TriangleTube Challenger Installation And Maintenance Manual

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Page 1

* 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 *

Combination

Boiler

Water Heater

and

* 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 L

NOTICE

WARNING

Date: 8/4/2011

Warranty Registration Card must be filled out by the customer and mailed within thirty (30) days of installation in order to gain warranty coverage.

When receiving the CHALLENGER, any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee.

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

If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or death.

• 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 the gas supplier.

FOR YOUR SAFETY

2010-1Challenger Manual

Page 2

Table of Contents

PRODUCT AND SAFETY INFORMATION

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

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

SECTION I - PRE-INSTALLATION ITEMS

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

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

Boiler or Water Heater 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 and/or Water Heater

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

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Table of Contents

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

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 - DOMESTIC PIPING

General Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Operating Restrictions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-22

Pressure Relief Valve - Standard Installations . . . . . . . . . . . . . . . . . . . . . . . 22

Temperature & Pressure (T&P) Relief Valve

- Storage Tank or SMART Installations . . . . . . . . . . . . . . . . . . 23

Drain Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Thermal Expansion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Water Hammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Vacuum Breaker - Storage Tank or SMART Installations . . . . . . . . . . . . . . 24

General Piping Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Thermostatic Mixing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-25

Recirculation Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Storage Tank Installations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Setting The Thermostatic Mixing Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Domestic Piping Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26-27

SECTION VI - INSTALLING VENT / COMBUSTION AIR & CONDENSATE DRAIN

Installing Vent and Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Installing Condensate Drain Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28-29

SECTION VII - GAS PIPING

Gas Supply Piping Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Natural Gas

Pipe Sizing -Natural Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Natural Gas Supply Pressure Requirements. . . . . . . . . . . . . . . . . . . 31

Natural Gas Orifice Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Propane Gas

Pipe Sizing - Propane Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Propane Gas Supply Pressure Requirements . . . . . . . . . . . . . . . . . . 32

Propane Gas Orifice Requirements . . . . . . . . . . . . . . . . . . . . . . . . . 32

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Table of Contents

SECTION VIII - INTERNAL WIRING

General Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

CHALLENGER Factory Wiring Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . 34

SECTION IX - EXTERNAL WIRING

Installation Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Line Voltage Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Control Module Circulator AMP Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Low Voltage Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Thermostat Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

CH Circulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

System Circulator - Zone Valve Application . . . . . . . . . . . . . . . . . . . . . . . . 37

Outdoor Reset Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

External Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38-39

SECTION X - START-UP PREPARATION

Check Boiler System Water Chemistry

Water pH Level 6.5 to 8.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Water Total Hardness Less Than 7 Grains/Gallon . . . . . . . . . . . . . . 40

Chlorinated Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Flush Boiler and Domestic System to Remove Sediment . . . . . . . . . . . . . . 40

Check and Test Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Use of Antifreeze in the Boiler System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Filling the Boiler System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Check Low Water Cut-Off/CH Pressure Sensor . . . . . . . . . . . . . . . . . . . . . 41

Check for Gas Leaks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Check Thermostat Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Inspection of Condensate Drain Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . 42

SECTION XI - START-UP PROCEDURES

Final Checks Before Start-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

CHALLENGER Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

If CHALLENGER Does Not Start Correctly . . . . . . . . . . . . . . . . . . . . . . . . 43

Check the CHALLENGER and System. . . . . . . . . . . . . . . . . . . . . . . . . . . . 43-44

Operating Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Appliance ON/OFF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Set Boiler Maximum Central Heating (CH) Set Point Temperature . . . . . . 46

Operation Verification - Space Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46-47

Set DHW Set Point Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

iii

Page 5

Table of Contents

Operation Verification - Domestic Hot Water . . . . . . . . . . . . . . . . . . . . . . . 47-48

Control Display

Appliance ON/OFF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Additional DHW Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Highfire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Lowfire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Setting the Appliance Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Error (Hard Lockout) Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Error (Hard Lockout) Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

SECTION XII - OUTDOOR RESET CONTROL

Mounting the Outdoor Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Wiring the Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Adjusting Outdoor Reset Curve

CH Maximum Boiler Operating Temperature. . . . . . . . . . . . . . . . . 56

CH Minimum Boiler Operating Temperature Setpoint (Parameter 5) . . . . . . . . 56

CH Reset Curve Coldest Day (Parameter 6) . . . . . . . . . . . . . . . . . . 56

CH Reset Curve Warmest Day (Parameter 7) . . . . . . . . . . . . . . . . . 56

Changing Outdoor Reset Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Outdoor Reset Curve Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

SECTION XIII - CHECK-OUT PROCEDURES

Check-Out Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

SECTION XIV - INSTALLATION RECORD

Installation Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

SECTIONS XV - MAINTENANCE SCHEDULE

Service Technician - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Owner Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

SECTION XVI - MAINTENANCE PROCEDURES

Annual Maintenance Procedures

Reported Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Check Surrounding Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Inspect Burner Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Page 6

Table of Contents

Check System Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Clean Condensate Drain Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 62

Check Ventilation Air Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Inspect Vent and Combustion Air Piping . . . . . . . . . . . . . . . . . . . . . 62

Check Boiler System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Removing Internal Flue and Condensate Pan for Inspection. . . . . . 62-63

Check Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Check Relief Valve (s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Inspection of Ignition Electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Check Ignition Wiring and Ground Wiring . . . . . . . . . . . . . . . . . . . 64

Check Control Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Check Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Perform Start-Up and Checkout Procedure . . . . . . . . . . . . . . . . . . . 66

Check Burner Flame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Check Combustion Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Clean Boiler Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Clean Domestic Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . 67-68

Review with Owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Handling Previously Fired Combustion Chamber Insulation . . . . . 68

REPLACEMENT PARTS

Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69-75

PRODUCT SPECIFICATIONS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Specifications Water Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77-79

Specification Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-83

Page 7

Product & Safety Information

Definitions

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

DANGER

Indicates the presence of a hazardous situation which, if ignored, will result in death, serious injury or substantial property damage.

WARNING

Indicates a potentially hazardous situation which, if ignored, can result in death, serious injury or substantial property damage.

CAUTION

Indicates a potentially hazardous situation which, if ignored, may result in minor injury or property damage.

NOTICE

Indicates special instructions on installation, operation or maintenance, which are important to equipment but not related to personal injury hazards.

BEST PRACTICE

Indicates recommendations made by Triangle Tube for the installers which will help to ensure optimum operation and longevity of the equipment.

NOTICE

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

Page 8

Product & Safety Information

DANGER

Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system which has been under water.

WARNING

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 the gas supplier.

WARNING

Should overheating occur or the gas supply fails to shut off, turn OFF the manual gas control valve external to the appliance.

WARNING

DO NOT add cold make up water when the appliance is hot. Thermal shock can cause potential cracks in the heat exchanger.

CAUTION

When servicing the appliance:

- Avoid electrical shock by disconnecting the electrical supply prior to performing maintenance.

WARNING

Qualified Installer:

Prior to installing this product read all instructions included in this manual and all accompanying manuals/documents with this appliance. Perform all installation steps required in these manuals in the proper order given. Failure to adhere to the guidelines within these manuals can result in severe personal injury, death or substantial property damage.

Homeowner:

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

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

NOTICE

Please reference the appliance model number and the serial number from the rating label, on the right panel when inquiring about service or troubleshooting.

NOTICE

Triangle Tube accepts no liability for any damage resulting from incorrect installation or from the use of components or fittings not specified by Triangle Tube.

Page 9

Product & Safety Information

BURN

DANGER

Bacteria can develop in the domestic water system if certain minimum water temperatures are not maintained.

DANGER

HOT WATER CAN SCALD!

Water temperature over 125ºF [52ºC] can cause severe burns instantly or death from scalds.

• Children, disabled and elderly are at highest risk of being scalded.

- Never leave them unattended in or

near shower, bathtub or sink.

- Never allow small children to use a

hot water faucet or draw their own bath.

DANGER

Protection must be taken against excessive pressure!

TO PROTECT AGAINST EXCESSIVE TEMPERATURE AND PRESSURE

• Check if a 150 psi [10 bar] pressure relief valve (field supplied) is installed as recommended for standard installations or a temperature/pressure relief valve for storage tank or Triangle Tube SMART Indirect Fired Water Heater (I.F.W.H.) installations. (DHW side)

• Check if the 30 psi [2 bar] pressure relief valve supplied is installed in the recommended location. (CH side)

• To avoid injury, install the relief devices to comply with local code requirements.

• To avoid any potential scald hazard or if codes require specific water temperatures at the hot water faucet, the installer must:

- Install the factory supplied thermo-

static mixing valve at this appliance and ensure it is working properly

and

- Set the thermostatic mixing valve to

the lowest temperature which satisfies your hot water needs.

- Feel and adjust water temperature

before bathing or showering.

- Water drained from the system drain

valves may be extremely hot.

TO AVOID INJURY:

- Make sure all connections are tight.

- Direct water flow away from any per-

son.

Page 10

Pre-Installation Items

SECTION I - Pre-Installation Items

Code Compliance

The CHALLENGER is certified to both the Boiler (ANSI Z21.13/CSA 4.9) and Water Heater (ANSI Z21.10.3/CSA4.3) standards.

Due to the CHALLENGER’s unique heat exchanger design which incorporates two independent copper water tube coils; one for space heating and the other for domestic hot water, the CHALLENGER can be installed as a Boiler or Water Heater or both. The unused system does not have to be connected or filled. Parameter 1 (Installation Type) will need to be set accordingly (0= Heat and DHW, 2 = DHW Only and 3 = Heat Only), see page 52 for Setting Parameters.

This appliance must be installed in accordance to the following:

- All applicable local, state, national and provincial codes, ordinances, regulations and laws.

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

NOTICE

The CHALLENGER gas manifold and gas controls meet the safe lighting and other performance requirements as specified in ANSI Z21.13 standard.

Determining Product Location

Before locating the CHALLENGER check for convenient locations to:

- Heating system piping

- Domestic water supply piping

- Venting

- Gas supply piping

- Electrical service

Ensure the appliance location allows the combustion air and vent piping to be routed directly through the building and terminate properly in the same pressure zone outside with a minimum amount of length and bends.

- For installations in Massachusetts, code requires the appliance to be installed by a licensed plumber or gas fitter, and if antifreeze is utilized, the installation of a reduced pressure backflow preventer device is required in the boiler’s cold water fill or make up water supply line.

- For installation in Massachusetts all direct vented appliances must comply with the guidelines as outlined on page 10.

- Massachusetts Plumbing Board Product Approval Code # is CI-0111-219 for the CHALLENGER.

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

- National Electric Code ANSI/NFPA 70.

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

Ensure the area chosen for the installation of the CHALLENGER is free of any combustible materials, gasoline and other flammable liquids.

WARNING

Failure to remove or maintain the area free of combustible materials, gasoline and other flammable liquids or vapors can result in severe personal injury, death or substantial property damage.

Ensure the CHALLENGER and its controls are protected from dripping or spraying water during normal operation or service.

The CHALLENGER should be installed in a location so that any water leaking from the appliance, piping connections or relief valve will not cause damage to the surrounding area or any lower floors in the structure. When such location cannot be avoided, it is recommended that a suitable drain pan, adequately drained, be installed under the appliance. The pan must not restrict combustion air flow.

Page 11

Pre-Installation Items

Boiler or Water Heater Replacement

If the CHALLENGER is replacing an existing boiler and/or hot water heater system, the following items should be checked and corrected prior to installation:

- Boiler and domestic piping leaks and corrosion.

- Proper location and sizing of the expansion tank on the boiler heating loop. Proper location and sizing of the thermal expansion tank (if used) on the domestic supply line.

- If applicable, amount and quality of propylene glycol.

- Vent condition

Clearances

The CHALLENGER is approved for following clearance to combustibles:

- Top panel - 12 inches [30.5 cm]

- Front - 0 inches

NOTICE

When maintaining the approved clearance or less than recommended service clearances, some product labeling may become hidden and unreadable.

WARNING

If the enclosure in which the appliance is installed is less than 45 cubic feet [1.3 m3], the space must be ventilated. See page 8 Ventilation Air Requirements for guidelines and requirements.

WARNING

When installing the CHALLENGER in a confined space, sufficient air must be provided to allow, under normal operating conditions, proper air flow around the product to maintain ambient temperatures within safe limits to comply with the National Fuel Gas Code NFPA 54 - Standard.

- 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 and Domestic Piping - 0.25 inches [0.6 cm]

- Reference the appropriate vent supplement for venting clearance requirements.

BEST PRACTICE

To provide serviceability to the appliance it is recommended that the following clearances be maintained:

Top panel - 24 inches [61 cm].

Front - 24 inches [61 cm].

Bottom panel - 24 inches [61 cm].

Rear - 0 inches

Residential Garage Installations

When installing the CHALLENGER in a residential garage, the following special precautions per NFPA 54/ANSI Z223.1 must be taken:

- Mount the appliance a minimum 18 inches [458 mm] above the floor level of the garage. Ensure the burner and ignition devices / controls are no less than 18 inches [458 mm] above the floor level.

- Locate or protect the appliance in a manner so it cannot be damaged by a moving vehicle.

Sides - 6 inches [15.2 cm]

Page 12

Pre-Installation Items

Boiler Freeze Protection Feature

The boiler control has a freeze protection feature. This feature monitors the boiler supply water temperature and responds as follows when no call for heat is present:

- 42ºF

[6ºC] Boiler circulator and burner are

ON.

- 50ºF

[10ºC] Boiler circulator and burner are

OFF.

CAUTION

The boiler freeze protection feature is disabled during a hard lockout, (burner does not operate) however the CH circulator will operate.

CAUTION

The boiler freeze protection feature is designed to protect the boiler, installed in a primary/secondary piping arrangement. See Section IV for primary/secondary piping examples. See Section X for antifreeze guidelines.

