Combination Boiler and/ or Water Heater * I N S TALLAT I O N AN D MAI N T E NAN C E * M A N U A L NOTICE Warranty Registration Card must be filled out by the customer and mailed within thirty (30) days of installation in order to gain warranty coverage. When receiving the CHALLENGER, any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee. Leave all documentation received with appliance with owner for future reference.
Table of Contents PRODUCT AND SAFETY INFORMATION Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Product and Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 SECTION I - PRE-INSTALLATION ITEMS Code Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Determining Product Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents Circulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Sizing Primary Piping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 System Piping - Zone Circulators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 System Piping - Zone Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Near Boiler Piping Diagrams . . . . . . . . . . . . . . . . . . .
Table of Contents SECTION VIII - INTERNAL WIRING General Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 CHALLENGER Factory Wiring Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . 34 SECTION IX - EXTERNAL WIRING Installation Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Line Voltage Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents Operation Verification - Space Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46-47 Set DHW Set Point Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Operation Verification - Domestic Hot Water . . . . . . . . . . . . . . . . . . . . . . . 47-48 Control Display Appliance ON/OFF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents SECTION XVI - MAINTENANCE PROCEDURES Annual Maintenance Procedures Reported Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Check Surrounding Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Inspect Burner Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Check System Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Clean Condensate Drain Assembly . . . . . .
Product & Safety Information Definitions The following terms are used throughout this manual to bring attention to the presence of potential hazards or important information concerning the product. DANGER NOTICE Indicates the presence of a hazardous situation which, if ignored, will result in death, serious injury or substantial property damage. Indicates special instructions on installation, operation or maintenance, which are important to equipment but not related to personal injury hazards.
Product & Safety Information DANGER WARNING Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system which has been under water. 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.
Product & Safety Information DANGER DANGER Protection must be taken against excessive pressure! Bacteria can develop in the domestic water system if certain minimum water temperatures are not maintained. TO PROTECT AGAINST EXCESSIVE TEMPERATURE AND PRESSURE 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.
Pre-Installation Items SECTION I - Pre-Installation Items - Code Compliance NOTICE The CHALLENGER is certified to both the Boiler (ANSI Z21.13/CSA 4.9) and Water Heater (ANSI Z21.10.3/CSA4.3) standards. The CHALLENGER gas manifold and gas controls meet the safe lighting and other performance requirements as specified in ANSI Z21.13 standard.
Pre-Installation Items Boiler or Water Heater Replacement NOTICE If the CHALLENGER is replacing an existing boiler and/or hot water heater system, the following items should be checked and corrected prior to installation: - - - - When maintaining the approved clearance or less than recommended service clearances, some product labeling may become hidden and unreadable. Boiler and domestic piping leaks and corrosion.
Pre-Installation Items Boiler Freeze Protection Feature 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. 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.
Combustion Air and Venting SECTION II- Combustion Air and Venting Potential contaminating products Combustion Air Contamination - Spray cans containing chloro/fluorocarbons - Chlorinated wax - WARNING If the CHALLENGER combustion air inlet is located in any area likely to cause or contain contamination, or if products, which could contaminate the air cannot be removed, the combustion air must be repiped and terminated to another location.
Combustion Air and Venting Ventilation Air Requirements Combustion Air and Vent Piping The CHALLENGER requires a Category IV venting system, which is designed for pressurized venting and condensate. For installations, involving only the CHALLENGER, in which the minimum service clearances are maintained as listed on page 5, no ventilation openings are required. The CHALLENGER is certified as Direct Vent (sealed combustion) appliance.
Combustion Air and Venting Removal of an Existing Boiler and or Water Heater from a Common Vent System 5. Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle, or smoke from a cigarette, cigar or pipe. BEST PRACTICE 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.
Combustion Air and Venting Commonwealth of Massachusetts Installations Only For direct-vent appliances, mechanicalvent heating appliances or domestic hot water equipment, where the bottom of the vent terminal and the air intake is installed below four feet above grade the following requirements must be satisfied: 4. A metal or plastic identification plate shall be mounted at the exterior of the building, four feet directly above the location of vent terminal.
