plate of the heatexchanger with bolts and washers onto the heatexchanger. Ensure the gasket and combustionchamber insulation is in place and not dam-aged, replace gasket and insulation if neces-sary. See WARNING on page 60. Ensure allscrews and bolts are tight.

Reconnect the wiring harness connectors to theblower.

Re-assemble the gas supply connections andelectrical connector to gas valve inside theappliance. Open the external manual gas valve.Check gas piping for any leaks as outlined onpage 35 and repair if necessary. Place the appli-ance back into service.

59


Check Combustion Levels

Refer to page 37 of this manual for measuringcombustion levels and burner adjustments.

Clean Boiler Heat Exchanger

1. Shut down the appliance:

- Follow the instructions on Page 38 "ToTurn Off Gas to Appliance"

- Do not drain the appliance unless it willbe subject to freezing conditions.

- Do not drain the appliance if freezeprotection fluid is used in the system.

2. Allow the appliance to cool down to roomtemperature before servicing.

3. Disconnect the gas piping and electricalconnector to the gas valve.

4. Disconnect the wiring harness connectorsfrom the blower.

5. Remove the mounting bolts and washerssecuring the front of the heat exchangerand set aside.

6. Carefully remove the front plate of the heatexchanger. Ensure combustion chamberinsulation is not damaged during removal.See WARNING on page 60.

7. Use a vacuum cleaner, compressed air orwater to remove any accumulation fromthe heat exchanger flue ways. Do not useany solvent.

8. Re-assemble the front plate of the heatexchanger onto the heat exchanger. Ensurethe gasket and combustion chamber insula-tion is in place and not damaged, replacegasket and insulation if necessary. SeeWARNING on page 60.

9. Re-assemble the blower the wiring harness.

10. Reconnect the gas piping and electricalconnector to gas valve. Check for leaks,repair if necessary.

11. Close isolation valves at the appliance boil-er piping to isolate the appliance from theheating system.

12. Attach a hose to the boiler drain valve andflush the boiler thoroughly with freshwater by using the purge valves to allowwater to enter through the make-up waterline to the boiler.

13. Once the boiler has been completelyflushed, return the boiler and system pip-ing back to operation.

14. Perform the required startup and checkoutprocedures as outlined on pages 33 to 50.

Review With Owner

Ensure the owner understands the impor-tance to perform the maintenance schedulespecified in this manual.

Remind the owner of the importance to calla licensed contractor should the appliance orsystem exhibit any unusual behavior.

60


The combustion chamber insulationcontains ceramic fibers, which are clas-sified as a possible human carcinogen.When exposed to extremely high tem-peratures, the ceramic fibers, whichcontain crystalline silica, can be con-verted into cristobalite.

Avoid Breathing and Contact with Skinand Eyes

When removing or repairing the combustionchamber insulation follow these precautionmeasures:

1. Use a NIOSH approved respirator whichmeets OSHA requirements for cristobalitedust, similar to N95. Contact NIOSH at

1-800-356-4676 or on the web atwww.cdc.gov/niosh for latest recommen-dations.

2. Wear long sleeved, loose fitting clothing,gloves and eyes protection.

3. Assure adequate ventilation.

4. Wash with soap and water after contact.

5. Wash potentially contaminated clothesseparately from other laundry and rinsewashing machine thoroughly.

6. Discard used insulation in an air tightplastic bag.

NIOSH Stated First Aid:Eye/Skin: Immediately irrigateBreathing: Clean fresh air

WARNING

Handling Previously Fired Combustion Chamber Insulation

61

Replacement Parts

Pressure relief and air vent assembly

T

S

Low voltage/terminal strip X4Blower

Ignition electrodeHigh voltage terminal strip

Condensate drain trap assemblyCondensate pan

Control/Display

CH Return sensor S2CH supply sensor S1

Fig. 27: CHALLENGER Internal Components

Replacement parts must be purchasedthrough a local Triangle Tube distribu-tor. When ordering part please providethe model number and descriptionand/or part number of replacement part.