Page 13

Combustion Air and Venting

SECTION II- Combustion Air and Venting

Combustion Air Contamination

WARNING

If the CHALLENGER combustion air inlet is located in any area likely to cause or contain contamination, or if products, which could contaminate the air cannot be removed, the combustion air must be repiped and terminated to another location. Contaminated combustion air will damage the appliance and its burner system, resulting in possible severe personal injury, death or substantial property damage.

WARNING

Do not operate a CHALLENGER if the combustion air inlet is located near a laundry room or pool facility. These areas will always contain hazardous contaminants.

Potential contaminating products

- Spray cans containing chloro/fluorocarbons

- Permanent Wave Solutions

- Chlorinated wax

- Chlorine - based swimming pool chemicals / cleaners

- Calcium Chloride used for thawing ice

- Sodium Chloride used for water softening

- Refrigerant leaks

- Paint or varnish removers

- Hydrochloric acid / muriatic acid

- Cements and glues

- Antistatic fabric softeners used in clothes dryers

- Chlorine-type bleaches, detergents, and cleaning solvents found in household laundry rooms

- Adhesives used to fasten building products and other similar products

Pool, laundry products, common household and hobby products often contain fluorine or chlorine compounds. When these chemicals pass through the burner and vent system, they can form strong acids. These acids can create corrosion of the heat exchanger, burner components and vent system, causing serious damage and presenting a possible threat of flue gas spillage or water leakage into the surrounding area.

Please read the information listed below. If contaminating chemicals are located near the area of the combustion air inlet, the installer should pipe the combustion air inlet to an area free of these chemicals per SECTION VI of this installation manual.

Areas likely to contain these products

- Dry cleaning / laundry areas and establishments

- 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 establishments

- New building construction

- Remodeling areas

- Garages with workshops

Page 14

Combustion Air and Venting

Ventilation Air Requirements

For installations, involving only the CHALLENGER, in which the minimum service clearances are maintained as listed on page 5, no ventilation openings are required.

For installations with less than the minimum service clearances involving only the CHALLENGER, the space / enclosure must provide two openings for ventilation. The openings must be sized to provide 1 square inch [6 square centimeters] of free area per 1,000 BTUH [0.3 Kw] of appliance input. The openings shall be placed 12 inches [30.5 cm] from the top of the space and 12 inches [30.5 cm] from the floor of the space.

For installations in which the CHALLENGER shares the space with air movers (exhaust fan, clothes dryers, fireplaces, etc.) and other combustion equipment (gas or oil) the space must be provided with adequate air openings to provide ventilation and combustion air to the equipment. To properly size the ventilation / combustion air openings, the installer must comply with the National Fuel Gas Code NFPA 54, ANSI Z223.1 for installations in the U.S or CAN/CSA B149.1 for installations in Canada/

Combustion Air and Vent Piping

The CHALLENGER requires a Category IV venting system, which is designed for pressurized venting and condensate.

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

NOTICE

Install combustion air and vent pipe as detailed in the CHALLENGER PVC, CPVC and SS Vent Supplement 2010-19 included in the appliance installation envelope. Refer to instructions for parts list and method of installation.

NOTICE

Contact Triangle Tube for other venting options including PVC Concentric Vent/Air Termination Supplement 200804 or CHALLENGER Concentric Vent/Air System Supplement 2010-23. Refer to these instructions for parts list and method of installation.

WARNING

The space must be provided with ventilation / combustion air openings properly sized for all make-up air requirements (exhaust fans, clothes dryers, fireplaces, etc.) and the total input of all appliances located in the same space as the CHALLENGER. The input of a CHALLENGER which uses combustion air directly from the outside, is excluded thus additional free area for the openings is not required. Failure to provide or properly size the openings could result in severe personal injury, death or substantial property damage.

DANGER

Verify installed combustion air and vent piping are sealed gas tight and meet all provided instructions and applicable codes, failure to comply will result in severe personal injury of death.

Page 15

Combustion Air and Venting

Removal of an Existing Boiler and or Water Heater from a Common Vent System

BEST PRACTICE

When an existing boiler and/or water heater is removed from a common venting system, the common venting system is likely to be too large for proper venting of the remaining appliances. At the time of removal of an existing boiler and/or water heater, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation.

1. Seal any unused openings in the common venting system.

2. Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition.

5. Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle, or smoke from a cigarette, cigar or pipe.

6. After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers, and any other gas-burning appliance to their previous condition of use.

7. Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or CAN/CSA B149.1, Installation codes. When resizing any portion of the common venting system, the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Part II of the National Fuel Gas Code ANSI Z223.1/NFPA 54 and/or CAN/CSA B149.1, Installation codes.

3. Insofar as is practical, close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers.

4. Place in operation the appliance being inspected. Follow the lighting instructions. Adjust thermostat so appliance will operate continuously.

DANGER

Do not install the CHALLENGER into a common vent with other gas or oil appliances. This may cause flue gas spillage or appliance malfunction, resulting in possible severe personal injury, death or substantial property damage.

Page 16

Combustion Air and Venting

Commonwealth of Massachusetts Installations Only

For direct-vent appliances, mechanicalvent heating appliances or domestic hot water equipment, where the bottom of the vent terminal and the air intake is installed below four feet above grade the following requirements must be satisfied:

1. If there is not one already present, on

each floor level where there are bedroom(s), a carbon monoxide detector and alarm shall be placed in the living area outside the bedroom(s). The carbon monoxide detector shall comply with NFPA 720 (2005 Edition).

2. A carbon monoxide detector shall also

be located in the room that houses the appliance or equipment and shall:

a. Be powered by the same electrical

circuit as the appliance or equipment such that only one service switch services both the appliance and the carbon monoxide detector;

b. Have battery back-up power;

c. Meet ANSI/UL 2034 Standards and

comply with NFPA 720 (2005 Edition); and

d. Have been approved and listed by

the Nationally Recognized Testing Laboratory as recognized under 527 CMR.

3. A Product-approved vent terminal must

be used, and if applicable, a Productapproved air intake must be used. Installation shall be in strict compliance with the manufacturer’s instructions. A copy of the installation instructions shall remain with the appliance or equipment at the completion of the installation.

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

NOTICE

Installer must provide tag identification plate and ensure the lettering meets code requirements.

For direct-vent appliances, mechanicalvent heating appliances or domestic hot water equipment, where the bottom of the vent terminal and the air intake are installed above four feet above grade the following requirements must be satisfied:

1. If there is not one already present, on each floor level where there are bedroom(s), a carbon monoxide detector and alarm shall be placed in the living area outside the bedroom(s). The carbon monoxide detector shall comply with NFPA 720 (2005 Edition).

2. A carbon monoxide detector shall:

a. Be located in the room that houses

the appliances or equipment;

b. Be either hard wired or battery

powered or both; and

c. Shall comply with NFPA 720 (2005

Edition)

3. A Product-approved vent terminal must be used, and if applicable, a Productapproved air intake must be used. Installation shall be in strict compliance with the manufacturer’s instructions. A copy of the installation instructions shall remain with the appliance or equipment at the completion of the installation.

Page 17

Appliance Preparations

SECTION III - Appliance Preparations

Shipping and Handling Instructions

WARNING

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

The CHALLENGER is generally easier to handle and maneuver once removed from the shipping carton.

To remove the shipping carton:

CAUTION

Use care not to lift the appliance from piping or damage can occur. Use care not to drop or bump the appliance as damage to the appliance may result.

Wall Mounting Installation

NOTICE

Prior to mounting appliance install piping support bracket according to instructions on page 13.

The CHALLENGER should be wall mounted using the bracket provided with the appliance and is not designed for floor installation. If floor installation is required an optional floor stand part number PSSTND04 is available through Triangle Tube. Appliance is not to be installed on carpeting.

1. Remove any shipping straps and the top shipping carton.

2. Carefully lift the appliance out of the carton.

3. Discard all packing materials.

Fig. 1: Optional Floor Stand Assembly, Part Number: PSSTND04

NOTICE

The wall used for mounting the CHALLENGER must be vertically plumb and capable of supporting a minimum 110 pounds [50 kg]. Failure to comply with these requirements could result in personal injury, death or substantial property damage.

Page 18

Appliance Preparations

Wall Mounting Guidelines

1. The wall-mounting bracket is designed for stud spacing of 12 inch [30.5 cm] or 16 inch [40.6 cm] on centers. For unconventional stud spacing, a solid / secure mounting surface must be provided for installation of the bracket.

2. For applications using wood studs, install the bracket using the lag screws provided with the appliance. Ensure both lag screws are installed securely in the studs.

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

4. DO NOT mount or attempt to mount the wall bracket to hollow sheet rock or lath walls using anchors. Only install appliance to studs or equivalent wood structure.

5. For applications using solid walls (rock, concrete, brick, cinder block, etc.), install the wall bracket using anchors (double expansion shields) bolts and washers provided with the appliance.

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

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

4. Remove the bracket from the wall and drill 1/4” [6 mm] diameter hole by 3” [76 mm] deep positioned in the center of each mark. For applications using metal studs and 3/16” [5 mm] toggle bolts, drill the required clearance hole.

5. Reposition the bracket onto the wall and align mounting slots/holes. Insert the two lag screws provided (or toggle bolts for metal studs) through the mounting slots/holes and loosely tighten.

6. Level bracket and tighten screws (bolts for metal studs) securely making sure not to overtighten to avoid damaging drywall or plaster.

Wall Bracket Installation - Solid Walls

1. Locate the general area of the appliance placement.

6. The appliance is too heavy and bulky for a single person to lift and attempt to mount; a minimum of 2 people is required for mounting the appliance.

NOTICE

Use extreme care not to drop the appliance or cause bodily injury while lifting or mounting the appliance onto the bracket. Once mounted verify that the appliance is securely attached to the bracket and wall. Failure to comply with the above guidelines could result in property damage, personal injury or death.

Stud Walls -Installation

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

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

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

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

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

5. Install the anchors (provided) flush or slightly recessed in the drilled holes with threaded side facing down.

6. Reposition the bracket on the wall and align mounting slots/holes. Insert the two bolts with washers (provided) through the mounting slots/holes and loosely tighten.

7. Level bracket and tighten bolts securely.

Page 19

Appliance Preparations

ag Screw

(

Stud Wall) Bolts with Washer (

Solid Wall)

all Anchors

(

Solid Wall Only)

ptional Concentric

Vent/Air Adapter

Fig. 2: Wall Mounting The CHALLENGER

BEST PRACTICE

Apply pipe joint compound suitable for potable water systems to the compression ferrule and compression nut threads of all brass fittings before installation. Install appliance pipes into the fittings until bottom of hex on gas pipe fitting rests against the top of the piping support bracket before tightening any compression nuts. Do not over tighten compression nuts. If fitting leaks loosen compression nut first and then retighten.

2. Prior to mounting the appliance on the wall and with the rear or back of appliance laying flat, slip the appliance piping into the fittings until bottom of hex on gas pipe fitting rests against the top of the piping support bracket before tightening any compression nuts.

Appliance Mounting

1. Obtain assistance in lifting the appliance onto the wall bracket.

2. Install the appliance making sure the appliance mounting lip located along the upper edge of the rear jacket panel engages the wall-mounting bracket. Ensure the appliance is seated properly and is secure.

Piping Support Bracket

CAUTION

Appliance must be installed using the supplied copper fittings and piping support bracket. DO NOT braze directly to copper appliance pipes or damage may result to internal parts (gaskets and flow switch).

1. Pre-install the 4 brass compression fittings into the piping support bracket as shown in Fig. 4, page 15. Use retaining clips to hold fittings in place.

3. Tighten all fittings to appliance piping connections with two wrenches.

WARNING

Use a two wrench method when tightening piping near the appliance and its piping connections. Use one wrench to prevent the appliance connections from turning and the second to tighten adjacent piping. Failure to support the appliance piping connections could damage piping.

4. Once appliance is mounted according to Appliance Mounting instructions on this page, secure piping support bracket to wall with hardware supplied.

Page 20

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 NOT support piping by the appliance or its components.

- Use isolation valves to isolate system components.

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

WARNING

Use a two wrench method when tightening piping onto the appliance connections. Use one wrench to prevent the appliance piping from turning / twisting. Failure to support the appliance piping and connections in this manner could cause damage to the appliance and its components.

above any drain connection to allow clear visibility of the discharge.

- Should terminate with a plain end, not with a threaded end. The material of the piping should have a serviceable temperature rating of 250ºF [121ºC] or greater.

- Should not be subject to conditions where freezing could occur.

- Should not contain any shut-off valves or obstructions. No shut-off valve should be piped between the appliance and relief valve.

WARNING

Failure to comply with the guidelines on installing the pressure relief valve and discharge piping can result in personal injury, death or substantial property damage.

Low Water Cut Off / CH Pressure Sensor

NOTICE

Pressure Relief Valve (PRV)

1. The CHALLENGER has a ASME Maximum Allowable Working Pressure of

43.5 PSI [3 bar]. The appliance is supplied with a 30 psi [2 bar] pressure relief valve and must be piped using the PRV connection as shown in Fig. 3 page 15.

2. To avoid potential water damage to the surrounding area or potential scalding hazard due to the operation of the relief valve, the discharge piping:

- Must be connected to the discharge out-

let of the relief valve and directed to a safe place of disposal.

- Length should be as short and direct as

possible. The size of the discharge line should not be reduced, maintain the same size as the outlet of the relief valve.

- Should be directed downward towards

the floor at all times. The piping should terminate at least 6 inches [153 mm]

The Low Water Cut Off (LWCO) only applies for space heating. Operation of the LWCO does not prevent a domestic hot water call for heat.

- The CHALLENGER is equipped with a factory 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 [0.5 bar] the main display will flash a soft lockout of “LOP” followed by the pressure reading. Once CH system pressure is increased above 7 psi [0.5 bar] normal boiler operation will be restored. If the appliance is installed as domestic hot water heater only, set parameter 1 (installation type) to 2 (domestic only) to eliminate the “LOP” error in the main display, see page 52 for setting parameters.