Appliance Preparations SECTION III - Appliance Preparations Wall Mounting Installation Shipping and Handling Instructions NOTICE Prior to mounting appliance install piping support bracket according to instructions on page 13. WARNING To avoid damage to gas fitting and piping at bottom of appliance, appliance must be shipped with rear or back of appliance (longest box length) laying down flat.
Appliance Preparations Wall Mounting Guidelines stud centers and ensuring the upper edge of the bracket is away from the wall. 1. The wall-mounting bracket is designed for stud spacing of 12 inch [30.5 cm] or 16 inch [40.6 cm] on centers. For unconventional stud spacing, a solid / secure mounting surface must be provided for installation of the bracket. 3. Level the bracket, while maintaining it’s centering with the studs and use a pencil to mark the location of the mounting slots/holes. 4.
Appliance Preparations BEST PRACTICE Wall Anchors (Solid Wall Only) Apply pipe joint compound suitable for potable water systems to the compression ferrule and compression nut threads of all brass fittings before installation. Install appliance pipes into the fittings until bottom of hex on gas pipe fitting rests against the top of the piping support bracket before tightening any compression nuts. Do not over tighten compression nuts. If fitting leaks loosen compression nut first and then retighten.
Boiler Piping SECTION IV - Boiler Piping 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 Should not contain any shut-off valves or obstructions.
Boiler Piping Pressure Relief Valve (Supplied with Boiler) 3/4" Street Elbow Manual Air Vent (Supplied with Boiler) Drain Piping Directed to a Suitable Place of Drainage Boiler Supply Connection with Tee Fitting and Temperature/ Pressure Gauge Boiler Return Connection with Tee Fitting and Boiler Drain Valve Fig.
Boiler Piping Additional Limit Control Boiler System Piping Applications If a Low Water Cut Off (LWCO) is required by certain local jurisdictions or when the boiler is installed above the system piping, the following guidelines must be followed: - - 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 79-81.
Boiler Piping Closed-Type Expansion Tank System Piping - Zone Circulators It is recommended to pitch any horizontal piping upwards toward the expansion tank 1 inch per 5 feet [2.5cm / 1.5 M] of piping. Use 3/4” piping to the expansion tank to allow air within the system to rise. Connect the CHALLENGER to the system piping as shown in Fig. 7 page 20 when zoning with zone circulators. The installer must provide a separate circulator for each zone of space heating.
Boiler Piping System Return System Supply 2 12" Max. [30.5 cm] 6 1 3 Cold Water Fill 6 4 6 7 10 11 5 Boiler Supply Fig. 5: Near Boiler Piping - Diaphragm Expansion Tank Boiler Return 9 System Supply 8 4 6 Minimum 3/4" Piping 1 Cold Water Fill 6 System Return 12" Max. [30.5 cm] 6 10 3 11 Boiler Supply Boiler Return Fig. 6 : Near Boiler Piping - Closed Type Expansion Tank 1. 2. 3. 4. 5. 6.
Boiler Piping System Piping - Radiant Heating NOTICE The boiler system piping must be a “closed” system to avoid any oxygen contamination and potential failure of the outer tank of the SMART. 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 CHALLENGER’s domestic piping should not be utilized.
Boiler Piping Fig. 7: Central Heating (CH) System Piping - Zoning with Zone Circulators 4 4 3 3 5 4 Additional Zone Load 3 5 3 4 Zone Load 9 12" Max. [30.5 cm] 4 4 6 7 8 4 4 11 1 10 2 12 Optional SMART I.F.W.H. 6 4 1. 2. 3. 4 5. 6. CHALLENGER boiler Boiler circulator with flow check Flow/check valve Isolation valve Zone circulator Drain/purge valve Fig. 8: CH System Piping - Zoning with Zone Valves 6 7. Pressure relief valve 8. Air separator 9. Automatic air vent 10.