Use only genuine Triangle Tube replace-ment parts to ensure warranty coverageand to avoid damage to appliance andimproper operation of appliance.Contact Triangle Tube at 856-228-8881or www.triangletube.com for list of dis-tributors nearest you.

WARNING

62

Replacement Parts

3

Fig. 28 : CHALLENGER Front Door

ItemPart Number

CC85s

Part Number

CC105s

Part Number

CC125s & CC150sDescription

1 CCRKIT04 Wall Bracket Assembly (Not Shown)

2 CCRKIT05Pipe Connectors & Brackets Assembly

(Not Shown)

2A CCFTG01 Connector Pipe CH (Not Shown) - 1/Kit

3 CCRKIT06 CCRKIT07 CCRKIT08 Front Door Assembly

63

Replacement Parts

2

2

3

1

2 3

3

4

3

Fig. 29: CHALLENGER Vent Components

ItemPart Number

CC85s

Part Number

CC105s

Part Number

CC125s

Part Number

CC150sDescription

1

CCRKIT0980/125 Concentric Vent /Air Adapter

Assembly (optional - shown)

CCRKIT353” Vent/Air Adaptor Assembly ( stan-

dard -not shown)

2 CCRKIT10 CCRKIT11 CCRKIT12 Vent Assembly

3 CCRKIT13 Condensate Collector Assembly

4 CCRKIT14 CCRKIT36 Condensate Drain Trap Assembly

64

Replacement Parts

9

1

3

2

8

4

7

4

Fig. 30 : CHALLENGER Internal Components

ItemPart Number

CC85s

Part Number

CC105s

Part Number


1 CCRKIT15 Igniter Assembly

2 CCCLB01 Ignition Cable

3 CCRKIT16 Sight Glass Assembly

4 CCRKIT17 CH Sensor Assembly - 1 / Kit

7 CCRKIT19 LWCO/CH Pressure Sensor Assembly

8 CCRKIT20 CCRKIT21 CCRKIT22 CH Supply pipe Assembly

9 CCRKIT23 CH Return Pipe Assembly

65

Replacement Parts

4

1

2

3

Fig. 31 : CHALLENGER Blower & Gas Valve Components

ItemPart Number

CC85s

Part Number

CC105s

Part Number


1 CCRKIT28 Ignition Transformer Assembly

2 CCRKIT29 Gas Valve Assembly

3 CCRKIT30 CCRKIT31 Gas Pipe Assembly

4 CCRKIT32 Blower Assembly

66

Replacement Parts

1

Fig. 32 : CHALLENGER Burner Components

ItemPart Number

CC85s

Part Number

CC105s

Part Number


1 CCRKIT33 Burner Assembly

67

Replacement Parts

3

4

2

1

Fig. 33 : CHALLENGER Control Components

ItemPart Number

CC85s

Part Number

CC105s

Part Number

CC125s

Part Number

CC150sDescription

1 CCCON01 CCCON02 Control/Display

2 CCCS01 Housing Plastic Control

3 CCRKIT34 Flip Panel

4 CCFUSE01 Fuse - 1/Kit

68

Product Specifications

AF

1.97

”[5

cm

]

[13

cm]

[8 c

m]

5.12

”

[13

cm]

5.12

”

3.15

”

H

9.45

”[2

4 cm

]

6.10

”[1

5.5

cm]

Z

33.07” [84 cm]30.71” [78 cm]

CH Supply

Vent/Air

CH Return

28.35” [72 cm]

Flexible

1” NPT1” NPT

1/2” NPT

C

80/125 Concentric AdapterChallenger CC85s

Condensate Drain

Challenger CC105sChallenger CC125s

37.40” [95 cm] Challenger CC150s

B

13.58”[34.5 cm]

(80/125 Concentric Vent/Air or 3” Vent)

4.63”[11.8 cm] (3” Air)

17.72”[45 cm]

( optional - shown) or 3”(standard -not shown)

Front View& Side CHALLENGER

69

Product Specifications - Boiler

CC85s Primary Loop Pumps - Grundfos

Graph 5 : Pressure Loss Through Boiler - Grundfos Circulators

CC85s Primary Loop Pumps - Taco

Graph 6 : Pressure Loss Through Boiler - Taco Circulators

Minimum allowable boiler flow rate at full input: 4 gpm [15 lpm] CHALLENGER CC85s

NOTICE

Pump curves and system curves do NOT include any allowance for near boiler piping.