- Check local codes if a LWCO is required. If so, determine if this device meets their requirements.

Page 21

Boiler Piping

Boiler Return Connection

with Tee Fitting and

Boiler Drain Valve

Boiler Supply

Connection

with Tee

Fitting 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

Drain Valve (by Others)

1 inch

Compression

Assembly (supplied)

1 inch

Compression

Assembly (supplied)

1 inch Tee (by Others)

1 inch

Tee

(supplied)

Temperature Pressure

Gauge (supplied)

Piping Bracket

(supplied)

Retaining Clip

(supplied)

Compression

Ferrule

Compression

Nut

Compression/NPT Adapater

Manual

Air Vent

(supplied)

3/4” Tee

(supplied)

3/4” Nipple

(supplied)

3/4” Street

Elbow (supplied)

Installer must provide relief valve drain piping directed to a suitable place of drainage

Pressure Relief Valve

(supplied)

Note:

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

Fig. 4: Near Appliance Piping Assembly

Page 22

Boiler Piping

Additional Limit Control

If a Low Water Cut Off (LWCO) is required by certain local jurisdictions or when the boiler is installed above the system piping, the following guidelines must be followed:

- The LWCO must be designed for water installations, electrode probe-type is recommended.

- The LWCO must be installed in a tee connection on the boiler supply piping above the appliance.

- Wiring of the LWCO to the CHALLENGER should be done in series with the 120 VAC service to the appliance .

If the installation is to comply with ASME CSD-1 or Canadian requirements, an additional high temperature limit may be needed. Consult local code requirements to determine compliance. The limit should be installed as follows:

- Install the limit in the boiler supply piping between the boiler and any isolation valve.

- Maximum set point for the limit is 200ºF [93ºC].

- Wiring of the limit device to the CHALLENGER should be done in series with the 120 VAC service to the appliance.

Backflow Preventer

- Use a backflow preventer valve in the make-up water supply to the appliance as required by local codes.

Boiler System Piping Applications

BEST PRACTICE

It is required on all piping applications to utilize a primary/secondary piping arrangement. Maintain the minimum boiler flow rate, see Graphs 5-10 on pages 80-82.

Expansion Tank and Makeup Water

Ensure the expansion tank is properly sized for the boiler water volume (approximately 1 gallon [4 L]) and the system water volume and temperature.

CAUTION

Undersized expansion tanks will cause system water to be lost through the pressure relief valve and cause additional makeup water to be added to the system. Eventual boiler heat exchanger failure can result due to this excessive makeup water addition.

The expansion tank must be located as shown in Fig. 5 and Fig. 6 on page 18 when using a primary/secondary piping arrangement or as per recognized design methods. Refer to the expansion tank manufacturer instructions for additional installation details.

Connect the expansion tank to an air separator only if the air separator is located on the suction side (inlet) of the system circulator. Always locate and install the system fill connection at the same location as the expansion tank connection to the system.

Diaphragm Expansion Tank

Always install an automatic air vent on the top of the air separator to remove residual air from the system.

Page 23

Boiler Piping

Closed-Type Expansion Tank

It is recommended to pitch any horizontal piping upwards toward the expansion tank 1 inch per 5 feet [2.5cm / 1.5 M] of piping. Use 3/4” piping to the expansion tank to allow air within the system to rise.

CAUTION

DO NOT install automatic air vents on a closed-type expansion tank system. Air must remain in the system and be returned to the expansion tank to provide an air cushion. An automatic air vent would cause air to be vented from the system resulting in a water-logged expansion tank.

Circulator

The CHALLENGER must be supplied with a Central Heating (CH) circulator. The circulator when wired directly to the CHALLENGER will allow for domestic hot water priority and to provide circulation for the freeze protection feature of the boiler control. See Graph 5-10 on page 80-82 for pressure drop and minimum flow rate through the boiler.

Sizing Primary Piping

System Piping - Zone Circulators

Connect the CHALLENGER to the system piping as shown in Fig. 7 page 20 when zoning with zone circulators.

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

NOTICE

To ensure an adequate flow rate through the CHALLENGER, the boiler supply and return piping size must be a minimum of 1 inch.

System Piping - Zone Valves

Connect the CHALLENGER to the system piping as shown in Fig. 8 page 20 when zoning with zone valves. The primary / secondary piping ensures that the boiler loop has sufficient flow.

NOTICE

To ensure an adequate flow rate through the CHALLENGER, the boiler supply and return piping size must be a minimum of 1 inch.

See Fig. 7 and 8, page 20, for recommended piping arrangements based on various applications. Size the piping and system components required in the space heating system, using recognized design methods.

Page 24

Boiler Piping

Max.

12"

Boiler

Supply

System

Return

System

[30.5 cm]

Cold

Water Fill

Boiler

Supply

Return

Cold

Water Fill

Boiler

Supply

Minimum

3/4" Piping

Boiler

Return

System

Supply

System

Max.

12"

[30.5 cm]

Fig. 5: Near Boiler Piping - Diaphragm Expansion Tank

Fig. 6 : Near Boiler Piping - Closed Type 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

Page 25

Boiler Piping

System Piping - Radiant Heating

The heat exchanger design of the CHALLENGER allows operation in a condensing mode. This feature requires no regulation of the return water temperature back to the boiler in radiant heating applications.

The maximum boiler water supply temperature can be maintained by the CHALLENGER, potentially eliminating the need for a mixing system to achieve the desired temperature if all zones of heat are at the same temperature set point.

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

NOTICE

To ensure an adequate flow rate through the CHALLENGER, the boiler supply and return piping size must be a minimum of 1 inch.

NOTICE

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

The CHALLENGER’s domestic piping should not be utilized. Refer to the installation manual provided with the SMART for additional installation details.

See Parameter 1 and Note 3, page 52 for parameter, wiring and operational details using the SMART I.F.W.H. with a CHALLENGER boiler.

System Piping - Special Application

If the boiler is used in conjunction with a chilled water/medium system, the boiler and chiller must be piped in parallel. Install flow/check valves to prevent the chilled medium from entering the boiler.

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

See Figs. 7 and 8, page 20 for recommended piping for a Triangle Tube SMART I.F.W.H.. This application will provide higher domestic hot water flow rates for a short period of time (dump load) and will recover the SMART tank faster than a domestic storage tank. The SMART’s boiler piping should be piped as a zone load in the system. The CHALLENGER’s boiler piping should be connected to the system piping in a primary secondary piping arrangement.

If the boiler is used to supply hot water to the heating coils of an air handler where they may be exposed to chilled air circulation, install flow/check valves or other automatic devices to prevent gravity circulation of the boiler water during cooling cycles.

Page 26

Boiler Piping

Additional

Max.

[30.5 cm]

12"

Zone Load

or SMART I.F.W.H.

[

30.5 cm]

Zone Load

or SMART I.F.W.H.

dditional

Max.

12"

one Load

Fig. 7: Central Heating (CH) System Piping - Zoning

with 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

9. Automatic air vent

10. Diaphragm expansion tank

11. Automatic fill valve

6. Drain/purge valve

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

1. CHALLENGER boiler

2. Boiler circulator with flow check 4 Isolation valve

5. Zone valve

6. Drain/purge valve

7. Pressure relief valve

8. Air separator

9. Automatic air vent

10. Diaphragm expansion tank

11. Automatic fill valve

12. System circulator

Page 27

Domestic Piping

SECTION V - Domestic Piping

WARNING

HOT WATER CAN SCALD!

• Water temperatures over 125ºF [52ºC] can cause severe burns instantly, or death from scalds.

• Feel water before bathing or showering.

• Consumer Product Safety Commission and some states recommend temperatures settings of 130ºF [54ºC] or less. Setting thermostat higher than 130ºF [54ºC] will increase risk of scald injury and cause severe personal injury or death.

• Water heated to a temperature suitable for clothes washing, dish washing and other sanitizing needs will scald and cause permanent injury.

• Children and elderly, infirm, or physically handicapped persons are more likely to be injured by hot water. Never leave them unattended in or near a bathtub. If anyone using hot water in the building fits this description, or if state laws or local codes require certain water temperatures at hot water faucets, take special precautions.

General Notes

• Household water usage patterns will affect water temperature at any faucet or shower. Occasionally check temperature at each point of use, then adjust thermostatic mixing valve accordingly. Always recheck temperature after adjusting.

• Lowering the thermostatic mixing valves as indicated in these instructions will reduce water temperature levels. Consult your installer or service technician.

Operating Restrictions

• Minimum DHW flow rate is 0.5 gpm [2 lpm] to initiate a domestic call for heat.

- Install the factory supplied thermostatic mixing valve at the water heater. Installation must comply with valve manufacturer’s recommendation and instructions.

- Use the lowest practical temperature setting.

- Check water temperature after any adjustment. You must follow “Setting the Thermostatic Mixing Valve” procedures.

• Maximum DHW outlet temperature is 149ºF [65ºC].

• Minimum domestic working pressure is 40 psig [3 bar].

NOTICE

When the CHALLENGER is installed in a domestic well application, the cut in pressure of the domestic well pump’s control must be set to 40 psig [3 bar] to ensure more consistant domestic flow and temperature performance.

Page 28

Domestic Piping

• Maximum domestic working pressure is 150 psig [10 bar].

• Water quality limitations (based on E.P.A National Secondary Drinking Water Regulations):

- Chloride, less than 150 ppm or mg/l

- pH value min. 6.5, max. 8.5

- Total hardness 3 - 7 grains/gallon or 50-

120 ppm or mg/l.

- Total Dissolved Solids (TDS), less than

120 ppm or mg/l.

- Iron less than 0.3 ppm or mg/l.

- Aluminum, less than 0.2 ppm or mg/l.

- Copper, less than 1 ppm or mg/l.

- Manganese, less than 0.05 ppm or mg/l.

- Zinc, less than 5 ppm or mg/l.

BEST PRACTICE

In hard water areas (more than 7 grains of hardness) soften the cold domestic supply water to the appliance to prevent scaling.

relieve at or below 150 psi [ 10 bar] of domestic water pressure and a minimum relieving capacity of 124,000 Btu/hr with 3/4” NPT threads. For safe operation of the domestic water heater, the relief valve must not be removed from its designated location of installation or plugged.

1. The CHALLENGER is not supplied with a 150 psi [10 bar] pressure relief valve and must be piped using a Pressure Relief Valve connected as shown in Fig. 11 page 26.

2. To avoid potential water damage to the surrounding area or potential scalding hazard due to the operation of the relief valve, the discharge piping:

- Must be connected to the discharge out-

let of the relief valve and directed to a safe place of disposal.

- Length should be as short and direct as

possible. The size of the discharge line should not be reduced, maintain the same size as the outlet of the relief valve.

- Should be directed downward towards

the floor at all times. The piping should terminate at least 6 inches [152 mm] above any drain connection to allow clear visibility of the discharge.

NOTICE

Any water conditioning system must be installed and maintained in accordance with manufacturer’s specifications.

Pressure Relief Valve - Standard Installations

The domestic water heater (if utilized) shall have a field supplied pressure relief valve installed within 6” [152 mm] of the DHW HOT outlet connection with the relief valve spindle installed in the vertical position.

The domestic water heater (if utilized) requires a field supplied pressure relief valve identified with the ASME V or HV symbol and set to

- Should terminate with a plain end, not

with a threaded end. The material of the piping should have a serviceable temperature rating of 250ºF [121ºC] or greater.

- Should not be subject to conditions

where freezing could occur.

- Should not contain any shut-off valves

or obstructions. No shut-off valve should be piped between the appliance and relief valve.

WARNING

Failure to comply with the guidelines on installing the pressure relief valve and discharge piping can result in personal injury, death or substantial property damage.

Page 29

Domestic Piping

Temperature & Pressure (T&P) Relief ValveStorage Tank or SMART Installations

CAUTION

To reduce risk of excessive pressures and temperatures in a storage tank or Triangle Tube SMART I.F.W.H., install temperature and pressure protective equipment required by local codes, but no less than a combination temperature and pressure relief valve certified by a nationally recognized testing laboratory that maintains periodic inspection of production of listed equipment or materials, as meeting the requirements for Relief Valves and Automatic Gas Shutoff Devices for Hot Water Supply Systems, ANSI Z21.22. This valve must be marked with the maximum working pressure of the domestic water heater (150 psi).

• The storage tank or SMART must be protected with a field supplied T&P relief valve.

• Size the T&P relief valve by the following specifications, unless they conflict with local codes: 3/4” NPT with an AGA Rating of 124,000 BTU/hr.

- plugged, reduced or restricted

- subject to freezing

WARNING

Do not install any valve between T&P relief valve and the storage tank or SMART connection or on T&P relief valve discharge piping. Do not plug T&P relief valve or discharge piping. Improper placement and piping of T&P relief valve can cause severe personal injury, death or substantial property damage.

WARNING

Isolation valves are only intended for servicing the domestic coil. During any domestic service the appliance should be turned off and the domestic coil drained to prevent over pressurization of the appliance’s domestic coil.

Drain Valves

Drain valves and fittings are field supplied.

T&P Relief Valve Discharge Piping

T&P relief valve discharge piping must be:

- made of material serviceable for temperatures of 250ºF [121ºC] or greater

- directed so that hot water flows away from all persons

- directed to a suitable place for disposal

- installed so as to allow complete draining of the T&P relief valve and discharge line

T&P relief valve discharge piping MUST NOT be:

- excessively long, using more than 2 elbows or 15 feet [4.5 m] of piping can reduce discharge capacity

- directly connected to a drain, terminate discharge piping within 6” [152 mm] from drain, refer to local codes

Thermal Expansion

If a backflow preventer, check valve or pressure reducing valve is installed on the cold water supply piping of the domestic water heater, install an expansion tank on the cold water supply line to prevent normal thermal expansion from repeatedly forcing open the relief valve.