Domestic Piping SECTION V - Domestic Piping WARNING HOT WATER CAN SCALD! • • • • • Water temperatures over 125ºF [52ºC] can cause severe burns instantly, or death from scalds. Feel water before bathing or showering. Consumer Product Safety Commission and some states recommend temperatures settings of 130ºF [54ºC] or less. Setting thermostat higher than 130ºF [54ºC] will increase risk of scald injury and cause severe personal injury or death.
Domestic Piping • • Maximum domestic working pressure is 150 psig [10 bar]. 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. Water quality limitations (based on E.P.
Domestic Piping Temperature & Pressure (T&P) Relief ValveStorage Tank or SMART Installations - plugged, reduced or restricted - subject to freezing CAUTION • • WARNING To reduce risk of excessive pressures and temperatures in a storage tank or ACVTriangle Tube SMART I.F.W.H.
Domestic Piping The domestic water volume of the CHALLENGER is approximately 0.26 gallons [ 1 l]. Remember to include this volume when sizing the expansion tank. • Water Hammer 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.
Domestic Piping Storage Tank Installations For applications requiring high domestic hot water flow rates for a short period of time (dump load), the installer may install a storage type tank (see Fig. 12 page 27) in the domestic piping. The installer must: BEST PRACTICE Additional thermostatic/anti-scald valves should be installed at each hot water faucet, bath and shower outlet. For applications with a domestic recirculation loop, the recirculation pump should be controlled by an aquastat.
Domestic Piping 1/2” compression x 3/4” NPT Adapter Fittings for DHW Fig. 10 : Installation of Domestic Compression Adapter Assemblies 1 5 8 6 2 9 M H 7 c 10 DHW Cold Recirculating Loop (optional) 2 To Dish Washer or High Temperature Application 6 Fig. 11 : Domestic Piping - Standard Installations 1. 2. 3. 4. 5. 6. CHALLENGER Isolation valve Backflow preventer or pressure reducing valve (*) Thermal expansion tank (potable) (*) Domestic pressure relief valve - 150 psi max.
Domestic Piping 1 Recirculating Loop (optional) 8 6 For service only see warning on page 23 9 2 10 6 2 M C H Remove any check valve 7 5 11 3 2 DHW Cold Water Inlet 4 Storage Tank 6 Note: 2 12 9 Domestic cold water inlet through a storage tank will yield a lower domestic pressure drop in addition to greater domestic performance. Domestic set point temperature should be set to 149ºF [65ºC] see page 52. DHW function button ( ) should be set to ON ( ) at the display panel, see page 49.
Installation Vent/Combustion Air & Condensate Drain SECTION VI - Installing Vent / Combustion Air & Condensate Drain 2. Remove front door and install trap. Ensure the trap is completely seated and secure on the appliance. Installing Vent and Combustion Air 3. Connect 13/16” ID tubing to the drain barbed fitting of the trap assembly.
Installation Vent/Combustion Air & Condensate Drain * * Carefully cut top of condensate drain trap assembly with hack saw or knife at location shown. Condensate Drain Trap Assembly Fig.
Gas Piping SECTION VII - Gas Piping - Gas Supply Piping Connection NOTICE 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. The gas supply piping must be installed in accordance to all applicable local, state and national codes and utility requirements. 7. Use pipe joint compound compatible with natural and propane gases.
Gas Piping NATURAL GAS 2. Install 100% lockup gas pressure regulator in the gas supply line if inlet pressure can exceed 13”w.c. [32 mbar] at any time. Adjust the lockup pressure regulator for 13”w.c. [32 mbar] maximum. Pipe Sizing - Natural Gas Refer to Table 1 for schedule 40 metallic pipe length and diameter requirements for natural gas, based on rated CHALLENGER input (divide by 1,000 to obtain cubic feet per hour). - - WARNING DO NOT adjust or attempt to measure gas valve outlet pressure.
Gas Piping PROPANE GAS WARNING Pipe Sizing - Propane Gas 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.
Internal Wiring SECTION VIII - Internal Wiring General Requirements WARNING - Wiring must be N.E.C Class 1. - 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. - 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.
Internal Wiring Note - Ladder 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. Schematic Diagram Fig.