70


CC105s Primary Loop Circulators - Grundfos


CC105s Primary Loop Circulators - Taco


Minimum allowable boiler flow rate at full input: 5 gpm [19 lpm] CHALLENGER CC105s

NOTICE


71


CC125s & CC150s Primary Loop Circulators - Grundfos


CC125s & CC150s Primary Loop Circulators - Taco


Minimum allowable boiler flow rate at full input: 6 gpm [23 lpm] CHALLENGER CC125sand 7 gpm [27 lpm] CHALLENGER CC150s

NOTICE


72


Fuel

DOEHeating Capacity

BTUH [KW]Note 1 & 4

Modulation

Input BTUH [KW]

Note 4

DOE Seasonal Efficiency AFUE

Note 3

Net Boiler IBR RatingBTUH [KW]

Note 2

23,000 [6.7]to

84,000 [24.6]95%

ShippingWeight

Lbs [Kg]

66 [30]Natural

orPropane

Naturalor

Propane

Naturalor

Propane

ModelNote 5

CC85s

CC105s

CC125s

65,000[19.3]110,000

94,000[27.8]

75,000[22.3]

29,000 [8.5]to

106,000 [31]95% 73 [33]82,000

[24.3]

96,000[28.4]

110,000[32.8]

33,000 [9.7]to

124,000 [36.3]95% 80 [36]

Naturalor

PropaneCC150s 112,000

[32.8]129,000

[37.8]

33,000 [9.7]to

145,000 [42.5]80 [36]

Note 1: The heating capacity of the CHALLENGER

is based on the test requirements of the U.S.

Department of Energy.

Note 2: The IBR rating is based on a piping and pick

up allowance of 1.15. This allowance should

be sufficient for the standard radiation

requirements for a building load.

Note 3: Based on the given AFUE the CHAL-

LENGER meets the energy efficiency guide-

lines established by Energy Star.

Note 4: Input and output ratings are shown for sea

level applications. The CHALLENGER

automatically derates the input at approxi-

mately 2% for every 1,000 Ft. of altitude. No

alterations to the appliance or burner system

are required.

Note 5: The trailing letter “s” in the model number

refers to CHALLENGER “Solo” Boilers

(heating only). The construction and compo-

nents of these models are identical to the

combination (heating and domestic) models

except the domestic coil is removed from the

heat exchanger along with all associated

domestic components (domestic piping,

domestic sensor, flow switch, domestic

wiring and labeling). The combustion, safety

and efficiency performance is identical to the

combination units.

The following efficiency performance is achieved when the CHALLENGER is operated asa Boiler according to ASHRAE 103 test procedure

NOTICE

73

Notes

74

Notes

Additional quality water heating equipment available

from Triangle Tube

- Exclusive Tank-in-Tank design

- Stainless steel construction

- Available in 8 sizes and 2 models

- Limited LIFETIME residential warranty

- 15 year limited commercial warranty

- Self cleaning/self descaling design

TTP Brazed Plate Heat Exchangers

- For domestic water, snow melting, radiant floor,

refrigeration

- Plates made of stainless steel, with a 99.9 % copper

and brazed, ensuring a high resistance to corrosion

- Self cleaning and self descaling

- Computerized sizing available from Triangle

Tube/Phase III

- Available in capacities from 25,000 BTU/hr to

5,000,000 BTU/hr

SMART Indirect Fired Water Heaters

1 Triangle Lane - Blackwood, NJ 08012

Tel: (856) 228 8881 - Fax: (856) 228 3584

http://www.triangletube.com

E-mail: [email protected]

Member of

Group

Maxi-Flo and Spa Heat Exchangers

- Construction of high quality corrosion resistant

stainless steel (AISI 316) or titanium

- Specially designed built-in flow restrictor to assure

maximum heat exchange

- Compact and light weight

- Available in 5 sizes that can accommodate any size

pool or spa

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