CAUTION

Relief valve is not intended for constant duty, such as relief of pressure due to repeated normal system water expansion. Correct this condition by installing a properly sized expansion tank in domestic water system. Refer to expansion tank manufacturer’s installation instructions for proper sizing.

Page 30

Domestic Piping

The domestic water volume of the CHALLENGER is approximately 0.26 gallons [ 1 l]. Remember to include this volume when sizing the expansion tank.

Water Hammer

Dishwashers, clothes washers and fast-closing positive shut-off valves incorporated in the system all contribute to creating water shock. Install a water hammer arrester to prevent damage to pipes and appliances. See device manufacturer’s instructions for application and installation.

Vacuum Breaker - Storage Tank or SMART Installations

Installing a vacuum breaker on the inlet of the storage tank will prevent damage to the tank if a negative pressure is developed in the domestic supply line. See manufacturer’s instructions for application and installation of the vacuum breaker.

General Piping Requirements

• For domestic water piping diagrams, see Figs 11 and 12, pages 26 and 27.

BEST PRACTICE

It is recommended to install flush valves as outlined in Fig. 11 and 12, pages 26 and 27 for servicing the domestic coil.

BEST PRACTICE

It is recommended to install a strainer on the domestic cold water inlet to prevent any nuisance issues with domestic flow switch. An optional lead free, 60 mesh ystrainer is available through Triangle Tube part number CCSTRA01, see Graph 4, page 79 for strainer pressure loss curve.

• Use pipe joint compound or tape suitable for potable water systems.

• Size all piping no smaller than the appliance’s DHW connections.

• Use isolation valves to isolate the DHW connections and system components.

• Use dielectric unions or couplings to protect hot and cold water fittings from corrosion when connecting dissimilar materials such as copper and galvanized iron pipe.

• If copper pipe is used for domestic water connections, first solder pipe to a threaded adapter and then screw adapter onto the domestic cold water inlet of the appliance. The domestic cold water inlet contains an internal plastic flow switch which can be damaged by heat from soldering.

NOTICE

Do not apply heat to the domestic cold water inlet when making solder connections to water heater. Solder tubing to adapter before fitting adapter to cold water inlet of heater. It is imperative that no heat be applied to the cold water inlet, as it contains a non metallic flow switch.

Thermostatic Mixing Valve

The CHALLENGER is factory supplied with a thermostatic mixing valve with built-in check valves on the hot and cold inlets. The mixing valve must be installed as shown in Figs. 9, 11 and 12.

The mixing water temperature range of the thermostatic mixing valve is 85ºF [30ºC] to 140ºF [60ºC].

The thermostatic mixing valve is preset to 120ºF [49ºC] maximum mixed water temperature.

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

Page 31

Domestic Piping

Adapter

Check Valve

(cold & hot)

Mixed

BEST PRACTICE

Additional thermostatic/anti-scald valves should be installed at each hot water faucet, bath and shower outlet.

For applications with a domestic recirculation loop, the recirculation pump should be controlled by an aquastat. The maximum recommended setting of the aquastat is 10ºF [5ºC] lower than the thermostatic mixing valve setting.

DANGER

For proper operation of the thermostatic mixing valve and to prevent potential scalding hazards, the recirculation loop should be controlled by an aquastat. DO NOT use continuous recirculation.

Storage Tank Installations

For applications requiring high domestic hot water flow rates for a short period of time (dump load), the installer may install a storage type tank (see Fig. 12 page 27) in the domestic piping. The installer must:

1. Relocate the thermostatic mixing valve from the CHALLENGER to the outlet of the storage tank.

2. Provide recirculation from the storage tank back to the CHALLENGER using a bronze or stainless steel type circulator.

Setting the Thermostatic Mixing Valve

NOTICE

The thermostatic mixing valve controls the outlet hot water temperature delivered to the faucets.

WARNING

Fig. 9: Mixing Valve Assembly

Recirculation Piping

• Recirculation return piping if applicable, must be installed in the cold water inlet as shown Figs 11 and 12, page 26 and 27.

• A stainless steel or bronze circulator is recommended and must be controlled by a aquastat. See Graph 3 page 79 for domestic pressure loss.

POTENTIAL SCALD HAZARD. The mixing valve must be installed on the CHALLENGER. Removal or adjustment of the mixing valve will create a potential scald hazard resulting in severe personal injury or death.

If any adjustment needs to be made to the valve’s temperature setpoint refer to the manufacturer’s instructions included with the valve.

Page 32

Domestic Piping

To Dish Washer

or High Temperature

Application

Cold

DHW

Water Inlet

Recirculating

Loop

(optional)

1/2” compression x 3/4” NPT Adapter

Fittings for DHW

Fig. 10 : Installation of Domestic Compression Adapter Assemblies

Fig. 11 : Domestic Piping - Standard Installations

1. CHALLENGER

2. Isolation valve

3. Backflow preventer or pressure reducing valve (*)

4. Thermal expansion tank (potable) (*)

5. Domestic pressure relief valve - 150 psi max.

6. Drain/flush valve

7. Mixing valve with check valve

8. Strainer (*)

9. Flow check valve (*)

10. Circulator (potable , must be controlled by a aquastat ) (*) (*) Optional device may be required by local codes

Page 33

Domestic Piping

Storage

Tank

Recirculating Loop (optional)

Remove any check valve

For service only see warning on page 23

DHW

Cold

Water

Inlet

Note:

Domestic cold water inlet through a storage tank will yield a lower domestic pressure drop in addition to greater domestic performance. Domestic set point temperature should be set to 149ºF [65ºC] see page 52. DHW

function button ( ) should be set to ON ( ) at the display panel, see page 49

Fig. 12 : Domestic Piping - Storage Tank Installations

1. CHALLENGER

2. Isolation valve

3. Backflow preventer or pressure reducing valve (*)

4. Thermal expansion tank (potable) (*)

5. Temperature/Pressure relief valve

6. Drain/flush valve

7. Mixing valve with check valve

8. Circulator (potable, must be controlled by a aquastat) (*)

9. Flow check valve

10. Strainer (*)

11. Vacuum breaker (*)

12. Domestic circulator (potable Grundfos UP26-99BF or Taco 009-SF5 or equivalent sized for 2.5 gpm [9.5 lpm] at 32 feet [9.7 m], must be controlled by a aquastat mounted on the storage tank with a maximum set point of 130ºF [55ºC].

(*) Optional device maybe required by local codes

Page 34

Installation Vent/Combustion Air & Condensate Drain

SECTION VI - Installing Vent / Combustion Air & Condensate Drain

Installing Vent and Combustion Air

DANGER

The CHALLENGER must be vented and supplied with combustion air as shown in the CHALLENGER PVC, CPVC and SS Vent Supplement 201019, included in the installation envelope. Refer to instructions for parts list and method of installation. Once installation is completed, inspect the vent and combustion air system thoroughly to ensure systems are airtight and comply with the instructions given in the venting supplement and are within all requirements of applicable codes. Failure to comply with the installation requirements on the venting and combustion air piping will cause severe personal injury or death.

2. Remove front door and install trap. Ensure the trap is completely seated and secure on the appliance.

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

NOTICE

The drain line materials must be an approved material by the authority having jurisdiction. In absence of such authority, PVC and CPVC piping must comply with ASTM D1785 or D2845. The cement and primer used on the piping must comply with ASME D2564 or F493. For installations in Canada, use ULC certified PVC or CPVC pipe, fittings and cement/primer.

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

NOTICE

Installing Condensate Drain Assembly

1. Locate the condensate trap assembly and cut top with hacksaw or knife and install as shown in Fig. 13 page 29.

NOTICE

The installer must fill the condensate trap with water prior to assembling on the appliance. Do not operate appliance without factory supplied condensate trap installed on appliance.

NOTICE

When selecting and installing a condensate pump, ensure the pump is approved for use with condensing appliances. The pump should be equipped with an overflow switch to prevent property damage from potential condensate spillage.

5. The CHALLENGER will typically produce a condensate that is considered slightly acidic with a pH content below 4.0. Install a neutralizing filter if required.

CAUTION

The condensate drain must remain filled, unobstructed and allow unrestricted flow of condensate. The condensate should not be subject to conditions where freezing could occur. If the condensate is subjected to freezing or becomes obstructed , it can leak, resulting in potential water damage to the appliance and surrounding area.

Page 35

Installation 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

Page 36

Gas Piping

Position Bracket so

Gas Pipe Hex Rests on Bracket

Tee Fitting (by Others)

Union Fitting (by Others)

Manual Gas

Valve

(Supplied)

Cap Fitting (by Others)

Sediment Trap

Min. Length of 3” [7.6 cm]

SECTION VII - Gas Piping

Gas Supply Piping Connection

NOTICE

The gas supply piping must be installed in accordance to all applicable local, state and national codes and utility requirements.

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

2. Install the factory supplied manual shutoff valve in the gas supply piping as shown in Fig. 14. For installations in Canada the installer must tag and identify the main shutoff valve.

3. Install a sediment trap (drip leg) on the gas supply line prior to connecting to the CHALLENGER gas train as shown in Fig. 14.

- Disconnect the CHALLENGER and its gas valve from the gas supply piping during any pressure test greater than 13”w.c. [32 mbar].

WARNING

Do not check for gas leaks with an open flame. Use a gas detection device or bubble test. Failure to check for gas leaks can cause severe personal injury, death or substantial property damage.

7. Use pipe joint compound compatible with natural and propane gases. Apply sparingly only to the male threads of pipe joints so that pipe dope does not block gas flow.

WARNING

Failure to apply pipe joint compound as detailed above can result in severe personal injury, death or substantial property damage.

4. Support the gas piping using hangers. Do not support the piping by the appliance or its components.

5. Purge all air from the gas supply piping.

6. Before placing the CHALLENGER into operation, check and test all piping connections for leaks.

- Close the manual shutoff valve during

any pressure test with less than 13”w.c. [32 mbar].

NOTICE

Support gas piping

WARNING

Use a two-wrench method of tightening gas piping near the appliance and its gas piping connection. Use one wrench to prevent the appliance gas line connection from turning and the second to tighten adjacent piping. Failure to support the appliance gas piping connection could damage the gas line components.

Fig. 14: Recommended Gas Supply Piping

Page 37

Gas Piping

NATURAL GAS

Pipe Sizing - Natural Gas

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

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

- For additional gas piping sizing information, refer to ANSI Z223.1. For Canadian installations refer to B149.1.

Natural Gas Supply Pressure Requirements

1. Pressure required at the gas valve inlet supply pressure port:

- Maximum 13”w.c. [32 mbar] at flow or

no flow conditions to the burner.

- Minimum 5”w.c. [13 mbar] during flow

conditions to the burner. Must be verified during start up and with all other gas appliances operating within the gas piping service.

- Maximum gas inlet pressure must not

be exceeded and minimum gas inlet pressure is for the purpose of input adjustment.

2. Install 100% lockup gas pressure regulator in the gas supply line if inlet pressure can exceed 13”w.c. [32 mbar] at any time. Adjust the lockup pressure regulator for 13”w.c. [32 mbar] maximum.

WARNING

DO NOT adjust or attempt to measure gas valve outlet pressure. The gas valve is factory-set for the correct outlet pressure. This setting is suitable for natural and propane gas and requires no field adjustment. Attempts by the installer to adjust or measure the gas valve outlet pressure could result in damage to the valve, causing potential severe personal injury, death or substantial property damage.

Table 2: Natural Gas Orifice Requirements

CHALLENGER

MODEL

CC85 0.256” [6.50 mm] 650

CC105 0.256” [6.50 mm] 650

CC125 0.285” [7.25 mm] 725

Natural

Orifice Size

Orifice

Marking

Length of Pipe in

Feet

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

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

Table 1: Gas Piping Sizing - Natural Gas

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

Page 38

Gas Piping

hrottle Screw

Gas Supply Inlet Pressure Port

Flow direction

Gas Orifice

O-Ring Gasket

PROPANE GAS

Pipe Sizing - Propane Gas

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

Propane Gas Supply Pressure Requirements

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

2. Pressure required at the gas valve inlet supply pressure port:

- Maximum 13”w.c. [32 mbar] at flow or

no flow conditions to the burner

- Minimum 5”w.c. [13 mbar] during flow con-

ditions to the burner. Must be verified during start up and with all other gas appliances operating within the gas piping service.

- Maximum gas inlet pressure must not be

excceded and minimum gas inlet pressure is for the purpose of input adjustment.

Table 3: Propane Gas, Orifice Requirements:

CHALLENGER

MODEL

CC85 0.199” [5.05 mm] 505

CC105 0.199” [5.05 mm] 505

CC125 0.220” [5.60 mm] - 580 -

Propane

Orifice Size

Orifice

Marking

WARNING

DO NOT adjust or attempt to measure gas valve outlet pressure. The gas valve is factory-set for the correct outlet pressure. This setting is suitable for natural gas and propane and requires no field adjustment. Attempts by the installer to adjust or measure the gas valve outlet pressure could result in damage to the valve, causing potential severe personal injury, death or substantial property damage.

WARNING

Prior to start up, ensure the appliance is set to fire propane. Check the rating label for the type of fuel. Check the gas valve for propane conversion label. If there is a conflict or doubt on the burner set up, remove the gas valve and check for the propane orifice, see Fig. 15. Failure to ensure proper burner setup could result in severe personal injury, death or substantial property damage.

Fig. 15 : Gas Orifice Assembly

Page 39

Internal Wiring

SECTION VIII - Internal Wiring

WARNING

ELECTRICAL SHOCK HAZARD. For your safety, disconnect electrical power supply to the appliance before servicing or making any electrical connections to avoid possible electric shock hazard. Failure to do so can cause severe personal injury or death.

CAUTION

Prior to servicing, label all wires before disconnecting. Wiring errors can cause improper and dangerous operation. Verify proper wiring and operation after servicing.

General Requirements

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

- If original wiring as supplied with the appliance must be replaced, use only Type T 194F [90ºC] wire or equivalent as a minimum.