External Wiring SECTION IX- External Wiring WARNING Installation Compliance The ON/OFF switch of the CHALLENGER only disables the function of the appliance. Electrical power remains at the control module. To avoid a shock hazard, disconnect power at the external service switch when servicing the appliance. All field wiring made during installation must comply with: - - National Electrical Code NFPA 70 and any other national, state, provincial or local codes or requirements.
External Wiring Low Voltage Connections Thermostat Wiring NOTICE 1. Open the display cover and unscrew both screws to remove the front cover Isolate 120V wiring from low voltage wiring to prevent any potential electrical “noise”. 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. 1.
External Wiring CH Circulator 3. Maximum DHW circulator continuous current draw is 2.3 A. 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. System Circulator - Zone Valve Application To energize the system circulator shown as item 12 in Fig. 8 page 20 reference Fig. 18.
External Wiring 4 Wire Zone Valve Transformer (Power) Zone 1 Zone 2 Additional zones H 120 N V.A.C. High Voltage Room Thermostat 24 V.A.C. Zone Valve Room Thermostat Zone Valve Additional zones may be added as shown above 8 7 To Challenger Low Voltage Terminal Strip 3 Wire Zone Valve Transformer (Power) Zone 1 Zone 2 H 120 N V.A.C. High Voltage Room Thermostat 24 V.A.C. Zone Valve NOTICE: Room Thermostat *Use isolation relay on 3-wire zone valve with non-isolated end switch.
External Wiring Fig. 20: Field Wiring with Zone Circulators 120 VAC H N Honeywell R845A Relay T T T T 2 1 Circulator Zone 1 T T 2 1 Thermostat zone 1 4 3 5 6 Thermostat zone 2 4 3 5 6 Circulator Zone 2 Additional zones may be added as shown above 7 Fig.
Start-Up Preparation SECTION X - Start-Up Preparation Flush Boiler and Domestic System to Remove Sediment Check Boiler System Water Chemistry The installer must flush the boiler system to remove any sediment to allow proper operation of the CHALLENGER . WARNING 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.
Start-Up Preparation Use of Antifreeze in the Boiler System Filling the Boiler System 1. Close the boiler drain valve located on the bottom of the appliance and any manual or automatic air vent in the system. WARNING NEVER use automotive or ethylene glycol antifreeze or undiluted antifreeze in the boiler system as freeze protection. This can cause severe personal injury, death or substantial property damage if ignored. 2. Open all system isolation valves. 3.
Start-Up Preparation Check For Gas Leaks NOTICE 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. 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.
Start-Up Procedures SECTION XI - Start-Up Procedures manual starting on page 52 for more information. Final Checks Before Start-Up c c c c c c 2. Check for loose electrical connections, blown fuse (external or internal at the appliance control) or open service switch. Read page 46 through 57 regarding the operation of the CHALLENGER control.
Start-Up Procedures c ACV-Triangle Tube Technical Support. Failure to comply with this requirement could result in severe personal injury, death or substantial property damage. Check Gas Piping Check around the appliance for gas odor following the procedure outlined in this manual on Page 42. Table 5: Recommended Combustion Levels WARNING c Natural Gas If any gas leaks are found or suspected, shut the appliance down immediately.
Start-Up Procedures WARNING FOR YOUR SAFETY READ BEFORE LIGHTING If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A. This appliance does not have a pilot. It is • If you cannot reach your gas supplier, call the fire department. equipped with an ignition device which automatically lights the burner. DO NOT try to light the burner by hand. C. Use only your hand to turn the external manual gas valve. Never use tools.
Start-Up Procedures Appliance ON/OFF 2. Turn off power to the appliance, wait a few seconds and turn on power to the appliance. 1. The appliance operation is started using the ON/OFF button. 3. The following operating displays should occur: 2. When appliance is in operation, the green LED above the ON/OFF will be lit. [A] Self check on power up [ ] No call for heat 3. When the appliance is not in operation, the green LED above the ON/OFF will not be lit.
