Combination Boiler and/ or Water Heater User s Information Manual WARNING To maintain the safety & longevity of your appliance read and follow the maintenance schedule information throughout this manual. WARNING If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life. FOR YOUR SAFETY • Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.
Table of Contents PRODUCT & SAFETY INFORMATION Page 1-2 Service and Maintenance CHALLENGER Operation Appliance & System Water SECTION I - Combustion Air - Prevention of Contamination Page 3 Potential Contaminating Products Areas likely to find these Products SECTION II - Maintenance Schedule Page 4 Service Technician Owner Maintenance SECTION III - Maintenance Procedures Page 5 Periodic Maintenance Monthly Maintenance 6-Month Maintenance SECTION IV - Operations Instructions Page 8 SECTION V - App
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 PRODUCT & SAFETY INFORMATION NOTICE TECHNICIAN: When calling or writing about the CHALLENGER, please have the appliance model and serial number available. WARNING HOMEOWNER: The CHALLENGER installation manual is for use only by a qualified heating installer / service technician. Refer to this User’s Information Manual for your reference. Failure to comply could result in severe personal injury, death or substantial property damage.
Appliance & System Water • Have the appliance and system water chemistry checked at least annually by a qualified service technician. • Do not use petroleum-based cleaning or sealing compounds in the appliance or system. Gaskets and seals in the system may be damaged. This can result in substantial property damage. • Do not use any product not specifically designed for hydronic heating systems. Serious damage to the appliance, piping system, personnel and / or property may result.
Combustion Air - Prevention of Contamination SECTION I - COMBUSTION AIR - PREVENTION OF CONTAMINATION Potential Contaminating Products WARNING If the CHALLENGER combustion air inlet is located in any area likely to cause or contain contamination, or if products, which would contaminate the air cannot be removed, the combustion air must be repiped and terminated to another location.
Maintenance Schedule SECTION II - Maintenance Schedule Owner Maintenance Service Technician Periodic At least on an annual basis the following maintenance should be performed by a qualified service technician: - Check the area around the appliance. - Check and remove any blockage from the combustion air inlet and ventilation openings. - Check the temperature/pressure gauge. General - Attend to any reported problems.
Maintenance Procedures SECTION III - MAINTENANCE PROCEDURES 1. Combustible / flammable materials - Do not store combustible materials, gasoline or other flammable vapors or liquids near the appliance. Remove immediately if found. WARNING 2. Air contaminates - Products containing chlorine or fluorine, if allowed to contaminate the combustion air, will cause acidic condensate within the appliance. This will cause significant damage to the appliance.
Maintenance Procedures of the drain line. If water does not appear at the end of the drain line, contact a qualified service technician to inspect and clean the condensate line. WARNING Failure to inspect the venting system as noted and have it repaired by a qualified service technician can result in the vent system failure, causing severe personal injury or death. 5.
Maintenance Procedures 6-Month Maintenance 2. Read the temperature and pressure gauge to ensure the system is pressurized. Lift the relief valve top lever slightly, allowing water to relieve through the valve and discharge piping. Check Water and Gas Piping 1. Remove the appliance front jacket panel and perform a gas leak inspection per steps 1 through 6 of the Operating Instructions on page 8. If gas odor or leak is detected, immediately shut down the appliance following procedures on page 8.
Operating Instructions SECTION IV - OPERATING INSTRUCTIONS 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.
Appliance Control Display SECTION V - Appliance Control Display Operation Read-Out A. On/Off button B. CH /DHW/parameter button C. - button D. + button E. Units U.S. customary or metric F. DHW function off/eco/on G. Service button H. Reset/store button 1. On/Off (Lit when on) 2. CH operation or setting maximum CH temperature 3. DHW operation or setting DHW temperature 4. Main display with temperature of CH or DHW or CH water pressure or fault code 5. Temperature ºF or pressure psi 6.
Appliance Control Display 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
Appliance Control Display Setting the Appliance Parameters 5. After all parameters have been changed, press the 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.
Appliance Control Display 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.