- The CHALLENGER must be electrically grounded as required by National Electrical Code ANSI/NFPA 70 - latest edition and / or the Canadian Electrical Code Part 1, CSA C22.1, Electrical Code.

Page 40

Internal Wiring

Boiler Circulator

Aquastat

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

Ladder Diagram

Note

Schematic Diagram

- The wiring for 120V field connections to the appliance shall have a minimum size of 14 AWG and a temperature rating of at least 194ºF (90º).

- If any of the original wire as supplied with the appliance must be replaced with T wire or it’s equivalent.

Fig. 16: CHALLENGER Factory Wiring Diagrams

Page 41

External Wiring

SECTION IX- External Wiring

Installation Compliance

All field wiring made during installation must comply with:

- National Electrical Code NFPA 70 and any other national, state, provincial or local codes or requirements.

- In Canada, CSA C22.1 Canadian Electrical Code Part 1, and any other local codes.

WARNING

ELECTRICAL SHOCK HAZARD. Before making any electrical connections to the CHALLENGER, disconnect electrical power supply at the service panel. Failure to comply can cause severe personal injury or death.

WARNING

The ON/OFF switch of the CHALLENGER only disables the function of the appliance. Electrical power remains at the control module. To avoid a shock hazard, disconnect power at the external service switch when servicing the appliance.

Control Module Circulator AMP Ratings

- AMP draw of the CH circulator must not exceed 2.3 amps.

Line Voltage Connections

1. Connect a 120 VAC/15A service to the 120V terminals L, N and G inside the CHALLENGER as shown in Fig. 16, page 34.

2. Route the incoming 120 VAC power wire through the provided openings in the bottom right side jacket panel.

3. The appliance must be provided with an external service switch, check local code requirements for compliance.

NOTICE

The installer must provide and install a fused disconnect or 15 amp (minimum) service switch. Check local electrical code requirements for compliance.

Page 42

External Wiring

Fuse

Control/Display

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)

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

NOTICE

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

1. Connect room thermostat or the end switch (isolated contact only) to the low voltage terminal strip on the drop down control panel, as shown in Fig. 16, page 34 and Fig.

17.

2. For proper operation install the room thermostat on an inside wall away from influences of heat and cold, i.e. water pipes, areas of draft, lighting fixtures and fireplaces.

3. Set the thermostat anticipator (if applicable) as follows:

- Set for 0.1 amps when wired directly to

the CHALLENGER.

- Set to match the total electrical power

requirements of the connected devices when wired to zone relays or other devices. Refer to the relay manufacturers’ specifications and the thermostat instructions for additional information on the anticipator setting.

NOTICE

When making low voltage connections to the CHALLENGER, ensure no external voltage is present in the thermostat circuits. If external voltage is present, provide an isolated contact to prevent damage to the appliance control.

Fig. 17: Accessing Low Voltage X4 Connections

Page 43

External Wiring

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

120V

To Challenger

CH Circulator

1. Connect the CH primary circulator to the CHALLENGER 120 V terminals 1,2 and 3 located inside the appliance as shown in Fig. 16, page 34.

2. Maximum CH circulator continuous current draw is 2.3 A.

System Circulator - Zone Valve Application

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

Outdoor Reset Control

The CHALLENGER may operate with a variable appliance operating temperature using the Triangle Tube outdoor sensor, see pages 55 through 57 for installation and set-up.

NOTICE

If the installer opts for a fixed operating temperature for the boiler system, the outdoor sensor is not required and should not be installed.

Fig. 18: Secondary System Circulator Wiring

Page 44

External Wiring

High Voltage

120

V.A.C.

.A.C.

Room

Thermostat

Room

Thermostat

Zone 1

Zone 2

Additional zones

Additional zones may

be added as shown above

To Challenger

Low Voltage Terminal Strip

Transformer

(Power)

Zone

Valve

Zone Valve

To Challenger

Low Voltage Terminal Strip

High Voltage

120

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

*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

Page 45

External Wiring

To Challenger

Low Voltage Terminal Strip

Circulator

one 1

Thermostat

zone 1

Honeywell

845A

elay

120

VAC

irculator

Zone 2

Thermostat

zone 2

Additional zones may be

added as shown above

Thermostat

Zone 1

Zone 1 Circulator

120 VAC

To Challenger

Low Voltage Terminal Strip

Zone 2 Circulator

Zone 3 Circulator

Thermostat

Zone 2

Thermostat

Zone 3

T1 T1 T2 T2 T3 T3

C2 C2 C1 C1 PR PR

X2 X1 L1 L2 ZC

Fig. 20: Field Wiring with Zone Circulators

Fig. 21: Typical Zone Relay Panel Wiring

Page 46

Start-Up Preparation

SECTION X - Start-Up Preparation

Check Boiler System Water Chemistry

WARNING

Do not use petroleum-base cleaning or sealing compounds in the boiler system. Damage to seals and gaskets in the system components could occur, resulting in substantial property damage.

NOTICE

System water including additives must be practically non-toxic, having a toxicity rating or Class of 1, as listed in Clinical Toxicology of Commercial Products.

Water pH Level 6.5 to 8.5

Flush Boiler and Domestic System to Remove Sediment

The installer must flush the boiler system to remove any sediment to allow proper operation of the CHALLENGER .

Flush the systems until the water runs clean and is free of sediment.

For zoned systems, each zone should be flushed through a purge valve. Purge valves and isolation valves should be installed on each zone to allow proper flushing of the system.

Check and Test Antifreeze

For boiler systems containing antifreeze solutions, follow the antifreeze manufacturer’s instructions in verifying the inhibitor level and to ensure the fluid characteristics are within specification requirements.

Maintain the boiler water pH between 6.5 and

8.5. Check using litmus paper or contact a water

treatment company for a chemical analysis.

If the pH does not meet this requirement, do not operate the CHALLENGER or leave the appliance filled, until the condition is corrected.

Water Total Hardness Less Than 7 Grains/Gallon

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

Chlorinated Water

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

Maintain the chlorine level of the water at levels considered safe for drinking.

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

NOTICE

System water including additives must be practically non-toxic, having a toxicity rating or Class of 1, as listed in Clinical Toxicology of Commercial Products.

Page 47

Start-Up Preparation

Use of Antifreeze in the Boiler System

WARNING

NEVER use automotive or ethylene glycol antifreeze or undiluted antifreeze in the boiler system as freeze protection. This can cause severe personal injury, death or substantial property damage if ignored.

Determine the antifreeze fluid quantity using the system water content volume and following the antifreeze manufacturer instructions.

The boiler water volume of the CHALLENGER CC 85 is 0.37 gallons [1.4 l], CC 105 is 0.42 gallons [1.6 l] and CC 125 is 0.50 gallons [1.9 l]. Remember to include this volume in sizing of the expansion tank.

Check with local codes requirements for the installation of backflow preventers or actual disconnection from the boiler’s cold water fill or make up water supply line.

Filling the Boiler System

1. Close the boiler drain valve located on the bottom of the appliance and any manual or automatic air vent in the system.

2. Open all system isolation valves.

3. Fill the boiler system to correct system pressure. Correct pressure will vary with each application.

NOTICE

Typical residential system fill pressure is 12 psi [0.8 bar]. System pressure will increase when system temperature increases. Operating pressure of the system should never exceed 25 psi [1.7 bar].

4. Purge air and sediment from each zone of the hydronic system through the purge valves. Open air vents to allow air to be vented from the zones.

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

NOTICE

Massachusetts Code requires the installation of a backflow preventer if antifreeze is used.

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

NOTICE

System water, including additives, must be practically non-toxic, having a toxicity rating or Class of 1, as listed in Clinical Toxicology of Commercial Products.

WARNING

Unrepaired system leaks will cause continual makeup water to be added to the appliance. Continual makeup water could cause mineral buildup within the heat exchanger, reducing the heat transfer, causing possible heat buildup and eventual heat exchanger failure.

Check Low Water Cut Off/CH Pressure Sensor

- The CHALLENGER is provided with a factory installed LWCO that senses boiler CH system pressure of more than 7 psig [0.5 bar].

- Compare CH system pressure gauge reading to CHALLENGER’s control pressure display reading, which can only be viewed when control is ON and no CH or DHW call is present. Adjust pressure accordingly.

Page 48

Start-Up Preparation

Check For Gas Leaks

WARNING

Prior to start-up and during initial operation, smell near the floor and around the appliance for gas odorant or any unusual odor. Do not proceed with the start-up if there is any indication of a gas leak. Any leaks found must be repaired immediately.

WARNING

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

Prior to start-up of the appliance and periodically after start-up have the propane supplier check and verify the odorant level.

NOTICE

In systems using 3-wire zone valves, backfeed of voltage to the appliance is a common problem. Use an isolation relay to prevent voltage from the external circuit entering the CHALLENGER control panel.

- Reconnect the external thermostat

wires to the control terminal strip.

Inspection of Condensate Drain Assembly

1. Inspect and ensure the Condensate Drain Assembly is properly installed as described on page 28 and shown in Fig. 13 on page

29.

2. Remove the Condensate Drain Assembly and fill with fresh water.

NOTICE

Check Thermostat Circuit

- Disconnect the external thermostat wires from the control terminal strip, located on the drop down panel.

- Connect a voltmeter across the wire ends of the external thermostat wiring.

- Energize each thermostat, zone valve and relay in the external circuit, individually and check the voltage reading across the wire ends.

- There should NEVER be voltage measured at the wire ends.

- If voltage is measured at the panel under any condition, check and correct the external wiring.

The condensate drain assembly must be installed on the appliance and filled with water when the CHALLENGER is in operation. The condensate drain assembly prevents flue gas emissions from entering the condensate line. Failure to ensure trap is filled with water could result in severe personal injury or death.

3. Re-Install the condensate drain assembly.

Page 49

Start-Up Procedures

SECTION XI - Start-Up Procedures

Final Checks Before Start-Up

c Read page 46 through 57 regarding the

operation of the CHALLENGER control.

c Verify the CHALLENGER and the boiler

system are full of water and all system components are correctly set for operation, including the minimum flow rate through the boiler, see pages 80-82.

c Verify Start-up Preparation items outlined on

pages 40 thru 42 have been completed.

c Verify all electrical connections are correct

and securely fastened.

c Inspect vent and combustion air piping for

signs of deterioration from corrosion, physical damage or sagging. Verify combustion air and vent piping are intact and correctly installed and supported. Reference the proper CHALLENGER vent supplement.

c Verify burner configuration - gas orifice

size.

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

- If there is doubt on the burner configuration, remove the gas valve and check for proper gas orifice size. See pages 31 and 32 for orifice sizes.

c Ensure the vent Condensate Drain

Assembly 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 Instructions outlined on page 45.

If CHALLENGER Does Not Start Correctly

1. Verify DHW and CH systems are turned ON (parameter 1) is set to “0”. Read setting the appliance parameters section of the

manual starting on page 52 for more information.

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

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

4. Is the gas supply valve(s) open at the appliance and meter?

5. Is incoming gas supply pressure at the appliance more than 5”w.c. [13 mbar] and less than 13” w.c. [32 mbar] for natural or propane with all gas appliances ON or OFF.

6. Are the heating thermostats set above room temperature?

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 for leaks. If found, shut down the appliance and repair immediately.

Purge any remaining air from the system piping. Air in the system piping will interfere with circulation creating heat distribution problems and system noise.

c Check Vent Piping and Combustion Air

Piping.

Check for gas-tight seal at every connection and seam of the venting and combustion air piping.

WARNING

Venting system must be sealed gas-tight to prevent flue gas spillage and potential carbon monoxide emissions, which will result in severe personal injury or death.

Page 50

Start-Up Procedures

c Check Gas Piping

Check around the appliance for gas odor following the procedure outlined in this manual on Page 42.

WARNING

If any gas leaks are found or suspected, shut the appliance down immediately. Use a gas detection device or bubble test to locate the source of the gas leak and repair at once. Do not operate the appliance until the leak is corrected. Failure to comply with this procedure could result in severe personal injury, death or substantial property damage.

c Verify Flame Pattern and Combustion

Check the flame pattern through the inspection port on the left side of the heat exchanger. The flame should be blue and stable and should be the length of the burner.

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

Table 5: Recommended Combustion Levels

Natural Gas Propane Gas

High Fire

(h or H)

( and +)

DOOR OFF*

Low Fire

(L)

( and -)

9% to 10.1% C0210.5% to 11.1% C0

5% to 3.2% 0

0 to 0.4 lower

C02than high fire

9.0 % min. C0

0 to 0.6 higher

02 than high fire

5.0% max. 0

5% to 4.1% 0

0 to 0.4 lower C0

than high fire

10.5 % min. C0

0 to 0.6 higher

02 than high fire

5.0% max. 0

WARNING

The combustion testing and adjustments must be performed by a qualified installer, service agency or the gas supplier. All combustion measurements must be performed with calibrated equipment to ensure proper reading and accuracy.

Test for C02or 02and for CO during high and low firing rate. To manually place the appliance into high or low fire mode, reference page 50. The combustion reading should be within the range listed in Table 5. The CO level should

not exceed 100 ppm when combustion is correct.

WARNING

The combustion levels should be measured at high and low firing rate, refer to page 50 of the CHALLENGER control section on how to set the firing rate. If the combustion levels are not within the range given in Table 5 for the firing rate, shut the appliance down and contact

CO Max. 100 ppm 100 ppm

* Door on can raise the maximum allowable C02by

0.4 or lower the minimum allowable 02by 0.6.

c Measure Input - Natural Gas Only

1. Ensure the appliance is firing at maximum

firing rate. To manually place the appliance into high fire mode, reference page 50.

2. Operate the appliance for approximately

10 minutes.

3. Turn off all gas appliances on the gas ser-

vice, except the CHALLENGER.

4. At the gas meter, record the time required

to use one cubic foot of gas.