Start-Up Procedures [1] The setpoint temperature has been reached. Combustion will cease and the post purge cycle of the blower begins. The control module will de-energize the gas valve and the blower will continue with the 10 second post purge cycle, before shutting down. The CH circulator will continue to run until the room thermostat is satisfied. 3. Press the reset button to close the setting menu and store the changes.
Start-Up Procedures - - If the burner flame is not established the control module will repeat the ignition sequence after approximately 15 seconds . If the flame is not established after four attempts the control will lockout and the main display will show [4]and the fault LED above the reset button will flash and [E] will flash in the operating display. [4] This is the normal DHW operation cycle. The control module will begin to modulate the burner firing rate based on actual DHW set point temperature.
Start-Up Procedures Control Display Operation Read-Out 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 Appliance ON/OFF 1.
Start-Up Procedures TO TEMPORARILY PLACE THE BURNER INTO LOW FIRE TEST MODE: press ” and “ ” button simuland hold both the “ taneously until operating display shows “L”. Test Mode Function TO TEMPORARILY PLACE THE BURNER INTO HIGH FIRE TEST MODE: press ” and “+” button simuland hold both the “ taneously once until operating display shows “h” for CH high fire or twice until the operating display shows “H” for DHW high fire.
Start-Up Procedures Function Main Display Operating Display Press button to turn appliance ON LED lite above button will be lit when appliance is ON No demand for heat OFF XXP The The XXP A Control self-test XXX 1 Fan pre purge or post purge cycle XXX 2 Ignition sequence XXX 3 Burner ON for space heating (CH) XXX 4 Burner ON for domestic hot water (DHW) XXX 6 Burner OFF due to reaching temperature setpoint 7 Space Heating (CH) post pump cycle 8 Burner ON for DHW pre-heating 9 Bur
Start-Up Procedures Setting the Appliance Parameters 5. After all parameters have been changed, press the reset button to close the setting menu and store the changes. The main display will go blank and a P will be displayed in the operating display to let you know the control was programmed. 1. Press the “ ” button at the display panel for approximately 2 to 3 seconds until main display begins to flash. 2. Press the “ ” button repeatedly to scroll through the list of parameters.
Start-Up Procedures Fluctuating Water Temperature CAUTION Domestic water temperatures can fluctuate with factory control settings when the domestic hot water flow is less than 0.7 gpm. The fluctuation is due to the interaction between the domestic water flow switch minimum setting and the domestic hot water mixing valve.
Start-Up Procedures Error (Hard Lockout) Codes* Main Display Operating Display (Flashing) Possible Solution Error Description 10, 11, 12, 13, 14 E - CH supply sensor fault S1 20, 21, 22, 23, 24 E - CH return sensor fault S2 0 E - Sensor fault after self check 1, 28 E - Temperature too high 2 E - CH supply sensor S1 and CH return sensor S2 interchanged 4 E - No flame signal 5 E - Poor flame signal 6 E - Flame detection fault 8 E - Incorrect fan speed 29,30 E - Gas valve rel
Outdoor Reset Control SECTION XII - Outdoor Reset Control 4. Mount the sensor enclosure at an elevation on the exterior wall to prevent accidental damage or tampering. An outdoor reset function is included in the CHALLENGER control. The use of the outdoor reset function is required to optimize boiler efficiency, see notice on page 56. If the outdoor sensor is not installed before turning on the boiler, an Outdoor Sensor Open ODS will be displayed.
Outdoor Reset Control Operating Temperature Setpoint becomes the appliance setpoint on the CH Reset Curve Coldest Day. NOTICE In accordance with Section 325 (f) (3) of the Energy Policy and Conservation Act, this boiler is equipped with a feature that saves energy by reducing the boiler water temperature as the heating load decreases. This feature is equipped with an override which is provided primarily to permit the use of an external energy management system that serves the same function.
Outdoor Reset Control Changing Outdoor Reset Parameters 4. Press the button to close the setting menu and store the changes. 1. Press the “ ” button at the display panel for approximately 2 to 3 seconds until main display begins to flash. The appliance control module has now been reprogrammed with the desired parameter values. 2. Press the “ ” button repeatedly to scroll through the list of parameters.