Appliance Control Display Error (Hard Lockout) Codes* Main Display Operating Display (Flashing) Possible Solution Error Description • Check wiring for break • Check for proper flow direction • Replace S1 • E10 Open sensor • E 11Flow switch sticking or miss-installed • E 11 Shorted sensor • E12 Decreased too quickly • E13 Increased too quickly • E14 Stuck 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
Replacement Parts S T U A Circulator (CC 125c only - Not Shown) LWCO/CH pressure sensor DHW sensor S3 (Combi only) Gas Valve Pressure relief and air vent assembly Sight glass Condensate drain trap assembly Control/Display CH supply sensor S1 CH Return sensor S2 Blower DHW flow switch (Combi only) Heat exchanger Vent/Air adapter (80/125 concentric optional shown or 3” standard not shown) Low voltage/terminal strip X4 Condensate pan Ignition electrode High voltage terminal strip U Flue Sen
Replacement Parts 3 CHALLENGER Front Door Item Part Number CC50 &CC85 Part Number CC105 Part Number CC125 & CC150 Description 1 CCRKIT04 Wall Bracket Assembly (Not Shown) 2 CCRKIT05 Pipe Connectors & Brackets Assembly (Not Shown) 2A CCFTG01 Connector Pipe CH (Not Shown) - 1/Kit 2B CCFTG02 Connector Pipe DHW (Not Shown) - 1/Kit (Combi only) 3 CCRKIT06 CCRKIT07 CCRKIT08 15 Front Door Assembly
Replacement Parts 1 2 2 6 5 3 3 2 3 4 3 CHALLENGER Vent Components Item Part Number Part Number Part Number CC50 & CC85 CC105 CC125 Part Number CC150 CCRKIT09 80/125 Concentric Vent /Air Adapter Assembly (optional - shown) CCRKIT35 3” Vent/Air Adaptor Assembly ( standard not shown) 11 2 3 44 CCRKIT10 Description CCRKIT11 CCRKIT12 CCRKIT13 CCRKIT14 Vent Assembly Condensate Collector Assembly CCRKIT14A Condensate Drain Trap Assembly 5 5 CCRKIT41 Condensate Collector/Trap Gasket 6 C
Replacement Parts 2 1 13 3 4 8 4 7 6 9* 11 5 10 * See page 20 for replacement Parts unique to CC125c Model CHALLENGER Internal Components Item 1 2 3 4 5 6 7 8 9 Part Number CC50 &CC85 CCRKIT20 Part Number CC105 CCRKIT15 CCCLB01 CCRKIT16 CCRKIT17 CCSENS02 CCRKIT18 CCRKIT19 CCRKIT21 CCRKIT23* Part Number CC125 & CC150 CCRKIT22 Description Igniter Assembly Ignition Cable Sight Glass Assembly CH Sensor Assembly - 1/Kit DHW Sensor (Combi only) DHW Flow Switch Assembly (Combi only) LWCO/CH Press
Replacement Parts 6 4 1 2 5 3 CHALLENGER Blower & Gas Valve Components Item Part Number Part Number Part Number CC50 CC85 CC105 Part Number CC125 & CC150 Description 1 CCRKIT28 Ignition Transformer Assembly 2 CCRKIT29 Gas Valve Assembly 33 CCRKIT30 CCRKIT31 4 CCRKIT32 N/A Blower Assembly CCRKIT45 N/A 5 CCRKIT52 6 Gas Pipe Assembly N/A N/A Venturi 406 CCRKIT46 Venturi 362 N/A CCRKIT47 N/A Venturi 541 N/A Blower Outlet Orifice 1” (25 mm) CCRKIT48 N/A N/A = Not Applicable 18
Replacement Parts 1 CHALLENGER Burner Components Item 1 Part Number CC50 &CC85 Part Number CC105 Part Number CC125 & CC150 CCRKIT33 Description Burner Assembly 19
Replacement Parts 6 4 1 5 2 3 CHALLENGER Control Components Item Part Number Part Number Part Number CC50 & CC85 CC105 CC125 Part Number CC150 1 CCCON01 CCCON02 Description Control/Display 2 CCCS01 Housing Plastic Control 3 CCRKIT34 Flip Panel 4 CCFUSE01 Fuse - 1/Kit 5 CCRKIT43 Connector - X4, 24V, 9 Pin (Not shown) 6 CCRKIT44 Connector - X2, 120V, 8 Pin (Not shown) Replacement Parts Unique to CC125C Model CCRKIT53 CH Return Pipe Assembly CCRKIT54 Circulator 20
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