5. Calculate Natural gas input using the fol-

lowing equation:

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

6. The BTU/H calculated should approximate

the input rating listed on the appliance.

Page 51

Start-Up Procedures

FOR YOUR SAFETY READ BEFORE LIGHTING

WARNING

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

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

equipped with an ignition device which automatically 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.

OPERATING INSTRUCTIONS

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 supply (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.

• 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.

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 instructions “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.

TO TURN OFF GAS TO APPLIANCE

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 clockwise to “CLOSE”, (valve handle shall be perpendicular to gas piping).

Page 52

Start-Up Procedures

Appliance ON/OFF

1. The appliance operation is started using the ON/OFF button.

2. When appliance is in operation, the green

LED above the ON/OFF will be lit.

3. When the appliance is not in operation, the

green LED above the ON/OFF will not be 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 to 3 seconds until the radiator symbol “ ” (CH) LED, lights up and the main display begins to flash.

2. Press the or buttons to set the desired

maximum temperature setting on the main display.

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

3. The following operating displays should occur:

A] Self check on power up

[

[ ] No call for heat

4. Initiate a call for heat by raising the set point of the room thermostat to the highest setting. The following operating display should occur

1] This is the prepurge cycle. The burner

[ blower and the boiler circulator become energized. The blower has a 5 second prepurge cycle.

2] This is the ignition cycle. The control

[ module will energize and open the gas valve and begin the spark for ignition.

- If the burner flame proves, the burner

will begin to modulate.

3. Press the reset button to close the setting menu and store the changes.

NOTICE

If the reset button is not pressed within 30 seconds, the settings menu is automatically 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

Operation Verification - Space Heating

NOTICE

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.

stored.

- If the burner flame is not established the control module will repeat the ignition sequence after approximately 15 seconds . If the flame is not established after four attempts the control will lockout. The main display will show [

flash in the operating display.

- To verify flame failure safety lockout, close the manual shut off valve on the gas supply piping to the appliance and repeat ignition sequence. When verification is completed, ensure the manual shut off valve is returned to the open position.

3] This is the normal Central Heating

[ (CH) operation cycle. The control module will begin to modulate the burner firing rate based on actual appliance outlet temperature and the set point temperature. The CH water temperature is displayed on the main display.

5. Allow the appliance to operate and the boiler outlet temperature to reach the set point temperature.

4] and the fault LED above the

reset button will flash and [E] will

Page 53

Start-Up Procedures

[1] The setpoint temperature has been reached. Combustion will cease and the post purge cycle of the blower begins. The control module will de-energize the gas valve and the blower will continue with the 10 second post purge cycle, before shutting down. The CH circulator will continue to run until the room thermostat is satisfied.

6. Lower the room thermostat set point below the room temperature to end the call for heat.

1] This begins a post purge cycle. When

[ the room thermostat is satisfied, the appliance will shutdown.

7] The CH circulator will continue to run

[ for a 1 minute post pump cycle.

NOTICE

The CH circulator automatically runs for 10 seconds once every 24 hours to prevent seizing. Timing for this automatic switching starts after the last call for heat.

[ ] The appliance is in Standby MODE

waiting for a call for heat.

7. Verify the operation of the appliance by repeating the operational sequence several times.

8. Return the room thermostat to a desired setting.

3. Press the reset button to close the setting menu and store the changes.

NOTICE

If the reset button is not pressed within 30 seconds, the settings menu is automatically 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

Operation Verification - Domestic Hot Water (if applicable)

NOTICE

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 few seconds and turn on power to the appliance.

3. The following operating displays should occur:

A] Self check on power up

[

[ ] No call for heat

stored.

Set DHW Set Point Temperature

1. Press the CH/DHW/parameter button “ ” at the display panel for approximately 2 to 3 seconds until the faucet “ ” (DHW) LED lights up and the main display begins to flash.

2. Press the or buttons to set the desired domestic water temperature on the main display. Minimum setting is 104ºF [40ºC], Maximum setting is 149ºF [65ºC], factory default is 120ºF [49ºC].

4. Turn on a domestic hot water faucet to initiate a domestic call. The display should show

1] This is the prepurge cycle. The burner

[ blower become energized. The blower has a 5 second prepurge cycle. The CH (central heating) circulator will remain off, to provide DHW priority.

2] This is the ignition cycle. The control

[ module will energize and open the gas valve and begin the spark for ignition.

- If the burner flame proves, the burner

will begin to modulate.

Page 54

Start-Up Procedures

flash in the operating display.

4]and the fault LED above the

reset button will flash and [E] will

4] This is the normal DHW operation

[ cycle. The control module will begin to modulate the burner firing rate based on actual DHW set point temperature. The DHW water temperature is displayed in the main display.

5. Turn off the domestic hot water faucet to end the call for heat.

1] This begins a post purge cycle. The

[ control module closes the gas valve and the blower continues to operate for approximately 10 seconds.

6. Verify the DHW operation by repeating the outlined operation sequence several times.

Page 55

Start-Up Procedures

1. On/Off (Lit when on)

2. CH operation or setting maximum CH temperature

3. DHW operation or setting DHW temperature

4. Main display with temperature of CH or DHW or CH water pressure or fault code

5. Temperature ºF or pressure psi

6. Temperature ºC or pressure bar

7. DHW function eco (learned)

8. DHW function on (minimum block temp)

9. Operating display

10. Flashes to indicate fault

A. On/Off button B. CH /DHW/parameter button C. - button D. + button E. Units U.S. customary or metric F. DHW function off/eco/on G. Service button H. Reset/store button

Read-Out

Operation

Control Display

Appliance ON/OFF

1. The appliance operation is started using the ON/OFF button.

2. When appliance is in operation, the green

LED above the ON/OFF will be lit.

3. When the appliance is not in operation, the

green LED above the ON/OFF will not be lit. The main display will show “OFF” and the operating display will show .

Units

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

NOTICE

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

Additional DHW Functions

Additonal DHW setting can be activated by pressing the DHW button.

- ON ( LED lit above the DHW

- ECO ( LED lit above the DHW

- OFF (no LED lit) - The appliance will not

BEST PRACTICE

In application in which the DHW is not utilized or the DHW demand is minimal, set the DHW function to OFF.

button) - The appliance DHW function is activated continuously. The appliance will maintain a minimum heat exchanger temperature to assure instant delivery of hot water.

button) - The DHW function is self-learning. The appliance will maintain a minimum heat exchanger temperature during times with typical domestic demands, learned over the past 3 days of use.

maintain a minimum heat exchanger temperature. This will affect the delivery and performance of the initial DHW temperature.

Page 56

Start-Up Procedures

Test Mode Function

TO TEMPORARILY PLACE THE BURNER INTO HIGH FIRE TEST MODE: press

and hold both the “

” and “+” button simul-

taneously once until operating display shows “h” for CH high fire or twice until the operating display shows “H” for DHW high fire.

While in the test mode:

- high limit will function

- appliance CH circulator will function

- the test mode will time out in approximately 10 minutes

TO TEMPORARILY PLACE THE BURNER INTO LOW FIRE TEST MODE: press

and 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.

Page 57

Start-Up Procedures

Function

Main Display

Operating Display

OFF

XXP

XXX

Press

No demand for heat

Control self-test

Fan pre purge or post purge cycle

Space Heating (CH) post pump cycle

XXX

Ignition sequence

XXX

Burner ON for space heating (CH)

XXX

LOP*

Burner ON for domestic hot water (DHW)

Burner ON for DHW pre-heating

Raise CH pressure above 7 psig [0.5 bar]

Burner ON for freeze protection

The

LED will be lit for CH (central heating call)

Burner OFF due to reaching temperature setpoint

button to turn appliance ON

LED lite above button will be lit

The

LED will be lit for DHW (domestic call)

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. Pressure 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).

Page 58

Start-Up Procedures

Adjustments

Description

Parameters

(Flashing)

Factory Settings

LED

(Flashing)

Installation type

186ºF [86Cº]

120ºF [49Cº]

0=Combi (Heat and DHW)

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

CH pump continuous

0=Intermittent pump on for heat and post purge 1=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

Adjustment range 0 to 15 minutes

Waiting time after a DHW demand before a CH demand is answered

Adjustment range 0 to 15 minutes

Anti-cycling period during CH operation

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

5 6

7 8

Main Display

Operating

Display

Boiler set point temperature

DHW (domestic) setpoint temperature

Adjustment range 86ºF to 194ºF [30ºC to 90ºC]

Adjustment range 104ºF to 149ºF [40ºC to 65ºC]

Note:

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.

The waiting time starts at the end of the DHW call (no DHW flow - DHW flow switch contacts are open) and blocks the burner and CH circulator. if DHW function is turned ON ( LED is lit above the DHW button) or ECO is ON ( LED is lit above DHW button) than the burner will continue to fire for DHW until a minimum heat exchanger temperature is achieved. Burner and CH circulator will continue to be blocked until the remaining waiting time ends. This feature only applies if parameter 1 is set to 0.

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 36. 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].

Setting the Appliance Parameters

1. Press the “”button at the display panel

for approximately 2 to 3 seconds until main display begins to flash.

2. Press the “”button repeatedly to scroll

through the list of parameters. The operating display will show the parameter number

5. After all parameters have been changed, press the reset button to close the setting menu and store the changes. The main display will go blank and a P will be displayed in the operating display to let you know the control was programmed.

NOTICE

and main display will show the parameter setting.

3. To modifiy a parameter press the or buttons.

4. Press the “”button to scroll to the next parameter to be changed.

If the reset button is not pressed within 30 seconds, the settings menu is automatically 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.

Page 59

Start-Up Procedures

Error (Hard Lockout) Mode

If a system fault occurs, the system enters a hard lockout condition which requires a manual reset by pressing the RESET button . A hard lock is indicated by a flashing [E] on the operating display as well as a flashing LED light above the reset button. The error code is located on the main display. The error must be corrected before the control will reset.

CAUTION

The appliance freeze protection feature is disabled during a Hard Lockout, however the CH circulator will operate.

CAUTION

Table 6: 12 K Ohm NTC Sensor Resistance

During a hard lockout or low water condition the appliance will not re-start without service. If the heating system is left unattended in cold weather appropriate safeguards or alarms should be installed to prevent property damage.

Page 60

Start-Up Procedures

10, 11, 12,

1, 28

29,30

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

• Flow switch sticking or miss-installed

• 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

Operating

isplay

(Flashing)

Main Display

Possible Solution

Error Description

18, 19

fault

- Flue sensor

• E18 open sensor

• E19 Shorted sensor

• Check/Replace sensor

7,16, 17

fault

- DHW sensor

• E16 Shorted sensor

• E17 Open sensor

• Check/replace sensor

• E7 Excessive temperature

• Check gas orifice

• Check combustion settings

50F

- Improper frequency

• Verify ground

• Frequency should be between 45 and 65 Hz

Error (Hard Lockout) Codes*

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

NOTICE

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

Page 61

Outdoor Reset Control

ensor Enclosure

lastic Anchors (2)

Seal Gasket

Front Cover

Mounting

crews

(2)

SECTION XII - Outdoor Reset Control

The appliance setpoint for a heating call can be fixed or vary with the outdoor temperature. If the application requires a constant supply temperature from the boiler, the outdoor temperature sensor should not be connected to the appliance. If an outdoor temperature sensor is connected to the appliance, the outdoor reset function is automatically enabled and will vary the CH setpoint with the change in outdoor temperature. The outdoor reset function has no affect on the DHW setpoint during a domestic call.

4. Mount the sensor enclosure at an elevation on the exterior wall to prevent accidental damage or tampering.

5. Avoid mounting the enclosure in areas subjected to excessive moisture.

6. Once an area on the exterior wall has been determined, to affix the enclosure use the enclosure as a template to mark the location of the mounting screws.

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

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

9. Mount the sensor enclosure using the screws provided.

Wiring the Sensor

1. Route two 18 gauge wires through the seal gasket. Connect the wires to the sensor terminals 1 and 2.

Fig. 22: Sensor Enclosure and Components

Mounting the Outdoor Sensor

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

2. When mounting the enclosure, the exterior wall selected should represent the coldest outdoor temperature. Typically a northern or northeastern wall will suit most buildings. A southern facing wall may suit buildings that have large glass walls or windows on the southern face.

3. Ensure the sensor enclosure is shielded from direct sunlight or the effects of heat or cold from other sources (exhaust fans, appliance vents...) to prevent false temperature sensing.

2. Route the sensor wire back to the CHALLENGER, ensuring the wires are not run parallel to telephone or power cables.

NOTICE

If the sensor wires are located in an area with sources of potential electromagnetic interference (close to 120 V wiring) the sensor wires should be shielded or the wires should be routed in a grounded metal conduit. If using shielded cable, the shielding should be connected to the common ground of the appliance.

3. Connect the sensor wires to the outdoor sensor terminals 9 and 10 on the low voltage X4 connector terminal strip located at the control on the swing out panel (see appliance wiring diagram, Fig. 16 page 34).

Page 62

Outdoor Reset Control

Adjusting Outdoor Reset Curve

The appliance CH set point along with Parameters 5, 6 & 7 define the settings of the outdoor reset curve. See Graph 1 and Table 7, page 57 for an example of modifying the outdoor reset curve.

CH Maximum Boiler Operating Temperature

Factory Setting

186ºF

[86ºC]

Minimum

Setting

86ºF

[30ºC]

Maximum

Setting

194ºF

[90ºC]

If an outdoor temperature sensor is not connected to the appliance, the appliance setpoint for a heating call will be set to the CH Maximum Boiler Operating Temperature Setpoint. If an outdoor temperature sensor is connected, the CH Maximum Boiler Operating Temperature Setpoint becomes the appliance setpoint on the CH Reset Curve Coldest Day.

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

CH Reset Curve Warmest Day (Parameter 7)

Factory Setting

64ºF

[18ºC]

Minimum

Setting

59ºF

[16ºC]

Maximum

Setting

77ºF

[26ºC]

This parameter is not applicable if an outdoor sensor is not connected to the appliance. When an outdoor temperature sensor is connected, the CH Reset Curve Warmest Day is the warmest design temperature of the heating system.