Check-Out Procedures SECTION XIII- Check-Out Procedures c 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. c c Check-Out Procedures c c c c c c c c c c c 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.
Installation Record SECTION XIV - Installation Record CHALLENGER Model Number: Serial Number: Date of Installation: Fuel: Natural Gas Propane Measured Rate of Input: Btu/hr Combustion Readings: CO2 % O2 % CO ppm The following items were completed during installation: Installation instructions have been followed and completed Check-out procedures have been followed and completed Information regarding the unit and installation received and left with owner / maintenance personnel.
Maintenance Schedule SECTION XV - Maintenance Schedule Owner Maintenance At least on an annual basis the following maintenance should be performed by a qualified service technician: - Check the area around the appliance. - Check the temperature and pressure gauges. Service Technician Periodic: - General - - - - - - - - - - Attend to any reported problems. Inspect the interior of the appliance jacket area; clean and vacuum if necessary.
Maintenance Procedures SECTION XVI - Maintenance Procedures Verify that combustion air inlet area is free of any contaminates. Refer to the materials listed on page 7 of this manual. If any of these products are in the area from which the appliance takes its combustion air, they must be removed immediately or the combustion air intake must be relocated to another area.
Maintenance Procedures Clean Condensate Drain Assembly Check Boiler System 2. Empty any water from the trap and drain assembly. Flush with fresh water as necessary to clean. Check the cold fill pressure for the system, typical cold water fill pressure is 12 psig [0.8 bar]. 1. Remove the condensate assembly from the appliance. Verify all system components are correctly installed and operating properly. 3. Check the drain piping from the condensate drain assembly to the drain.
Maintenance Procedures 1 3 Fig. 23: Loosening of Flue Pipe Retaining Ring 2 Fig. 24: Removal of Flue Pipe 3 2 1 Fig.
Maintenance Procedures WARNING WARNING Before manually operating the relief valve(s), ensure the discharge piping is directed to a suitable place of disposal to avoid a potential scald hazard. The discharge piping must be full size without restriction and installed to permit complete drainage of both the valve and line. When re-assembling the condensate pan and flue pipe ensure all gaskets are in place and correctly installed. Ensure all associated joints are complete, tight and secure.
Maintenance Procedures º) (45 0.43” [11 mm] 1.06” -1.12” [27 mm - 29 mm] 0.12” [3 mm] 1.18” [30 mm] 1.75” [44 mm] 0.12” [ 3 mm] Spark gap app. 0.18” [5 mm] Fig.
Maintenance Procedures Check Control Wiring Disconnect the wiring harness connectors from the blower. Inspect all control wiring. Ensure wiring is in good condition and properly connected. Remove the mounting bolts and washers securing the front of the heat exchanger and set bolts and washers aside. Check Control Settings 1. Check the control CH/DHW/parameter settings by pressing the thermometer button “ ” Carefully remove the front plate of the heat exchanger.
Maintenance Procedures Check Combustion Levels 12. Attach a hose to the boiler drain valve and flush the boiler thoroughly with fresh water by using the purge valves to allow water to enter through the make-up water line to the boiler. Refer to page 44 of this manual for measuring combustion levels and burner adjustments. Clean Boiler Heat Exchanger 13. Once the boiler has been completely flushed, return the boiler and system piping back to operation. 1.
Maintenance Procedures 7. Attach separate hose to the field installed domestic cold water inlet drain/flush valve. 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. 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. 15.
Replacement Parts S T U DHW sensor S3 Pressure relief and air vent assembly Condensate drain trap assembly Control/Display CH supply sensor S1 CH Return sensor S2 Blower Low voltage/terminal strip X4 DHW flow switch & Restrictor Condensate pan Ignition electrode High voltage terminal strip U Fig. 27: CHALLENGER Internal Components WARNING Replacement parts must be purchased through a local ACV-Triangle Tube distributor.
Replacement Parts 3 Fig.
Replacement Parts 1 2 2 6 5 3 3 2 3 4 3 Fig.
Replacement Parts Fig.
Replacement Parts 6 4 1 2 5 3 Fig.
Replacement Parts 1 Fig.
Replacement Parts 6 4 1 5 2 3 Fig.
Specifications 9.45” [24 cm] 6.10” [15.5 cm] 17.72” [45 cm] 4.63” [11.8 cm] (3” Air) Z F A CH Supply CH Return C [8 cm] 3.15” [6.5 cm] 2.56” [6.5 cm] 2.56” E [6.5 cm] 2.56” [5 cm] 1.97” [6.5 cm] 2.56” H 13.58” [34.5 cm] (80/125 Concentric Vent/Air or 3” Vent) D B 1” NPT 1” NPT 1/2” NPT DHW Cold 3/4” NPT DHW Hot 3/4” NPT Condensate Drain Flexible 33.07” [84 cm] Challenger CC 125 Challenger CC 105 30.71” [78 cm] 28.
Specifications - Water Heater NOTICE The following efficiency performance is achieved when the CHALLENGER is operated as a Water Heater according to DOE 10CFR, Part 430, subpart B, Appendix E, test procedure. Continuous Domestic Flow 77ºF Rise Water Heater Energy Factor Shipping Weight Lbs [Kg] Model Fuel Modulation Input BTUH [KW] CC 85 Natural or Propane 23,000 [6.7] to 84,000 [24.6] 1.8 gpm [6.8 lpm] 110,000 .87 66 [30] Natural or Propane 29,000 [8.5] to 106,000 [31] 2.3 gpm [8.7 lpm] .
78 Domestic Flow Rate (GPM) @ 120F Domestic Outlet Temperature 40 50 55 CC85 CC105 CC125 Domestic Inlet Temperature (F) 45 60 Graph 2 : Domestic Flow Rate at 120ºF Domestic Outlet and Varying Domestic Inlet Temperature 1.5 2.0 2.5 3.0 3.
Specifications - Boiler CC85 Primary Loop Pumps - Grundfos Graph 5 : Pressure Loss Through Boiler - Grundfos Circulators CC85 Primary Loop Pumps - Taco Graph 6 : Pressure Loss Through Boiler - Taco Circulators NOTICE Minimum allowable boiler flow rate at full input: 4 gpm [15 lpm] CHALLENGER CC85 Pump curves and system curves do NOT include any allowance for near boiler piping.
Specifications - Boiler CC105 Primary Loop Circulators - Grundfos Graph 7 : Pressure Loss Through Boiler - Grundfos Circulators CC105 Primary Loop Circulators - Taco Graph 8 : Pressure Loss Through Boiler - Taco Circulators NOTICE Minimum allowable boiler flow rate at full input: 5 gpm [19 lpm] CHALLENGER CC105 Pump curves and system curves do NOT include any allowance for near boiler piping.
Specifications - Boiler CC125 Primary Loop Circulators - Grundfos Graph 9 : Pressure Loss Through Boiler - Grundfos Circulators CC125 Primary Loop Circulators - Taco Graph 10 : Pressure Loss Through Boiler - Taco Circulators NOTICE Minimum allowable boiler flow rate at full input: 6 gpm [23 lpm] CHALLENGER CC125 Pump curves and system curves do NOT include any allowance for near boiler piping.
Specifications - Boiler NOTICE The following efficiency performance is achieved when the CHALLENGER is operated as a Boiler according to ASHRAE 103 test procedure Note 1: Note 2: Modulation Input BtTU/H (kW) Note 4 DOE Heating Net Boiler Capacity IBR Rating Btu/h (kW) BTUH (kW) Note1 & 4 Note 2 DOE Seasonal Efficiency AFUE Note 3 Shipping Weight Lbs (Kg) Model Fuel CC 85 Natural or Propane 23 000 (6,7) to 84 000 (24,6) 75 000 (22,3) 110,000 65 000 (19,3) 94% 66 (30) CC 105 Natural or Propan
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