Changing Outdoor Reset Parameters

1. Press the “”button at the display panel for approximately 2 to 3 seconds until main display begins to flash.

CH Minimum Boiler Operating Temperature Setpoint (Parameter 5)

Factory Setting

86ºF

[30ºC]

Minimum

Setting

59ºF

[16ºC]

Maximum

Setting

140ºF

[60ºC]

This parameter is not applicable if an outdoor sensor is not connected to the appliance. When an outdoor temperature sensor is connected, the CH Minimum Boiler Operating Temperature Setpoint becomes the appliance setpoint on the CH Reset Curve Warmest Day.

CH Reset Curve Coldest Day (Parameter 6)

Factory Setting

00ºF

[- 18ºC]

Minimum

Setting

-22ºF

[-30ºC]

Maximum

Setting

50ºF

[10ºC]

2. Press the “”button repeatedly to scroll through the list of parameters. The operating display will show the parameter number and main display will show the parameter setting.

3. To modifiy a parameter press the or buttons.

4. Press the button to close the setting menu and store the changes.

The appliance control module has now been reprogrammed with the desired parameter values.

NOTICE

Pressing the ON/OFF button will exit the parameter setting mode without storing the parameter changes.

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

Page 63

Outdoor Reset Control

100

140

10 0

-10

Boiler Temperature ( F)

Outdoor Air Temperature ( F)

Boiler CH Set Point

Parameter 5

Set Point

Parameter 7 Setting

Parameter 6 Setting

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 at 10ºF outdoor air temperature

Note: Factory setting of CH set point is 186ºF

Page 64

Check-Out Procedures

SECTION XIII- Check-Out Procedures

NOTICE

Perform the following check-out procedures as outlined and check off items as completed. When procedures are completed, the installer should complete the installation record on page 59.

Check-Out Procedures

c Boiler system water chemistry checked and

verified as outlined on page 40.

c Any automatic air vents caps placed within

the system are open one full turn.

c Air is purged from the heating zones and

appliance system piping.

c Confirm the appliance has proper gas ori-

fice as noted on pages 31 and 32.

c Thermostat circuit wiring checked and ver-

ified that no voltage is present to the low voltage terminals as outlined on page 42.

c Checked and verified room thermostat(s)

function properly and the thermostat(s) heat anticipator (if used) was properly set.

c Observed several operating cycles for

proper operation of the CHALLENGER and the system.

c Set the room thermostat(s) to the desired

room temperature.

c Reviewed all instructions shipped with the

CHALLENGER with the homeowner or maintenance personnel.

c Completed the Installation Record on page

59.

c Ensure all manuals and other documents

are returned to the Installation envelope and given to the owner for safekeeping.

c Operating Instructions on page 45 were fol-

lowed during start-up.

c Combustion levels and flame pattern veri-

fied as outlined on page 44.

c Measured the rate of input on Natural Gas

as outlined on page 44.

c Checked the incoming gas pressure to the

CHALLENGER to ensure a minimum pressure of 5”w.c [13 mbar] during flow conditions to all gas appliances and a maximum pressure of 13”w.c [32 mbar] during non-flow conditions for Natural and Propane gas.

c Adjusted balancing valves and system limit

controls to provide design temperatures to the primary space heating system.

c In multiple zone applications, adjusted for

correct flow of appliance water to each zone.

Page 65

CHALLENGER Model Number:

Serial Number:

Date of Installation:

Fuel: Natural Gas Propane

Measured Rate of Input:

Combustion Readings:

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)

(Phone Number)

Btu/hr

____________________________________________________________________

_________________________________________________________________

ppm

Installation Record

SECTION XIV - Installation Record

Page 66

Maintenance Schedule

SECTION XV - Maintenance Schedule

Service Technician

At least on an annual basis the following maintenance should be performed by a qualified service technician:

General

- Attend to any reported problems.

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

- Clean the condensate drain assembly and fill with fresh water.

- Check for leaks: water, gas, flue and condensate.

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

- Check appliance water pressure, piping and expansion tank.

- Check control settings.

Owner Maintenance

Periodic:

- Check the area around the appliance.

- Check and remove any blockage from the combustion air inlet and ventilation openings.

- Check the temperature and pressure gauges.

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 piping for corrosion or potential signs of leakage.

- Operate the pressure relief valve.

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

- Check ignition wiring and ground wiring.

- Check all control wiring and connections.

- Check burner flame pattern (stable and uniform).

Additional items if combustion or performance is poor:

- Clean heat exchanger and flue ways.

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

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

WARNING

Follow the maintenance procedures given throughout this manual. Failure to perform the service and maintenance or follow the directions in this manual could result in damage to the CHALLENGER or in system components, resulting in severe personal injury, death or substantial property damage.

Page 67

Maintenance Procedures

SECTION XVI - Maintenance Procedures

Annual Maintenance Procedures

WARNING

The CHALLENGER should be inspected and serviced annually, preferably at the start of the heating season, by a qualified service technician. In addition, the maintenance and care of the appliance as outlined on page 60 and further explained on pages 61 through 67 should be performed to assure maximum efficiency and reliability of the appliance. Failure to service and maintain the CHALLENGER and the system components could result in equipment failure, causing possible severe personal injury, death or substantial property damage.

NOTICE

Verify that combustion air inlet area is free of any contaminates. Refer to the materials listed on page 7 of this manual. If any of these products are in the area from which the appliance takes its combustion air, they must be removed immediately or the combustion air intake must be relocated to another area.

Inspect Burner Area

Remove the appliance front jacket panel.

Vacuum any dirt or debris from the blower component.

Re-install front jacket panel when completed.

WARNING

Do not use solvents to clean any of the components. The components could be damaged, resulting in unreliable or unsafe operation.

The following information provides detailed instruction for completing the maintenance items outlined in the maintenance schedule on page 60. In addition to this maintenance, the CHALLENGER should be serviced at the beginning of the heating season by a qualified service technician.

Reported Problems

Any problems reported by the owner should be checked, verified and corrected before proceeding with any maintenance procedures.

Check Surrounding Area

Verify that the area surrounding the CHALLENGER is free of combustible / flammable materials or flammable vapors or liquids. Remove immediately if found.

Check System Piping

Inspect all piping (water and gas) for leaks and verify that the piping is leak free and properly supported.

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

WARNING

Eliminate all boiler leaks. Continual fresh make-up water will reduce the heat exchanger life causing appliance failure. Leaking water may also cause severe property damage to the surrounding area. Inspect the gas supply piping using the procedure outlined on Page 42.

Page 68

Maintenance Procedures

Clean Condensate Drain Assembly

1. Remove the condensate assembly from the appliance.

2. Empty any water from the trap and drain assembly. Flush with fresh water as necessary to clean.

3. Check the drain piping from the condensate drain assembly to the drain. Flush to clean as necessary.

4. Fill the condensate drain assembly with water.

5. Reassemble the condensate drain assembly onto the appliance.

WARNING

When re-assembling the condensate drain assembly ensure all gaskets are in place and correctly installed. Ensure all associated internal joints are complete, tight and secure. Failure to comply can result in flue gas leakage resulting in severe personal injury, death or substantial property damage.

Check Ventilation Air Openings

Verify that all ventilation openings to the mechanical room or building are open and unobstructed. Check the operation and wiring of any automatic ventilation dampers.

Check and verify the vent discharge and the combustion air intake are free of debris and obstructions.

Inspect Vent and Combustion Air Piping

Visually inspect the venting system and combustion air piping for blockage, deterioration or leakage. Repair any deficiencies.

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

WARNING

Failure to inspect the vent system and combustion air inlet piping and to have any conditions repaired, can result in severe personal injury or death.

Check Boiler System

Verify all system components are correctly installed and operating properly.

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

Verify the system pressure, as the appliance operates at high temperature, to ensure the pressure does not exceed 25 psig [1.7 bar]. Excessive pressure reading may indicate expansion tank sizing is incorrect or system performance problems.

Inspect air vent and air separators in the system. Remove the caps on automatic air vents and briefly depress the valve stem if present to flush vent. Replace the cap when completed. Ensure vents do not leak. Replace any leaking vents.

Removing Internal Flue and Condensate Pan For Inspection

1. Loosen the flue pipe retaining ring as shown in Fig. 23, page 63.

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

3. Pull the flue pipe down and out to disengage from the vent adapter as shown in Fig. 24, page 63.

4. Lift up the condensate pan to disengage from trap.

5. Once the condensate pan is clear of the bottom jacket, rotate it towards the front of the appliance and push down on the rear to disengage from the heat exchanger as shown in Fig. 25, page 63.

- Inspect the flue pipe and condensate

pan for cracks, damage or distortion. Check all gaskets for tears, discoloration or other damage, replace as necessary.

- Once inspection is completed re-assem-

ble the condensate pan and flue pipe in reverse order.

Page 69

Maintenance Procedures

Fig. 23: Loosening of Flue Pipe Retaining Ring

Fig. 24: Removal of Flue Pipe

Fig. 25: Removal of Condensate Pan

Page 70

Maintenance Procedures

WARNING

When re-assembling the condensate pan and flue pipe ensure all gaskets are in place and correctly installed. Ensure all associated joints are complete, tight and secure. Failure to comply can result in flue gas leakage resulting in severe personal injury, death or substantial property damage.

Check Expansion Tank

Refer to Section IV - Boiler Piping for recommended location of the expansion tank and air eliminators.

Closed -Type Tank:

- Ensure tank is partially filled with water leaving an air gap as a cushion. Refer to the manufacturer’s instruction for proper fill level.

- Ensure the tank is fitted with a device that reduces gravity circulation of air-saturated tank water back into the system. This device prevents air from bubbling up through the water as it returns from the system.

- Ensure no automatic air vents are used in the system. This will allow air to escape from the system instead of returning to the tank.

Diaphragm Tank:

- Ensure the system contains a minimum of one automatic air vent. Recommended location of the air vent should be atop an air eliminator.

WARNING

Before manually operating the relief valve(s), ensure the discharge piping is directed to a suitable place of disposal to avoid a potential scald hazard. The discharge piping must be full size without restriction and installed to permit complete drainage of both the valve and line.

If after closing the valve, the valve fails to seat properly or continually weeps, replace the relief valve. Ensure the cause of the relief valve to weep is the valve itself, not due to system over-pressurization caused by an expansion tank that is waterlogged or undersized.

Inspection of Ignition Electrode

Remove the ignition electrode using a 3 mm or T-15 hex key inserted through the two top panel holes located above the igniter. If necessary separate the top panel from the right side by inserting a straight screw driver in two slots on right side of top panel and bending metal tab in slots away from the side. Lift top panel .

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

When replacing the ignition electrode, ensure the gasket is in good condition and correctly positioned replace gasket if necessary.

Check igniter to Fig. 26, page 65.

Check Ignition Wiring and Ground Wiring

- Remove the tank from the system and check the charge pressure. For residential applications the charge pressure is typically 12 psig [0.8 bar]. If tank does not hold a charge pressure, then the membrane is damaged and the tank should be replaced.

Check Relief Valve(s)

Inspect the relief valve(s) and lift the lever to verify flow at least annually or as recommended on the warning tag of the valve.

Inspect the ignition wiring from the burner control module to the ground at heat exchanger.

Ensure wiring is in good condition and securely connected.

Check ground continuity of the wiring to the appliance heat exchanger or piping using a continuity meter.

Replace and correct ground wire if ground continuity is not completed and satisfactory.

Page 71

Maintenance Procedures

0.12” [ 3 mm]

0.12” [3 mm]

0.43” [11 mm]

Spark gap app. 0.18”

1.06” -1.12” [27 mm - 29 mm]

[5 mm]

1.75” [44 mm]

1.18” [30 mm]

(

)

Fig. 26: Igniter Dimensions

Page 72

Maintenance Procedures

Check Control Wiring

Inspect all control wiring. Ensure wiring is in good condition and properly connected.

Check Control Settings

1. Check the control CH/DHW/parameter settings by pressing the thermometer button “ ” on control display. When the LED is

lit for “ ” this is the CH setting. When the LED is lit for “ ” this is the DHW setting. Adjust settings with “ ” or “ ” buttons as necessary.

2. Press the reset button to close the setting menu and store the changes.

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

Perform Start-up and Checkout Procedures

electrical connector to the gas valve inside the appliance.

Disconnect the wiring harness connectors from the blower.

Remove the mounting bolts and washers securing the front of the heat exchanger and set bolts and washers aside.

Carefully remove the front plate of the heat exchanger. Ensure combustion chamber insulation is not damaged during removal. See WARNING on page 68.

Remove the burner head mounting screws and remove the burner head. Inspect the burner head for deterioration. Use compressed air or a vacuum to clean the burner head. Replace burner head if necessary. Replace burner head gasket.

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

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

Verify the cold water fill pressure is correct and the operating pressure of the boiler is within normal operating range.

Complete the checkout procedures as referenced in this manual.

Check Burner Flame

Inspect the burner flame through the observation port on left side off the heat exchanger.

Verify flame pattern is blue and covers the entire burner surface during high fire. Ensure combustion at both high and lowfire meet the requirements listed in Table 5, page 44. If combustion is OK and flame pattern is not fully blue & covers the entire burner surface during highfire, shut the appliance down and allow it to cool thoroughly before disassembly.

Close the external manual gas valve on the gas supply line and disconnect the gas piping and

Remove the blower.

Use a vacuum cleaner or compressed air to clean the interior of the blower and venturi assembly. Inspect the blower blades to ensure they are clean and not damaged.

Re-assemble the blower and venturi onto front plate of the heat exchanger . Ensure all gaskets are in good condition, and positioned correctly. Replace gaskets if necessary.

Re-assemble the front plate of the heat exchanger with bolts and washers onto the heat exchanger. Ensure the gasket and combustion chamber insulation is in place and not damaged, replace gasket and insulation if necessary. See WARNING on page 68. Ensure all screws and bolts are tight.

Reconnect the wiring harness connectors to the blower.

Re-assemble the gas supply connections and electrical connector to gas valve inside the appliance. Open the external manual gas valve. Check gas piping for any leaks as outlined on

Page 73

Maintenance Procedures

page 42 and repair if necessary. Place the appliance back into service.

Check Combustion Levels

Refer to page 44 of this manual for measuring combustion levels and burner adjustments.

Clean Boiler Heat Exchanger

1. Shut down the appliance:

- Follow the instructions on Page 45 "To Turn Off Gas to Appliance"

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

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

2. Allow the appliance to cool down to room temperature before servicing.

3. Disconnect the gas piping and electrical connector to the gas valve.

4. Disconnect the wiring harness connectors from the blower.

5. Remove the mounting bolts and washers securing the front of the heat exchanger and set aside.

6. Carefully remove the front plate of the heat exchanger. Ensure combustion chamber insulation is not damaged during removal. See WARNING on page 68.

7. Use a vacuum cleaner, compressed air or water to remove any accumulation from the heat exchanger flue ways. Do not use any solvent.

8. Re-assemble the front plate of the heat exchanger onto the heat exchanger. Ensure the gasket and combustion chamber insulation is in place and not damaged, replace gasket and insulation if necessary. See WARNING on page 68.

9. Re-assemble the blower the wiring harness.

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

11. Close isolation valves at the appliance boiler piping to isolate the appliance from the heating system.

12. Attach a hose to the boiler drain valve and flush the boiler thoroughly with fresh water by using the purge valves to allow water to enter through the make-up water line to the boiler.

13. Once the boiler has been completely flushed, return the boiler and system piping back to operation.

14. Perform the required startup and checkout procedures as outlined on pages 40 to 58.

Clean Domestic Heat Exchanger

1. Shut down the appliance:

- Follow the instruction on Page 45 “To

Turn Off Gas to Appliance”

2. Shut off all electrical power feed to the appliance.

3. Allow the appliance to cool down to room temperature before servicing.

4. Close the field installed isolation (shut off) valves on both the domestic cold and hot water lines to the appliance as shown in figure 11 & 12 on pages 26 & 27.

5. Submerge one end of hose halfway into cleaning fluid in a clean bucket with 4 gallons of new undiluted, food grade, white vinegar.

6. Attach other end of hose to a potable (bronze or stainless steel) circulating pump with a 2.5 gallon per minute [9.5 liters per minute] flow rate with 32 feet [9.7 meters] of head equivalent to Grundfos UP 2699BF or Taco 009-SF5, use another hose to connect from the pump to the field installed domestic hot water outlet drain/flush valve.

7. Attach separate hose to the field installed domestic cold water inlet drain/flush valve.

8. Submerge the other end of this hose halfway in fluid in the same bucket.

9. Open both drain/flush valves on the domestic cold and hot water lines.

Page 74

Maintenance Procedures

WARNING

To avoid risk of electrocution ensure all power is off to the appliance before servicing. Use G.F.C.I. protected power supply to pump. Additionally before powering up the circulating pump ensure all hose connections and fittings are leak free and no water is on the floor.

15. Rinse the domestic heat exchanger for 5 minutes by opening both the domestic hot water outlet drain/flush valve and the isolation (shut) off valve on the domestic cold water inlet.

16. Close drain/flush valve on the domestic hot water outlet.

17. Remove hose from the drain/flush valve on the domestic hot water outlet.

10. Carefully power up the pump allowing the vinegar to circulate through the domestic heat exchanger for 1 hour.

11. Turn pump off and carefully remove all power to the pump.

12. Close both drain/flush valves on the domestic cold and hot water lines.

13. Remove hose from bucket and pump connected to the drain/flush valve on the domestic hot water outlet.

14. Relocate the remaining hose still connected to the domestic cold water inlet drain/flush valve to the domestic hot water outlet drain/flush valve and the other end of this hose from the bucket to a suitable drain.

Handling Previously Fired Combustion Chamber Insulation

WARNING

The combustion chamber insulation contains ceramic fibers, which are classified as a possible human carcinogen. When exposed to extremely high temperatures, the ceramic fibers, which contain crystalline silica, can be converted into cristobalite.

Avoid Breathing and Contact with Skin and Eyes

18. Open the field installed isolation (shut off) valve on the domestic hot water outlet.

19. Turn on all electric to the appliance.

20. Perform the required startup and checkout procedures as outlined on pages 40 to 58.

Review With Owner

Ensure the owner understands the importance to perform the maintenance schedule specified in this manual.

Remind the owner of the importance to call a licensed contractor should the appliance or system exhibit any unusual behavior.

1-800-356-4676 or on the web at www.cdc.gov/niosh for latest recommendations.

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 clothes separately from other laundry and rinse washing machine thoroughly.

When removing or repairing the combustion chamber insulation follow these precaution measures:

1. Use a NIOSH approved respirator which meets OSHA requirements for cristobalite dust, similar to N95. Contact NIOSH at

6. Discard used insulation in an air tight plastic bag.

NIOSH Stated First Aid:

Eye/Skin: Immediately irrigate Breathing: Clean fresh air

Page 75

Replacement Parts

Pressure relief and air vent assembly

Low voltage/terminal strip X4

DHW sensor S3

Blower

DHW flow switch

Ignition electrode

High voltage terminal strip

Condensate drain trap assembly

Condensate pan

Control/Display

CH Return sensor S2

CH supply sensor S1

Fig. 27: CHALLENGER Internal Components

WARNING

Replacement parts must be purchased through a local Triangle Tube distributor. When ordering part please provide

the model number and description and/or part number of replacement part.

Use only genuine Triangle Tube replacement parts to ensure warranty coverage and to avoid damage to appliance and improper operation of appliance. Contact Triangle Tube at 856-228-8881 or www.triangletube.com for list of distributors nearest you.

Page 76

Replacement Parts

Fig. 28 : CHALLENGER Front Door

Part Number

Item

CC85

1 CCRKIT04 Wall Bracket Assembly (Not Shown)

2 CCRKIT05

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

2B CCFTG02 Connector Pipe DHW (Not Shown) - 1/Kit

3 CCRKIT06 CCRKIT07 CCRKIT08 Front Door Assembly

Part Number

CC105

Part Number

CC125

Description

Pipe Connectors & Brackets Assembly (Not Shown)

Page 77

Replacement Parts

Fig. 29: CHALLENGER Vent Components

Part Number

Item

CC85

2 CCRKIT10 CCRKIT11 CCRKIT12 Vent Assembly

3 CCRKIT13 Condensate Collector Assembly

4 CCRKIT14 Condensate Drain Trap Assembly

Part Number

CC105

CCRKIT09

CCRKIT35

Part Number

CC125

Description

80/125 Concentric Vent /Air Adapter Assembly (optional - shown)

3” Vent/Air Adaptor Assembly ( standard not shown)

Page 78

Replacement Parts

Fig. 30 : CHALLENGER Internal Components

Part Number

CC105

Part Number

CC125

Description

Item

Part Number

CC85

1 CCRKIT15 Igniter Assembly

2 CCCLB01 Ignition Cable

3 CCRKIT16 Sight Glass Assembly

4 CCRKIT17 CH Sensor Assembly - 1/Kit

5 CCSENS02 DHW Sensor

6 CCRKIT18 DHW Flow Switch Assembly

7 CCRKIT19 LWCO/CH Pressure Sensor Assembly

8 CCRKIT20 CCRKIT21 CCRKIT22 CH Supply pipe Assembly

9 CCRKIT23 CH Return Pipe Assembly

10 CCRKIT26 DHW Supply Pipe Assembly

11 CCRKIT27 DHW Return Pipe Assembly

Page 79

Replacement Parts

Fig. 31 : CHALLENGER Blower & Gas Valve Components

Item

Part Number

CC85

Part Number

1 CCRKIT28 Ignition Transformer Assembly

2 CCRKIT29 Gas Valve Assembly

3 CCRKIT30 CCRKIT31 Gas Pipe Assembly

4 CCRKIT32 Blower Assembly

CC105

Part Number

CC125

Description

Page 80

Replacement Parts

Fig. 32 : CHALLENGER Burner Components

Item

Part Number

CC85

1 CCRKIT33 Burner Assembly

Part Number

CC105

Part Number

CC125

Description

Page 81

Replacement Parts

Fig. 33 : CHALLENGER Control Components

Part Number

Item

CC85

1 CCCON01 Control/Display

2 CCCS01 Housing Plastic Control

3 CCRKIT34 Flip Panel

4 CCFUSE01 Fuse - 1/Kit

Part Number

CC105

Part Number

CC125

Description

Page 82

Specifications

1.97”

[5 cm]

[6.5 cm]

[8 cm]

2.56”

3.15”

9.45” [24 cm]

6.10” [15.5 cm]

33.07” [84 cm]

30.71” [78 cm]

CH Supply

DHW Cold DHW Hot

Vent/Air

CH Return

28.35” [72 cm]

Flexible

1” NPT

1/2” NPT

80/125 Concentric Adapter

Challenger CC 85

Condensate Drain

Challenger CC 105

Challenger CC 125

3/4” NPT

13.58”

[

34.5 cm]

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

4.63”

[11.8 cm] (3” Air)

7.72”

[

45 cm]

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

Front View& Side CHALLENGER

Page 83

Specifications - Water Heater

Fuel

Modulation

Input

BTUH [KW]

23,000 [6.7]

84,000 [24.6]

Shipping

Weight

Lbs [Kg]

66 [30]

Natural

Propane

Natural

Propane

Natural

Propane

Model

CC 85

CC 105

CC 125

110,000

29,000 [8.5]

106,000 [31]

73 [33]

33,000 [9.7]

124,000 [36.3]

80 [36]

Water

Heater

Energy

Factor

Continuous

Domestic

Flow

77ºF Rise

2.3 gpm

[8.7 lpm]

1.8 gpm

[6.8 lpm]

2.7 gpm

[10.41 lpm]

.86

.87

.85

NOTICE

The following efficiency performance is achieved when the CHALLENGER is operated as a Water Heater according to DOE 10CFR, Part 430, subpart B, Appendix E, test procedure.

Page 84

Specifications - Water Heater

Challenger Domestic Performance

NOTICE

If actual flow rate exceeds the value listed in Graph 2 the domestic outlet temperature will be reduced.

Graph 2 : Domestic Flow Rate at 120ºF Domestic Outlet and Varying Domestic Inlet Temperature

Page 85

Specifications - Water Heater

Domestic Pressure Drop

Graph 3 : Pressure Loss Through Domestic

CCSTRA01 Optional Strainer

Pressure Drop Curve

Graph 4 : Pressure Loss Through Optional Domestic Strainer

Page 86

Specifications - Boiler

CC85 Primary Loop Pumps - Grundfos

Graph 5 : Pressure Loss Through Boiler - Grundfos Circulators

CC85 Primary Loop Pumps - Taco

Graph 6 : Pressure Loss Through Boiler - Taco Circulators

NOTICE

Minimum allowable boiler flow rate at full input: 4 gpm [15 lpm] CHALLENGER CC85

Pump curves and system curves do NOT

include any allowance for near boiler piping.

Page 87

Specifications - Boiler

CC105 Primary Loop Circulators - Grundfos

Graph 7 : Pressure Loss Through Boiler - Grundfos Circulators

CC105 Primary Loop Circulators - Taco

Graph 8 : Pressure Loss Through Boiler - Taco Circulators

NOTICE

Minimum allowable boiler flow rate at full input: 5 gpm [19 lpm] CHALLENGER CC105

Pump curves and system curves do NOT

include any allowance for near boiler piping.

Page 88

Specifications - Boiler

CC125 Primary Loop Circulators - Grundfos

Graph 9 : Pressure Loss Through Boiler - Grundfos Circulators

CC125 Primary Loop Circulators - Taco

Graph 10 : Pressure Loss Through Boiler - Taco Circulators

NOTICE

Minimum allowable boiler flow rate at full input: 6 gpm [23 lpm] CHALLENGER CC125

Pump curves and system curves do NOT

include any allowance for near boiler piping.

Page 89

Specifications - Boiler

uel

DOE

Heating Capacity

BTUH [KW]

Note 1 & 4

Modulation

Input

BTUH [KW]

Note 4

DOE Seasonal

Efficiency AFUE

Note 3

Net Boiler

IBR Rating

BTUH [KW]

Note 2

3,000 [6.7]

84,000 [24.6]

95%

Shipping

Weight

Lbs [Kg]

6 [30]

atural

Propane

Natural

Propane

Natural

Propane

Model

CC 85

CC 105

CC 125

5,000

[19.3]

110,000

94,000

[27.8]

75,000

[22.3]

29,000 [8.5]

106,000 [31]

95%

73 [33]

82,000

[24.3]

96,000

[28.4]

110,000

[32.8]

33,000 [9.7]

124,000 [36.3]

95%

80 [36]

NOTICE

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

Note 1: The heating capacity of the CHALLENGER

CC 85/105/125 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 CC 85/105/125 meets the energy efficiency guidelines established by Energy Star.

Note 4: Input and output ratings are shown for sea

level applications. The CHALLENGER automatically derates the input at approximately 2% for every 1,000 Ft. of altitude. No alterations to the appliance or burner system are required.

Page 90

Notes

Page 91

Notes

Page 92

Additional quality water heating equipment available

from Triangle Tube

Maxi-Flo and Spa Heat Exchangers

SMART Indirect Fired Water Heaters

- 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

TTP Brazed Plate Heat Exchangers

- 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

- 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

1 Triangle Lane - Blackwood, NJ 08012 Tel: (856) 228 8881 - Fax: (856) 228 3584 http://www.triangletube.com E-mail: info@triangletube.com

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TriangleTube Challenger Installation And Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual